T4020 Deluxe - T4020 Supersteer - T4030 Deluxe T4030 Supersteer - T4040 Deluxe - T4040 Supersteer T4050 Deluxe - T4050 Supersteer TRACTORS
SERVICE MANUAL SECTIONS GENERAL GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER TAKE-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAB AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATFORM, CAB, BODYWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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00 10 18 21 23 25 27 31 33 35 41 44 50 55 90
INTRODUCTORY NOTES -
This manual is divided into sections identified by two-figure numbers and each section has independent page numbering.
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The different sections can easily be found by consulting the table of contents on the following pages.
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The document number of the manual and the edition/update dates are given at the bottom of each page.
-
Pages updated in the future will be identified by the same document number followed by an additional digit: first edition standard manual 87666787A - 1st update 87666787A1 - 2nd update 87666787A2 - etc. The update pages can replace or supplement the pages of the standard manual; the information necessary for the procedure for adding or replacing pages is given on the title page of the update. The publication will be completed with an appropriate index. If it is necessary to issue a new updated manual (2nd edition) it will have document number 87666787B, this indicates that the manual is composed of the standard version 87666787A completed with all the updates: 1st update 87666787A1 - 2nd update 87666787A2 - etc.
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The information contained in this manual was current on the date printed on each section. As NEW HOLLAND constantly improves its product range, some information may be out of date subsequent to modifications implemented for technical or commercial reasons, or to meet legal requirements in different countries. In the event of conflicting information, consult the NEW HOLLAND Sales and Service Departments.
IMPORTANT WARNINGS -
All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND service technicians, in strict accordance with the instructions given and using any specific tools necessary.
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Anyone performing the operations described herein without strictly following the instructions is personally responsible for any eventual injury or damage to property.
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The Manufacturer and all organisations belonging to the Manufacturer's distribution network, including but not restricted to national, regional or local distributors, will accept no responsibility for personal injury or damage to property caused by abnormal function of parts and/or components not approved by the Manufacturer, including those used for maintenance and/or repair of the product manufactured or marketed by the Manufacturer. In any case, the product manufactured or marketed by the Manufacturer is covered by no guarantee of any kind against personal injury or damage to property caused by abnormal function of parts and/or components not approved by the Manufacturer.
No part of the text or illustrations may be reproduced
PRINTED IN FRANCE
Š CNH GLOBAL N.V.
Print No. 87666787A1 - 03 - 2008
CONTENT
3
CONTENT Page
Date
00 − GENERAL GUIDELINES General instructions . . . . . 1−2
11−07
Safety regulations . . . . . . . 3−4−5
11−07
Tractor refuelling . . . . . . . . 6
11−07
10 − ENGINE CHAPTER 1 − Engine T4040 and T4050 models Summary . . . . . . . . . . . . . . . 1
11−07
General specifications . . . . 2−3−4
11−07
Fuel system data . . . . . . . . 4
11−07
Engine block data . . . . . . . 5
11−07
Crankshaft data . . . . . . . . . 5
11−07
Connecting rod data . . . . . 6
11−07
Piston data . . . . . . . . . . . . . 6−7
11−07
Timing gear data . . . . . . . . 7
11−07
Cylinder head data . . . . . . 8−9
11−07
Tightening torques . . . . . . . 10−11
11−07
Tools . . . . . . . . . . . . . . . . . . 12
11−07
Engine diagrams . . . . . . . . 13
11−07
Lubrication diagrams . . . . . 14
11−07
Cooling diagram . . . . . . . . . 15
Page Engine disassembly− assembly . . . . . . . . . . . . . . . 33−34−35− 36−37−38− 39−40−41− 42−43−44− 45−46−47− 48−49−50− 51−52−53− 54−55−56− 57−58−59− 60−61−62− 63−64−65− 66 Checks and measurements − cylinder block and liners
67−68−69
Date
11−07
11−07
Checks and measurements − crankshaft, bearings and flywheel . . . . . . 70−71
11−07
Checks and measurements − connecting rods . . . . . . . 72−73
11−07
Checks and measurements − pistons . . . . . 74−75−76− 77
11−07
Checks and measurements − camshaft, tappets and valves . . . . . . . . . . . . . . . . . 78−79−80− 81
11−07
11−07
Checks and measurements − cylinder head 82
11−07
Additional counterweight diagrams . . . . . . . . . . . . . . . 16
11−07
Checks and measurements − lubrication system . . . . . . 83
11−07
Exhaust gas recirculation system (EGR) . . . . . . . . . . . 17
11−07
Checks and measurements − cooling system . . . . . . . . 84
11−07
Fault finding . . . . . . . . . . . . 18−19−20− 21
11−07
Removal−Installation − crankshaft front seal . . . . . 85−86
11−07
Replacing crankshaft rear seal . . . . . . . . . . . . . . . . . . . 87−88−89
11−07
Valve clearance adjustment .............. 90−91
11−07
Removal−Installation − injectors . . . . . . . . . . . . . . . . . 92−93−94
11−07
Removal − Installation − Bosch injection pump . . . . 95−96−97
11−07
Bosch injection pump − timing . . . . . . . . . . . . . . . . . . . . 98−99−100
11−07
Bosch injection pump − air bleeding . . . . . . . . . . . . . . . . 100
11−07
Engine removal−installation . . . . . . . . . . . . . . . . . . . . 22−23−24− 25−26−27− 28−29−30− 31−32
11−07
87666787A2 − 06 − 2009
CONTENT
4 Page
Date
Page
Date
21 − TRANSMISSIONS
Removal−Installation − coolant pump . . . . . . . . . . . 101−102
11−07
Removal−Installation − thermostat valve . . . . . . . . . 103−104
11−07
CHAPTER 1 − Transmission and range gear (16x16)
Removal−Installation − 105−106− radiator . . . . . . . . . . . . . . . . 107−108
11−07
Data . . . . . . . . . . . . . . . . . . . 1−2
11−07
Coolant pump and generator drive belt . . . . . . . . . . . 109−110
Tightening torques . . . . . . . 2−3
11−07
11−07
Tools . . . . . . . . . . . . . . . . . . 4−5−6−7
11−07
Sections . . . . . . . . . . . . . . . 8−9−10−11
11−07
Description and operation
11−07
CHAPTER 2 − Engine T4020 and T4030 models Summary . . . . . . . . . . . . . . . 1
03−08
General specifications . . . . 2−3
03−08
Engine removal−installation . . . . . . . . . . . . . . . . . . . . 4−5−6−7−8 −9−10−11− 12−13−14− 15−16−17
03−08
18 − CLUTCH Data . . . . . . . . . . . . . . . . . . . 1−2
11−07
Tightening torques . . . . . . . 2
11−07
Tools . . . . . . . . . . . . . . . . . . 2−3
11−07
Sections . . . . . . . . . . . . . . . 3−4
11−07
Fault finding . . . . . . . . . . . . 5
11−07
12
Fault finding . . . . . . . . . . . . 12−13
11−07
Removal−Installation − rear transmission − gearbox casing . . . . . . . . . . . . . . 14−15−16− 17−18−19− 20
11−07
Disassembly−Assembly − transmission−gearbox casing . . . . . . . . . . . . . . . . . . . . 21−22−23− 24−25−26− 27−28
11−07
Gearbox driving and driven shafts end float adjustment 29
11−07
Sealing compound application diagram . . . . . . . . . . . . 30
11−07
Gearbox control lever. Removal − Installation . . . . . . 31
11−07
Range gear control lever. Removal − Installation . . . . 32
11−07
Shuttle control lever. Removal − Installation . . . . . . 33
11−07 11−07
Removal−Installation − clutch . . . . . . . . . . . . . . . . . . 6−7−8−9− 10−11−12− 13−14−15
11−07
Clutch Overhaul . . . . . . . . . 16−17−18− 19−20
11−07
Checks and measurements − clutch . . . . . . . . . . . . . . . . 21−22
11−07
Fuel tank. Removal − Installation . . . . . . . . . . . . . . . 34−35
Adjustments − clutch disengagement levers . . . . . . . . 22−23
11−07
CHAPTER 2 − Mechanical transmission and splitter
Adjustments − clutch pedal 24
11−07
PTO control adjustment . . 25
11−07
Sectional view of PTO clutch servo control . . . . . . 26
11−07
Description and operation of PTO servo control . . . . . 27−28
11−07
PTO servo control adjustment . . . . . . . . . . . . . . . . . . . 29
11−07
PTO engaged switch adjustment . . . . . . . . . . . . . . . . 30
11−07
87666787A2 − 06 − 2009
Data . . . . . . . . . . . . . . . . . . . 1−2
11−07
Tightening torques . . . . . . . 2
11−07
Tools . . . . . . . . . . . . . . . . . . 2
11−07
Sections . . . . . . . . . . . . . . . 3−4−5
11−07
Description and operation . 6
11−07
Fault finding . . . . . . . . . . . . 7
11−07
Splitter device and creeper unit casing, shafts and bearings disassembly . . . . 8−9−10
11−07
CONTENT Page
Page
Date
CHAPTER 3 − Power Shuttle transmission with dual command (2 Speed Power Shift) function Data . . . . . . . . . . . . . . . . . . . 1−2
11−07
Tightening torques . . . . . . . 3
11−07
Tools . . . . . . . . . . . . . . . . . . 4−5−6
11−07
Sections . . . . . . . . . . . . . . . 7−8−9−10− 11
11−07
Clutch control pressure test 10
11−07
Description and operation . 12
11−07
Fault finding . . . . . . . . . . . . 12
11−07
Disassembly−Assembly − transmission−gearbox casing . . . . . . . . . . . . . . . . . . . . 13−14
11−07
Disassembly−Reassembly − Power Shuttle control valve . . . . . . . . . . . . . . . . . . 15−16−17
11−07
Disassembly−Assembly − accumulator . . . . . . . . . . . . 18
11−07
Gearbox control valve solenoid valve. Removal − Installation . . . . . . . . . . . . . . . 19−20
11−07
Disassembly−Assembly − clutch casing . . . . . . . . . . . . 21−22−23− 24
11−07
CHAPTER 4 − Power Shuttle transmission (16 + 16 and 8 + 8 versions) Data . . . . . . . . . . . . . . . . . . . 1
11−07
Tightening torques . . . . . . . 2
11−07
Sections . . . . . . . . . . . . . . . 3−4−5−6
11−07
Clutch control pressure test 6
11−07
23 − DRIVE LINES Data . . . . . . . . . . . . . . . . . . . 1
11−07
Tightening torques . . . . . . . 2
11−07
Tools . . . . . . . . . . . . . . . . . . 3−4
11−07
Sections . . . . . . . . . . . . . . . 5−6−7
11−07
Description and operation . 8−9
11−07
Fault finding . . . . . . . . . . . . 9
11−07
Drive shafts and guard. Disassembly− Assembly . . 10−11−12
11−07
Removal−Installation − drive gear casing . . . . . . . . 13−14
11−07
5
Disassembly−Assembly − drive gear casing . . . . . . . . 15−16−17− 18
Date
11−07
25 − FRONT AXLE MECHANICAL TRANSMISSION CHAPTER 1 − Front mechanical transmission (mod. T4040 Supersteer and T4050 Supersteer) Data . . . . . . . . . . . . . . . . . . . 1−2−3
11−07
Tightening torques . . . . . . . 4−5−6
11−07
Tools . . . . . . . . . . . . . . . . . . 7−8−9
11−07
Sections . . . . . . . . . . . . . . . 10−11−12− 13
11−07
Description and operation
11−07
13−14
Fault finding . . . . . . . . . . . . 15
11−07
Removal−Installation − front axle . . . . . . . . . . . . . . . 16−17−18− 19
11−07
Removal−Installation − front axle differential and bevel drive support . . . . . . 20−21−22− 23
11−07
Overhaul − front axle bevel drive . . . . . . . . . . . . . . . . . . . 24−25
11−07
Adjustments − bevel drive
26−27−28− 29−30−31
11−07
Overhaul − front differential 32
11−07
Overhaul − differential lock unit . . . . . . . . . . . . . . . . . . . . 33−34−35
11−07
Disassembly−Assembly − front epicyclic final drive with brake . . . . . . . . . . . . . . 36−37−38− 39
11−07
Disassembly−Assembly − front epicyclic final drive . . 40−41−42
11−07
Wheel hub seal. Renew . . 43
11−07
Wheel hub and steering knuckle. Disassembly− Assembly . . . . . . . . . . . . . . . . . 44
11−07
Adjustments − steering knuckle bearings . . . . . . . . 45
11−07
Replacing steering knuckle pins and bearings . . . . . . . 46
11−07
Lead−drive wheel position check . . . . . . . . . . . . . . . . . . 47
11−07
87666787A2 − 06 − 2009
CONTENT
6 Page
Date
CHAPTER 2 − Front mechanical transmission (mod. T4040 Deluxe and T4050 Deluxe) Data . . . . . . . . . . . . . . . . . . . 1−2
11−07
Tightening torques . . . . . . . 3−4
11−07
Tools . . . . . . . . . . . . . . . . . . 5−6
11−07
Sections . . . . . . . . . . . . . . . 7−8
11−07
Description and operation
11−07
8−9
Fault finding . . . . . . . . . . . . 10 Removal−Installation − front axle . . . . . . . . . . . . . . . 11−12−13− 14
11−07
11−07
Page Adjustments − differential lock engagement sleeve position . . . . . . . . . . . . . . . . 20 Adjustments − bevel drive
Date
11−07
21−22−23− 24−25
11−07
Removal−Installation − final drive casing . . . . . . . . 26−27−28− 29
11−07
Disassembly−Assembly − drive wheel shaft . . . . . . . . 29−30−31
11−07
Disassembly−Assembly − epicyclic final drive . . . . . . . 31
11−07
Front axle. Disassembly− Assembly . . . . . . . . . . . . . . 15−16−17− 18−19−20− 21−22−23
11−07
Overhaul − differential lock unit . . . . . . . . . . . . . . . . . . . . 24−25
CHAPTER 1 − Mechanical power take−off
11−07
Data . . . . . . . . . . . . . . . . . . . 1−2−3
11−07
Replacing steering knuckle pins and bearings . . . . . . . 26
11−07
Tools . . . . . . . . . . . . . . . . . . 4
11−07
Adjustments − steering knuckle bearings . . . . . . . . 27−28
Tightening torques . . . . . . . 5−6
11−07
11−07
Sections . . . . . . . . . . . . . . . 7−8
11−07
Description and operation . 9−10−11
11−07
Fault finding . . . . . . . . . . . . 11
11−07
Disassembly − Assembly − power take−off . . . . . . . . . . 12−13−14− 15
11−07
Adjustments − bevel drive
29−30−31− 32−33−34− 35
Overhaul − front differential 36 LIM−SLIP self−locking differential . . . . . . . . . . . . . . . . 37−38 Checking leading wheel alignment . . . . . . . . . . . . . . 39 Disassembly−Assembly − front epicyclic final drive . . 40−41 Disassembly−Assembly − front epicyclic final drive with brake . . . . . . . . . . . . . . 42−43−44
31 − POWER TAKE−OFF
11−07 11−07 11−07
33 − BRAKES 11−07 11−07
11−07
27 − REAR MECHANICAL TRANSMISSION Data . . . . . . . . . . . . . . . . . . . 1−2
11−07
Tightening torques . . . . . . . 3−4
11−07
Tools . . . . . . . . . . . . . . . . . . 5−6−7−8
11−07
Sections . . . . . . . . . . . . . . . 9−10
11−07
Description and operation . 11−12
11−07
Fault finding . . . . . . . . . . . . 12−13
11−07
Disassembly−Assembly − transmission−gearbox casing . . . . . . . . . . . . . . . . . . . . 14−15−16− 17−18−19 87666787A2 − 06 − 2009
11−07
Data . . . . . . . . . . . . . . . . . . . 1−2
11−07
Tightening torques . . . . . . . 2
11−07
Sections . . . . . . . . . . . . . . . 3−4−5
11−07
Tools . . . . . . . . . . . . . . . . . . 5−6
11−07
Description and operation . 6
11−07
Fault finding . . . . . . . . . . . . 7−8
11−07
Removal−Installation − service brake . . . . . . . . . . . . . . 9−10
11−07
Removal−Installation − service brake pump . . . . . . . . . 11−12−13− 14
11−07
Adjustments − service brake pedals travel . . . . . . 15−16
11−07
Service brake circuit air bleeding . . . . . . . . . . . . . . . . 16−17−18
11−07
Removal−Installation − parking brake . . . . . . . . . . . 19−20
11−07
CONTENT Page Adjustments − parking handbrake travel . . . . . . . . 21
Date 11−07
7 Page
Removal−Installation − trailer brake valve . . . . . . . 11
Date 11−07
35 − HYDRAULIC SYSTEMS
CHAPTER 4 − Electronically controlled hydraulic lift
CHAPTER 1 − Rear mechanical hydraulic lift
Data . . . . . . . . . . . . . . . . . . . 2−3
11−07
Data . . . . . . . . . . . . . . . . . . . 1−2−3
11−07
Tightening torques . . . . . . . 4
11−07
Tightening torques . . . . . . . 3−4
11−07
Tools . . . . . . . . . . . . . . . . . . 4−5−6
11−07
Tools . . . . . . . . . . . . . . . . . . 5−6
11−07
Sections . . . . . . . . . . . . . . . 7−8−9
11−07
Sections . . . . . . . . . . . . . . . 7−8−9−10− 11
11−07
Location of Components . . 10−11−12
11−07
Description and operation . 12−13−14− 15
11−07
Description and operation . 13−14−15− 16−17−18
11−07
Fault finding . . . . . . . . . . . . 16−17
11−07
Removal−Installation − lift . 19−20−21− 22−23
11−07
Draft sensor support. Removal − Installation . . . . . . 24
11−07
Replacement − control unit 25
11−07
Lift arm potentiometer. Renew . . . . . . . . . . . . . . . . . 26−27
11−07
Replacement − draft sensor .............. 28−29
11−07
Electronically controlled hydraulic lift. Disassembly− Assembly . . . . . . . . . . . . . . 30−31−32− 33−34
11−07
Removal−Installation − hydraulic control valve . . . . . . 35
11−07
CHAPTER 2 − Open centre system auxiliary control valves
Hydraulic control valve. Disassembly− Assembly . . 36−37−38
11−07
Data . . . . . . . . . . . . . . . . . . . 2
11−07
CHAPTER 5 − Constant flow gear pump
Tools . . . . . . . . . . . . . . . . . . 2
11−07
Data . . . . . . . . . . . . . . . . . . . 1−2
11−07
Tightening torques . . . . . . . 2
11−07
Description and operation . 2
11−07
Sections . . . . . . . . . . . . . . . 3−4
11−07
Diagrams . . . . . . . . . . . . . . . 3
11−07
Description and operation . 5−6−7−8
11−07
Lift electronic control unit. Renew . . . . . . . . . . . . . . . . . 9
11−07
Disassembly−Assembly − lift oil pump . . . . . . . . . . . . . 4
11−07
Auxiliary control valves. Disassembly− Assembly . . 10−11−12
11−07
Lift internal controls. Disassembly− Assembly . . . . . . . 18−19−20− 21 Adjusting the lift . . . . . . . . . 22−23−24− 25−26−27− 28−29−30− 31
11−07
11−07
Lift cylinder and arms shaft. Disassembly− Assembly . . 32−33−34− 35
11−07
Disassembly−Assembly − lift control valve . . . . . . . . . 36−37−38− 39
11−07
Lift pressure relief valve . . 40
11−07
CHAPTER 3 − Trailer brakes auxiliary control valves
CHAPTER 6 − Electronic lift and front Power Take−Off Main specifications of front lift . . . . . . . . . . . . . . . . . . . . . 1−2−3
11−07
Tightening torques . . . . . . . 3−4−5
11−07
Sections . . . . . . . . . . . . . . . 1
11−07
Description and operation . 1−2−3−4−5 −6−7
Cross−sectional views of implement linkage . . . . . . . 6−7
11−07
11−07
Fault finding . . . . . . . . . . . . 8−9−10
11−07
Cross−sectional views of front PTO . . . . . . . . . . . . . . 8−9−10
11−07
87666787A2 − 06 − 2009
CONTENT
8 Page Description and operation . 11−12−13− 14
11−07
Front lift hydraulic diagram
11−07
15
Front lift troubleshooting . . 16−17 Removal−Installation − Front power take−off transmission shaft . . . . . . . . . . . 18−19−20− 21−22−23− 24−25
11−07
11−07
Disassembly−Assembly − Front PTO transmission shaft . . . . . . . . . . . . . . . . . . . 26
11−07
Front PTO casing cross− sectional view . . . . . . . . . . . 27
11−07
Removal−Installation − Front PTO electromagnetic coupling . . . . . . . . . . . . . . . . 28−29−30 Disassembly−Assembly − Front PTO electromagnetic coupling . . . . . . . . . . . . . . . . 31−32−33− 34 Removal−Installation − Front lift support . . . . . . . . . 35−36−37
Page
Date
11−07
11−07
11−07
CHAPTER 7 − Front lift and power take−off (for mod. T4030 Deluxe, T4040 Deluxe and T4050 Deluxe) Data . . . . . . . . . . . . . . . . . . . 1−2
03−08
Tightening torques . . . . . . . 3−4
03−08
Sections . . . . . . . . . . . . . . . 5−6
03−08
Description and operation of front power take−off . . . 7
03−08
Front power take−off control adjustment . . . . . . . . . . 8
03−08
Front power take−off control valve . . . . . . . . . . . . . . . 9
03−08
Sectional view of front power take−off clutch . . . . 10
03−08
Front mechanical lift . . . . . 11
03−08
Electronic front lift . . . . . . . 12−13−14
03−08
Date
Description and operation of front electronic lift hydraulic control valve . . . . . . 17−18−19− 20
03−08
Fault finding . . . . . . . . . . . . 21−22
03−08
Front electronic lift operating instructions . . . . . . . . . . 23−24−25− 26
03−08
Front electronic lift calibration . . . . . . . . . . . . . . . . . . . . 27−28−29
03−08
Removal−Installation − front mechanical/electronic lift . . . . . . . . . . . . . . . . . . . . . 30−31
03−08
Removal−Installation − front power take−off . . . . . . 32−33
03−08
Disassembly−Assembly − front power take−off . . . . . . 34−35
03−08
Removal−Installation − front electronic lift control unit . . . . . . . . . . . . . . . . . . . . 36
03−08
Removal−Installation − front electronic lift hydraulic control valve . . . . . . . . . . . . 37
03−08
Fault code indication . . . . . 38
03−08
Diagnostics . . . . . . . . . . . . . 39−40−41− 42−43−44− 45−46−47− 48−49−50− 51−52−53− 54−55−56
06−09
41 − STEERING CHAPTER 1 − Steering Data . . . . . . . . . . . . . . . . . . . 2
11−07
Tightening torques . . . . . . . 2
11−07
Tools . . . . . . . . . . . . . . . . . . 2
11−07
Description and operation . 3−4−5
11−07
View of hydrostatic steering control valve components . 6
11−07
Fault finding . . . . . . . . . . . . 7−8
11−07
Front electronic lift hydraulic control valve diagram . . . . . . . . . . . . . . . . . . . 15
03−08
Front electronic lift hydraulic control valve . . . . . . 16
Replacement − hydrostatic steering wheel . . . . . . . . . . 9
11−07
03−08
Removal−Installation − hydrostatic steering control valve . . . . . . . . . . . . . . . . . . 10−11−12
11−07
87666787A2 − 06 − 2009
CONTENT Page Disassembly−Assembly − hydrostatic control valve . . 13−14−15− 16−17−18− 19−20−21− 22−23−24− 25−26−27− 28
9 Page
Date
Date
Conditioning system components . . . . . . . . . . . . . . . . 6−7−8−9− 10
11−07
Cab controls . . . . . . . . . . . . 11−12−13
11−07
11−07
Testing operation and cooling . . . . . . . . . . . . . . . . . . . . 14−15
11−07
Hydrostatic steering control valve bench testing . . . . . . 29−30
11−07
Air conditioning system maintenance . . . . . . . . . . . . 16−17
11−07
Pressure relief valve testing 31
11−07
Fault finding . . . . . . . . . . . .
Steering control cylinder. Removal − Installation . . . . 32−33
11−07
18−19−20− 21
11−07
11−07
Refrigerant recovery − recycling and evacuation − charging stations . . . . . . . . 22−23
11−07
Data . . . . . . . . . . . . . . . . . . . 1−2
11−07
Diagrams . . . . . . . . . . . . . . . 3−4
11−07
Dehydration, recharging and refrigeration check . . . 24−25−26− 27−28−29− 30
11−07
Description and operation . 4
11−07
Checking for and eliminating any gas leaks . . . . . . . . 31−32
11−07
Compressor drive belt tension adjustment . . . . . . . . . 33
11−07
Cab air infeed vents. Removal − Installation . . . . . . 34
11−07
Cab heating/air−conditioning system. Removal − Installation . . . . . . . . . . . . . . . 35−36
11−07
Cab heater. Disassembly− Assembly . . . . . . . . . . . . . . 37
11−07
11−07 11−07
Steering control cylinder. Disassembly−Assembly . . 34−35 CHAPTER 2 − Constant flow gear pump
Disassembly−Assembly − hydrostatic steering oil pump . . . . . . . . . . . . . . . . . . 5
11−07
44 − AXLES AND WHEELS Data . . . . . . . . . . . . . . . . . . . 1−2
11−07
Front wheel track diagram
2
11−07
Sections . . . . . . . . . . . . . . . 3
11−07
Tightening torques . . . . . . . 4−5−6
11−07
Tools . . . . . . . . . . . . . . . . . . 6−7
11−07
Fault finding . . . . . . . . . . . . 7
11−07
Cab air conditioning system evaporator unit. Disassembly− Assembly . . . . . . . . . . 38
Disassembly−Assembly − wheel axle hub . . . . . . . . . . 8−9−10
11−07
Cab electric fan unit. Disassembly− Assembly . . . . . . . 39
Removal−Installation − front axle . . . . . . . . . . . . . . . 11−12−13
11−07
Stub axle hub overhaul . . . 14−15−16− 17
11−07
Checking leading wheel alignment . . . . . . . . . . . . . . 18
11−07
50 − CAB AIR CONDITIONING SYSTEM Safety regulations . . . . . . . 2
11−07
Data . . . . . . . . . . . . . . . . . . . 3
11−07
Tools . . . . . . . . . . . . . . . . . . 4
11−07
Operating principles . . . . . 5
11−07
55 − ELECTRICAL SYSTEM CHAPTER 1 − Instruments Analogue instrumentation . 1−2−3−4
11−07
Digital instrumentation . . . . 5−6−7−8−9
11−07
Transmitters, sensors and switches . . . . . . . . . . . . . . . 10−11−12− 13−14−15− 16−17
11−07
CHAPTER 2 − Components Introduction . . . . . . . . . . . . . 1
11−07
87666787A2 − 06 − 2009
CONTENT
10 Page
Date
Page
Date
Components . . . . . . . . . . . . 1−2−3−4−5 −6−7
11−07
CHAPTER 10 − HH Menu and calibrations
Service . . . . . . . . . . . . . . . . 8−9−10−11 −12
11−07
Index . . . . . . . . . . . . . . . . . . 1
Technical data . . . . . . . . . . 1
11−07
Description and operation . 2
11−07
CHAPTER 11 − Front electronic lift (mod. T4030 Deluxe, T4040 Deluxe and T4050 Deluxe)
Fault finding . . . . . . . . . . . . 3
11−07
Index . . . . . . . . . . . . . . . . . . 1
03−08
System testing . . . . . . . . . . 4−5−6
11−07
View of starter motor components . . . . . . . . . . . . . . . . 7
11−07
Electrical circuit components . . . . . . . . . . . . . . . . . . 2−3
03−08
Revision . . . . . . . . . . . . . . . 8−9
11−07
Wiring diagrams . . . . . . . . 4
03−08
Starter motor testing . . . . . 9−10
11−07
Wiring diagrams . . . . . . . . . 6−7−8−9− 10−11
03−08
03−08
CHAPTER 3 − Starting System
CHAPTER 4 − Charging system Technical data . . . . . . . . . . 1
11−07
Tightening torques . . . . . . . 1
11−07
Description and operation . 2−3
11−07
Connectors . . . . . . . . . . . . . 14−15−16− 17−18−19− 20
System testing . . . . . . . . . . 4−5−6−7−8 −9
11−07
90 − PLATFORM, CAB, BODYWORK
Removal−Installation and Overhaul − alternator . . . . 9−10−11− 12−13−14− 15−16
06−09
CHAPTER 1 − Cab 11−07
Hood. Removal − Installation . . . . . . . . . . . . . . . . . . . . 2
11−07
Technical data . . . . . . . . . . 1
11−07
Description and operation . 1
11−07
Instrument panel lower guard. Removal − Installation . . . . 3
11−07
Removal−Installation − battery . . . . . . . . . . . . . . . . . . . . 2
11−07
Battery Service . . . . . . . . . . 3
11−07
Platform assembly. Removal − Installation . . . . 4−5−6−7− 8−9−10
11−07
Battery charging . . . . . . . . . 4−5−6
11−07
Canopy for rops. Removal − Installation . . . . . . . . . . . . 11
11−07
Battery troubleshooting . . . 6
11−07
Cab assembly with platform. Removal − Installation . . . . 12−13−14− 15−16−17− 18−19
11−07
Cab windows. Renew . . . . 20−21−22
11−07
Right/left−hand upright seals. Removal − Installation . . . . 23
11−07
Cab ceiling fitting. Removal − Installation . . . . 24−25
11−07
Sunshade. Removal − Installation . . . . 26
11−07
CHAPTER 5 − Battery
CHAPTER 6 − Electrical circuits for tractors with cab Index . . . . . . . . . . . . . . . . . . 1
06−09
CHAPTER 7 − Electrical circuits for tractors with platform Index . . . . . . . . . . . . . . . . . . 1
11−07
CHAPTER 8 − Connectors Index . . . . . . . . . . . . . . . . . . 1
11−07
CHAPTER 9 − Error codes Index . . . . . . . . . . . . . . . . . . 1
87666787A2 − 06 − 2009
06−09
SECTION 00 -- GENERAL -- CHAPTER 1
1
GENERAL INSTRUCTIONS IMPORTANT NOTICE All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND service technicians, in strict accordance with the instructions given and using any specific tools necessary. Anyone performing the operations described herein without strictly following the instructions is personally responsible for any eventual injury or damage to property.
BATTERY Before carrying out any kind of service operation disconnect and isolate the battery negative lead, unless otherwise requested for specific operations (e.g.: operations that require the engine running). Once the specific operation has been completed, disconnect the lead in order to complete the operation.
SHIMMING For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add up the recorder values: Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value indicated for each on shim.
ROTATING SHAFT SEALS For correct rotating shaft seal installation, proceed as follows: -- before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes; -- thoroughly clean the shaft and check that the working surface on the shaft is not damaged; -- position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that they will deviate the fluid towards the inner side of the seal; -- smear the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing lip and the dust lip on double lip seals with grease; -- insert the seal in its seat and press down using a flat punch; do not tap the seal with a hammer or mallet; -- whilst inserting the seal, check that the it is perpendicular to the seat; once settled, make sure that it makes contact with the thrust element, if required; -- to prevent damaging the seal lip on the shaft, position a protective guard during installation operations.
O--RING SEALS Lubricate the O--RING seals before inserting them in the seats, this will prevent them from overturning and twisting, which would jeopardise sealing efficiency.
SEALING COMPOUNDS Apply one of the following sealing compounds on the mating surfaces marked with an X: RTV SILMATE, RHODORSIL CAF 1 or LOCTITE PLASTIC GASKET. Before applying the sealing compound, prepare the surfaces as follows: -- remove any incrustations using a wire brush; -- thoroughly de--grease the surfaces using one of the following cleaning agents: trichlorethylene, petrol or a water and soda solution.
BEARINGS When installing bearings it is advised to: -- heat the bearings to 80 รท 90 0C before fitting on the shafts; -- allow the bearings to cool before installing them from the outside.
87666787A - 11 - 2007
2
SECTION 00 -- GENERAL -- CHAPTER 1 SPRING PINS
When fitting split socket elastic pins, ensure that the pin notch is positioned in the direction of the force required to stress the pin. Spiral spring pins do not require special positioning
SPARE PARTS Use genuine parts only. Only genuine spare parts guarantee the same quality, duration and safety as they are the same parts that are assembled during production. Only genuine parts can offer this guarantee. When ordering spare parts, always provide the following information: -- tractor model (commercial name) and frame number; -- engine type and number; -- part number of the ordered part, which can be found in the ”Microfiches” or the ”Spare Parts Catalogue”, used for order processing.
NOTES FOR EQUIPMENT The tools that NEW HOLLAND propose and illustrate in this manual are: -- specifically researched and designed for use with NEW HOLLAND vehicles; -- necessary to make reliable repair; -- accurately built and strictly tested to offer efficient and long--lasting working means. By using these tools, repair personnel will benefit from: -- operating in optimal technical conditions; -- obtaining the best results; -- saving time and effort; -- working in safe conditions.
IMPORTANT NOTES Wear limit values indicated for certain parts are recommended, but not binding. The terms ”front”, ”rear”, ”right--hand” and ”left--hand” (when referred to different parts) are intended as seen from the driving position with the tractor in the normal direction of movement.
MOVING THE TRACTOR WITH THE BATTERY REMOVED External power supply cables should only be connected to the respective positive and negative cable terminals, using efficient clamps that guarantee adequate and secure contact. Disconnect all services (lights, windshield wipers, etc.) before starting the vehicle. If the vehicle electrical system requires checking, carry out operations with the power supply connected; once checking is completed, disconnect all services and switch off the power supply before disconnecting the cables.
87666787A - 11 - 2007
SECTION 00 -- GENERAL -- CHAPTER 1
3
SAFETY REGULATIONS WARNING AND DANGER SYMBOL This warning symbol points out important messages concerning your safety. Carefully read the following safety regulations and observe advised precautions in order to avoid potential hazards and safeguard your health and safety. In this manual the symbol is accompanied by the following key--words: WARNING -- Warnings concerning unsuitable repair operations that may jeopardise the safety of Repair personnel. DANGER -- Specific warnings concerning potential hazards for operator safety or for other persons directly or indirectly involved.
--
TO PREVENT ACCIDENTS Most accidents or injuries that occur in workshops are the result of non--observance of simple and fundamental safety regulations. For this reason, IN MOST CASES THESE ACCIDENTS CAN BE AVOIDED: by foreseeing possible causes and consequently acting with the necessary caution and care. Accidents may occur with all types of vehicle, regardless of how well it was designed and built. A careful and judicious service technician is the best guarantee against accidents. Precise observance of the most basic safety rule is normally sufficient to avoid many serious accidents. DANGER. Never carry out any cleaning, lubrication or maintenance operations when the engine is running.
SAFETY REGULATIONS
--
---
---
--
--
GENERAL ---
Carefully follow specified repair and maintenance procedures. Do not wear rings, wristwatches, jewellery, unbuttoned or loose articles of clothing such as: ties, torn clothing, scarves, open jackets or shirts with open zips that may remain entangled in moving parts. It is advised to wear approved safety clothing, e.g.: non--slip footwear, gloves, safety goggles, helmets, etc.
--
--
1 Do not carry out repair operations with someone sitting in the driver’s seat, unless the person is a trained technician who is assisting with the operation in question. Do not operate the vehicle or use any of the implements from different positions, other than the driver’s seat. Do not carry out operations on the vehicle with the engine running, unless specifically indicated. Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps, covers, valves, etc. All repair and maintenance operations must be carried out using extreme care and attention. Service steps and platforms used in a workshop or in the field should be built in compliance with the safety rules in force. Disconnect the batteries and label all controls to indicate that the vehicle is being serviced. Block the machine and all equipment which should be raised. Do not check or fill fuel tanks, accumulator batteries, nor use starting liquid when smoking or near naked flames, as these fluids are inflammable. Brakes are inoperative when manually released for repair or maintenance purposes: Use blocks or similar devices to control the machine in these conditions. The fuel nozzle should always be in contact with the filling aperture: Maintain this contact until the fuel stops flowing into the tank to avoid possible sparks due to static electricity build--up.
87666787A - 11 - 2007
SECTION 00 -- GENERAL -- CHAPTER 1
4 --
--
--
--
-----
-----
---
--
Only use specified towing points for towing the vehicle. Connect parts carefully: make sure that all pins and/or locks are secured in position before applying traction. Never remain near the towing bars, cables or chains that are operating under load. Transport vehicles that cannot be driven using a trailer or a low--loading platform trolley, if available. When loading or unloading the vehicle from the trailer (or other means of transport), select a flat area capable of sustaining the trailer or truck wheels. Firmly secure the vehicle to the truck or trailer and lock the wheels in the position used by the carrier. Electric heaters, battery--chargers and similar equipment must only be powered by auxiliary power supplies with efficient ground insulation to avoid electrical shock hazards. Always use suitable hoisting or lifting devices when raising or moving heavy parts. Take extra care if bystanders are present. Never pour petrol or diesel oil into open, wide or low containers. Never use gasoline, diesel oil or other inflammable liquids as cleaning agents: use non--inflammable, non toxic commercially available solvents. Wear safety goggles with side guards when cleaning parts with compressed air. Limit the air pressure to a maximum of 2.1 bar, according to local regulations. Do not run the engine in confined spaces without suitable ventilation. Do not smoke, use naked flames, or cause sparks in the area when fuel filling or handling highly inflammable liquids. Never use naked flames for lighting when working on the machine or checking for leaks. All movements must be carried out carefully when working under, on or near the vehicle. Wear protective equipment: helmets, goggles and special footwear. When carrying out checks with the engine running, request the assistance of an operator in
87666787A - 11 - 2007
--
--
--
--
--
---
--
--
--
the driver’s seat. The operator must maintain visual contact with the service technician at all times. If operating outside the workshop, position the vehicle on a flat surface and lock in position. If working on a slope, lock the vehicle in position. Move to a flat area as soon as is safely possible. Damaged or bent chains or cables are unreliable: do not use them for lifting or towing. Always use suitable protective gloves when handling chains or cables. Chains should always be safely secured: make sure that the hitch--up point is capable of sustaining the load in question. Keep the area near the hitch--up point, chains or cables free of all bystanders. Maintenance and repair operations must be carried out in a CLEAN and DRY area. Eliminate any water or oil spillage immediately. Do not create piles of oil or grease--soaked rags: as they represent a serious fire hazard. Always store rags in a closed metal container. Before starting the tractor or its attachments, check, adjust and block the operator’s seat. Also check that there are no persons within the vehicle or implement range of action. Empty pockets of all objects that may fall unobserved into the vehicle parts. In the presence of protruding metal parts, use protective goggles or goggles with side guards, helmets, special footwear and gloves. When welding, use protective safety devices: tinted safety goggles, helmets, special overalls, gloves and footwear. All persons present in the area where welding is taking place must wear tinted goggles. NEVER LOOK DIRECTLY AT THE WELDING ARC WITHOUT SUITABLE EYE PROTECTION. Metal cables tend to fray with repeated use: always use suitable protective devices (gloves, goggles, etc.) when handling cables. Handle all parts with great care. Do not put your hands or fingers between moving parts. Always wear suitable safety clothing -- safety goggles, gloves and shoes.
SECTION 00 -- GENERAL -- CHAPTER 1 START UP
HYDRAULIC SYSTEMS
--
--
--
Never run the engine in confined spaces that are not equipped with adequate ventilation for exhaust gas extraction. Never place the head, body, limbs, feet, hands or fingers near fans or rotating belts.
ENGINE --
--
--
--
Always loosen the radiator cap slowly before removing it to allow any remaining pressure in the system to be discharged. Filling up with coolant should only be carried out with the engine stopped or idling (if hot). Never fill up with fuel when the engine is running, especially if hot, in order to prevent the outbreak of fire as a result of fuel spillage. Never check or adjust fan belt tension when the engine is running. Never adjust the fuel injection pump when the vehicle is moving. Never lubricate the vehicle when the engine is running.
--
--
--
--
If it is necessary to use auxiliary batteries, remember that both ends of the cables must be connected as follows: (+) with (+) and (--) with (--). Avoid short--circuiting the terminals. GAS RELEASED FROM BATTERIES IS HIGHLY INFLAMMABLE. During charging, leave the battery compartment uncovered to improve ventilation. Never check the battery charge using �jumpers� (metal objects placed on the terminals). Avoid sparks or flames near the battery zone. Do not smoke to prevent explosion hazards. Before servicing operations, check for fuel or current leaks: eliminate any eventual leaks before proceeding with work. Do not charge batteries in confined spaces: make sure that there is adequate ventilation in order to prevent accidental explosion hazards as a result of the accumulation of gases released during charging operations. Always disconnect the batteries before performing any kind of servicing on the electrical system.
A liquid leaking from a tiny hole may be almost invisible but, at the same time, be powerful enough to penetrate the skin. NEVER USE HANDS TO CHECK FOR LEAKS: but use a piece of cardboard or wood for this purpose. If any liquid penetrates skin tissue, call for medical aid immediately. Failure to treat this condition with correct medical procedure may result in serious infection or dermatosis. In order to check the pressure in the system use suitable instruments.
WHEELS AND TYRES --
---
ELECTRICAL SYSTEMS --
5
---
---
Make sure that the tyres are correctly inflated at the pressure specified by the manufacturer. Periodically check the rims and tyres for damage. Stand away from (at the side of) the tyre when checking inflation pressure. Only check pressure when the vehicle is unloaded and the tyres are cold, to avoid incorrect readings as a result of over--pressure. Do not use parts of recovered wheels as incorrect welding brazing or heating may weaken and eventually cause damage to the wheel. Never cut or weld a rim mounted with an inflated tyre. To remove the wheels, lock both the front and rear vehicle wheels. After having raised the vehicle, position supports underneath, according to regulations in force. Deflate the tyre before removing any object caught in the tyre tread. Never inflate tyres using inflammable gases; as this may result in explosions and injury to bystanders.
REMOVAL AND RE--FITTING --
--
--
Lift and handle all heavy parts using suitable hoisting equipment. Make sure that parts are sustained by appropriate hooks and slings. Use the hoisting eyebolts for lifting operations. Extra care should be taken if persons are present near the load to be lifted. Handle all parts extremely carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing -- safety goggles, gloves and shoes. Avoid twisting chains or metal cables. Always wear safety gloves when handling cables or chains.
87666787A - 11 - 2007
SECTION 00 -- GENERAL -- CHAPTER 1
6
CONSUMABLES COMPONENT TO BE FILLED OR TOPPED UP
QUANTITY dm3 (litres)
Cooling system: less cab: . . . . . . . . . . . . . . . .
14.0
with cab . . . . . . . . . . . . . . . . .
16.0
Windscreen wash reservoir
RECOMMENDED NEW HOLLAND NEW HOLLAND SPECIFICATION PRODUCT
INTERNATIONAL SPECIFICATION
Water and AMBRA AGRIFLU fluid 50% + 50%
NH 900 A
--
2.0
Water and antifreeze
--
--
Fuel tank: . . . . . . . . . . . . . . .
88
Decanted, filtered diesel fuel
--
--
Engine oil sump: without filter: . . . . . . . . . . . . .
8.9
with filter: . . . . . . . . . . . . . . . .
9.5
Brake circuit
............
0.7
With front brakes . . . . . . . . .
1.0
Front axle: axle housing . . . . . . . . . . . . . final drives without brakes (each) . . . . . . . . . . . . . . . . . . final drives with brakes (each) . . . . . . . . . . . . . . . . . .
Oil AMBRA MASTERGOLD HSP
NH 324H (SAE 10W--30) NH 330H (SAE 15W--40))
API CI--4/CH--4 ACEA E7/E5
AMBRA BRAKE LHM oil
NH 610 A
ISO 7308
AMBRA MULTI G oil
NH 410 B
API GL4 ISO 32/46 SAE 10W--30 10W 30
4.5 1.0 1.5
Rear transmission (bevel drive, final drives and brakes), gearbox, hydraulic lift, PTO and hydraulic steering: . . . . . . . . . . . . . . . .
42
Grease fittings . . . . . . . . . . .
--
AMBRA GR9 grease
NH 710 A
NLGI 2
Air conditioning system -- coolant . . . . . . . . . . . . . . . -- oil . . . . . . . . . . . . . . . . . . . .
-0.80 0.15
--
--
R--134a SP20
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
1
SECTION 10 -- ENGINE
Chapter 1 -- Engine CONTENT Section
Description
Page
10 000
General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Schematic diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
10 001 10
Engine Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
10 001 54
Engine Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10 102 70
Crankshaft front seal -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
10 102 74
Crankshaft rear seal -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
10 106 12
Valve/rocker arm clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10 218 30
Engine injectors Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10 246 14
Bosch injection pump Removal--Installation, timing and air bleeding . . . . . . . . . . . . . . . . . 95
10 402 10
Coolant pump Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
10 402 30
Thermostatic valve Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10 406 10
Radiator Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10 414 10
Coolant pump and generator drive belts Adjusting tension . . . . . . . . . . . . . . . . . . . . . . . . 109
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
2
GENERAL SPECIFICATIONS Engine, technical type: --
Model T4040 type F4CE9484N*J601 (BOSCH pump) . . . .
--
Model T4050 -- type F4CE9484M*J601 (BOSCH pump) . .
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
diesel, 4--stroke
Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct
Number of cylinders in line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Piston diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104 mm
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
132 mm
Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4485 cm3
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.5:1
Maximum Power Output: --
Model T4040 -- type F4CE9484N*J601 . . . . . . . . . . . . . . . . .
63 kW (86 Hp)
--
Model T4050 -- type F4CE0454C*D600/*D603 . . . . . . . . . .
71 kW (97 Hp)
Maximum power speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2300 rpm
--
Maximum torque: Model T4040 -- type F4CE9484N*J601 .
370 Nm
--
Maximum torque: Model T4050 -- type F4CE9484M*J601
418 Nm
Maximum torque speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1300 rpm
Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Sump pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
structural, cast iron
Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
forced, with lobe pump
Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
from crankshaft
Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . .
1:1
Oil filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mesh screen on oil pick--up and filter cartridge in delivery line
Normal oil pressure with motor warmed--up at slow idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 bar
at fast idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9 bar (continued)
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
3 (overleaf)
GENERAL SPECIFICATIONS Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
coolant circulation
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 lines of vertical pipes with copper fins
Fan, attached to the pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
intake, in plastic with 11 blades
Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
centrifugal vane--type
Engine speed/coolant pump speed ratio . . . . . . . . . . . . . . . . . . . Coolant thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature ranges corresponding to each section: -- Initial blue section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- Middle green section (normal working conditions) . . . . . . . . . -- Final red section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1:1.977 coloured scale divided into three sections
Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
via thermostat valve
--
initial opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40° ÷ 60 °C 60° ÷ 110 °C 110° ÷ 120 °C 81 ± 2 °C
Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by tappets, rods and rocker arms via the camshaft located in the engine block; the camshaft is driven by the crankshaft using straight--tooth gears Intake: --
start: before T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10° ± 30’
--
end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10° ± 30’
Exhaust: --
start: before B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64°
--
end: after T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26°
Clearance between valves and rocker arms with engine cold: --
intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.25 ± 0.05 mm
--
exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.50 ± 0.05 mm
Power supply Air filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
dual cartridge dry air filter, with clogged filter indicator with centrifugal pre--filter and automatic dust ejector
Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with double diaphragm
Fuel filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . through wire filter in fuel supply pump, and replaceable cartridge on delivery line to injection pump Minimum fuel flow rate with pump shaft rotating at 1800 rpm .
127.6 l/h
Cam operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
via engine timing (continued)
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
4
(overleaf)
GENERAL SPECIFICATIONS BOSCH Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rotating distributor type
All--speed governor, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
centrifugal counterweights
Automatic advance regulator, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
hydraulic
Turbocharger: --
type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOLSET HX25 rotating distributor with speed governor and advance variator incorporated
BOSCH pump: --
Model T4040 -- type F4CE9484N*J601 . . . . . . . . . . . . . . . . .
VE 4/12 F1150--2856534
--
Model T4050-- type F4CE9484M*J601 . . . . . . . . . . . . . . . . .
VE 4/12 F1150--2856537
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
anticlockwise 1--3--4--2 (for all models)
SPECIFICATIONS
BOSCH--type injectors: F4CE9484N*J601/F4CE9484M*J601 . . . . . . . . . . . . . . . . .
2856255
Number of nozzle holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Nozzle hole diameter mm: F4CE9484N*J601/F4CE9484M*J601 . . . . . . . . . . . . . . . . .
0.237
Calibration pressure bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
260 รท 274
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
ENGINE BLOCK DATA
5
mm
Engine sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cast--iron monobloc with cylinder liners, crankshaft, camshaft and tappets
Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104.000 ÷ 104.024
Oversized cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . .
104.400 ÷ 104.424
Main journal half bearing seat diameter
external
no. 1--5
87.982 ÷ 88.008
internal
no. 2--3--4
87.977 ÷ 88.013
-- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59.222 ÷ 59.248
-- mid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59.222 ÷ 59.248
-- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59.222 ÷ 59.248
Diameter of standard tappet bores in crankcase . . . . . . . . . . . . . .
16.000 ÷ 16.030
Camshaft bushing seat diameter:
CRANKSHAFT AND BEARINGS DATA
mm
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
balanced with integral counterweights
Standard journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82.99 ÷ 83.01
Journal undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.250 -- 0.500
Main journal half bearing thickness . . . . . . . . . . . . . . . . . . . . . . . . .
2.456 ÷ 2.464
Main bearing shell undersizes on internal diameter . . . . . . . . . . . .
0.250 -- 0.500
Clearance between bearings and main journal
no. 1--5
0.022 ÷ 0.053
no. 2--3--4
0.019 ÷ 0.055
Standard crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68.987 ÷ 69.013
Crankpin undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.250 -- 0.500
Standard connecting rod half bearing thickness . . . . . . . . . . . . . . .
1.955 ÷ 1.968
Big--end bearing shell undersizes on internal diameter . . . . . . . . .
0.250 -- 0.500
Bearing to crankpin clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.019 ÷ 0.058
Standard crankshaft thrust washer width . . . . . . . . . . . . . . . . . . . .
37.280 ÷ 37.380
Width of main bearing for thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32.180 ÷ 32.280
Width of corresponding crankshaft journal . . . . . . . . . . . . . . . . . . .
37.475 ÷ 37.550
Crankshaft assembly endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.095 ÷ 0.270
87666787A - 11 - 2007
6
SECTION 10 -- ENGINE -- CHAPTER 1
CONNECTING ROD DATA
mm
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
printed in steel, oblique--cut type
Diameter of small end bushing seat . . . . . . . . . . . . . . . . . . . . . . . . .
40.987 ÷ 41.013
Outside diameter of small end bushing . . . . . . . . . . . . . . . . . . . . . .
41.279 ÷ 41.553
Interference between small end bushing and seat . . . . . . . . . . . . .
0.266 ÷ 0.566
Internal diameter of small end bushing (after press--fitting) . . . . .
38.019 ÷ 38.033
Diameter of seat for bearing shells on connecting rod . . . . . . . . .
72.987 ÷ 73.013
Connecting rod--crankpin end float . . . . . . . . . . . . . . . . . . . . . . . . . .
0.100 ÷ 0.330
PISTON DATA Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm light alloy with three compression rings, including two seal rings and one scraper ring
Standard piston diameter, measured at 61 mm from skirt base and perpendicularly to the gudgeon pin axis . . . . . . . . . . . . . . . . . .
103.714 ÷ 103.732
Piston clearance in cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.268 ÷ 0.310
Spare piston oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0,400
Piston protrusion at T.D.C. from cylinder block face . . . . . . . . . . .
0.280 ÷ 0.520
Gudgeon pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37.994 ÷ 38.000
Diameter of gudgeon pin seat in piston . . . . . . . . . . . . . . . . . . . . . .
38.010 ÷ 38.016
Gudgeon pin to seat clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.010 ÷ 0.022
Gudgeon pin to small end bearing clearance . . . . . . . . . . . . . . . . .
0.019 ÷ 0.039
Piston ring seat depth: -- 1st ring (measured on a diameter of 99 mm) . . . . . . . . . . . . . . .
2.705 ÷ 2.735
-- 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.440 ÷ 2.460
-- 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.030 ÷ 4.050
Piston ring thickness: -- 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.560 ÷ 2.605
-- 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.350 ÷ 2.380
-- 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.970 ÷ 3.990 (continued)
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
7 (overleaf)
PISTON DATA
mm
Piston ring groove clearance (measured vertically): -- 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.100 ÷ 0.175
-- 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.060 ÷ 0.110
-- 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.040 ÷ 0.080
Assembly clearance between piston ring ends in cylinder sleeves: -- 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.30 ÷ 0.40
-- 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.60 ÷ 0.80
-- 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.30 ÷ 0.55
Spare piston ring oversizing . . . . . . . . . . . . . . . . .
.....
......
VALVE TIMING GEAR DATA
0.400
mm
Internal diameter of camshaft support bushings (press--fitted and finished in seats): -- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54.083 ÷ 54.147
-- mid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54.083 ÷ 54.147
-- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54.083 ÷ 54.147
Diameter of camshaft journals: -- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53.995 ÷ 54.045
-- mid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53.995 ÷ 54.045
-- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53.995 ÷ 54.045
Clearance between camshaft journals and bushings . . . . . . . . . .
0.038 ÷ 0.152
Camshaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.230 ± 0.130
Crankshaft to camshaft teeth clearance . . . . . . . . . . . . . . . . . . . . .
0.076 ÷ 0.280
TAPPET DATA
mm
Tappet bore in crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.000 ÷ 16.030
Outside diameter of standard tappets . . . . . . . . . . . . . . . . . . . . . . .
15.929 ÷ 15.959
Tappet running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.041 ÷ 0.101
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
8
ROCKER ARM -- VALVE DATA
mm
Rocker--arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18.963 ÷ 18.975
Rocker--arm shaft seat diameter . . . . . . . . . . . . . . . . . . . . . . . . . . .
19.000 ÷ 19.026
Rocker arm bore to shaft clearance . . . . . . . . . . . . . . . . . . . . . . . . .
0.025 ÷ 0.063
Valve clearance for normal running (engine cold): -- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.25 ± 0.05
-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.50 ± 0.05
Cam lift: -- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.045
-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.239
CYLINDER HEAD DATA Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm in cast iron with fitted valve seats and seats for injectors and thermostat valve
Maximum face re--grinding depth. that can be removed from the cylinder head in the event of reboring . . . . . . . . . . . . . . . . . . . . . . . . .
0.130
Diameter of valve stem seat in cylinder head . . . . . . . . . . . . . . . . .
8.019 ÷ 8.039
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.960 ÷ 7.980
Assembly clearance between valve stem and seat . . . . . . . . . . . .
0.039 ÷ 0.079
Valve seat angle in head: --
inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60°
--
exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45°
Valve face angle: --
inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60°
--
exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45°
Diameter on head for fitting valve seat: --
inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46.987 ÷ 47.013
--
exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43.637 ÷ 43.663
Valve seat insert outside diameter: --
inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47.063 ÷ 47.089
--
exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43.713 ÷ 43.739
Valve stand--in relative to cylinder head face: --
inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.00 ÷ 1.52
--
exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.00 ÷ 1.52
Interference between valve seat and head: --
inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.050 ÷ 0.102
--
exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.050 ÷ 0.102 (continued)
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
9 (overleaf)
CYLINDER HEAD DATA
mm
Valve head diameter: -- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44.870 รท 45.130
-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41.870 รท 42.130
Inlet and exhaust valve springs: --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63.500
--
length under load of 329 N . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49.020
--
length under load of 641 N . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38.200
Injector protrusion relative to head face: D BOSCH injectors 2856255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not adjustable
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
10
TORQUE SETTINGS WITH ANGLE Tightening torque PARTS TO BE TIGHTENED
Thread
Angle Nm
kgm
Main bearing cap bolts phase 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12 x 1.5
50 ± 6
5.0 ± 0.6
--
phase 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12 x 1.5
80 ± 6
8.0 ± 0.6
--
phase 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12 x 1.5
--
--
90° ± 5°
phase 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 10 x 1.25
30 ± 3
3.0 ± 0.3
--
phase 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 10 x 1.25
60 ± 5
6.0 ± 0.5
--
phase 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 10 x 1.25
--
--
60° ± 5°
Bolts securing cylinder head . . . . . . . . . . . . . . .
M 12 x 1.75 x 70
50 ± 5
5.0 ± 0.5
90°
M 12 x 1.75 x 140
40 ± 5
4.0 ± 0.5
180°
M 12 x 1.75 x 180
70 ± 5
7.0 ± 0.5
180°
M 12 x 1.25
30 ± 4
3.0 ± 0.4
60° ± 5°
Big--end cap bolts
Note:
For the tightening sequence, see page 56, Fig. 124.
Bolts securing engine flywheel . . . . . . . . . . . . .
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
11
TORQUE WRENCH SETTINGS PARTS TO BE TIGHTENED
Thread
Bolts fastening pulley on crankshaft . . . . . . . . . . . . . . . . . . . . . Flywheel casing retaining bolts
Tightening torque Nm
kgm
M 12 x 1.75
110 ± 5
11.0 ± 0.5
M 12 x 120
85 ± 10
8.5 ± 1
M 12 x 80
85 ± 10
8.5 ± 1
M 10 x 80
49 ± 5
4.9 ± 0.5
M 10 x 40
49 ± 5
4.9 ± 0.5
M 8 x 1.25
24 ± 4
2.4 ± 0.4
M 8 x 1.50
60 ± 9
6 ± 0.9
Oil sump threaded plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 22 x 1.5
50 ± 5
5 ± 0.5
Rocker arm support retaining bolts . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
24 ± 4
2.4 ± 0.4
Tappet cover retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
24 ± 4
2.4 ± 0.4
Exhaust manifold retaining bolts . . . . . . . . . . . . . . . . . . . . . . .
M 10 x 1.50
53 ± 6
4.3 ± 0.6
Intake manifold retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
24 ± 4
2.4 ± 0.4
Oil cooler retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
24 ± 4
2.4 ± 0.4
Coolant pump retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
24 ± 4
2.4 ± 0.4
Coolant inlet manifold retaining bolts . . . . . . . . . . . . . . . . . . .
M 10 x 1.50
24 ± 4
2.4 ± 0.4
Thermostat valve assembly retaining bolts . . . . . . . . . . . . . .
M 8 x 1.25
24 ± 4
2.4 ± 0.4
Fan support retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25 x 50 M 10 x 1.50 x 25
10 ± 2 43 ± 6
1 ± 0.2 4.3 ± 0.6
Injector fastener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
60 ± 5
6.0 ± 0.5
Fuel pump retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
24 ± 4
2.4 ± 0.4
Nuts securing turbine mod. T4050 . . . . . . . . . . . . . . . . . . . . .
M 10 x 1.25
43 ± 6
4.3 ± 0.5
Alternator retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.50
24 ± 4
2.4 ± 0.4
Starter motor retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . .
M 10 x 1.50
49 ± 5
4.9 ± 0.5
Camshaft plate retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
24 ± 4
2.4 ± 0.4
Injection pump retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
12 ± 5
1.2 ± 0.5
Oil pump gear casing retaining bolts . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
24 ± 4
2.4 ± 0.4
Additional counterweight retaining bolts . . . . . . . . . . . . . . . . .
M 10 x 1.5
48 ± 8
4.8 ± 0.8
Bolts securing camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
36 ± 4
3.6 ± 0.4
.......................
Oil sump retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
12 SPECIAL TOOLS
Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual. List of specific tools required for the various operations described in this Section. X 380000216 380000220 X 380000221
380000301
X 380000302 380000304
380000362 X 380000364
Engine removal and installation tool. Clamp for fitting piston in cylinder liner (60--125 mm). Pliers for piston ring disassembly and reassembly (65--110 mm). Rotating stand for overhaul operations (capacity 1000 daN, torque 120 daN/m). Tool for engine valve disassembly and reassembly. Pair of gauges for angular tightening with 1/2� and 3/4� square connection. Crankshaft lifting tool. Dial gauge base for various measurements (use with 380000228).
X 380000664
Splining tool for fitting rear seal on crankshaft.
X 380000665
Tool to extract crankshaft front seal.
X 380000666
Splining tool for fitting front seal on crankshaft.
X 380000667
Drift for camshaft bushing disassembly and reassembly (use with 380000668).
380000668
Grip for interchangeable drifts.
X 380000669
Gasket extraction tool.
X 380000670
Tool for cartridge filter disassembly.
380000671
Injector extraction tool.
380000975
Box with full set of tools to regrind valve seats.
380000976
Spring load test appliance.
380001003
Complete square to check for connecting rod distortion.
380001268
Belt tension gauge.
Injection pump bench test. 380000228
Dial gauge (0--5 mm).
X 380000732
Tool for engine flywheel rotation (use with 380000988).
Movable tool for dismantling tractors with bracket 380000500 and adapter plate 380000844.
X 380000914
Dial--gauge holder tool for rotary injection pump timing (use with 380000228).
X 380000661
Engine mounting brackets for rotating stand 380000301.
X 380000988
Plate for engine flywheel rotation tool with flywheel timing pin (use with 380000732).
X 380000663
Tool to extract crankshaft rear seal.
380000569
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
13
MIF1096A
1 Engine view
87666787A - 11 - 2007
14
SECTION 10 -- ENGINE -- CHAPTER 1
Oil path under pressure Oil return path under gravity MIF1098A
2 Engine lubrication diagram
Forced--circulation lubrication is accomplished by the following components: -- oil pump, housed at the front of the crankcase, driven by the grooved bushing keyed onto the shank of the crankshaft; -- water / oil cooler, housed in the crankcase;
87666787A - 11 - 2007
----
oil pressure control valve incorporated in the cooler assembly; by--pass valve to cut off clogged oil filter, incorporated in the cooler assembly; cartridge oil filter.
SECTION 10 -- ENGINE -- CHAPTER 1
15
Coolant recirculating in the engine Coolant entering the pump MIF1099A
3 Cooling diagram
The forced circulation, closed--circuit engine cooling system is composed of the following components: -- a lubricating oil cooler;
---
a centrifugal coolant pump housed at the front of the crankcase; a thermostat valve governing coolant circulation.
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
16
MIF1102A
4 Additional counterweight diagram
1. 2. 3. 4. 5.
Retaining bolts Support Retaining bolts Gear Balancing weight
87666787A - 11 - 2007
6. 7. 8. 9. 10.
Half bearings Counter--shaft Gear Ring O--rings
SECTION 10 -- ENGINE -- CHAPTER 1
17
5 Camshaft view A. Inlet valve cam.
B. Exhaust valve cam.
EXHAUST GAS RECIRCULATION SYSTEM (EGR)
The internal EGR system is not provided with any electronically controlled elements: the system is always on.
On the TIER 3 version, the exhaust cam profile has been modified to permit partial opening of the related valve during the inlet phase (exhaust gas recirculation EGR) with the consequent re--introduction of some of the exhaust gases into the engine cylinders. The exhaust gases can be partially redirected into the cylinders in order to reduce the maximum combustion temperature values which are responsible for the production of nitrogen oxide (NOx). The exhaust gas recirculation system (EGR), reducing the temperature of combustion by decreasing the concentration of oxygen in the combustion chamber, is therefore an effective system to control emissions of NOx.
Its configuration needs no additional elements such as control valves, pipes or heat exchangers. The exhaust cam (B) in addition to the main lobe has another lobe (see sect. A--A, fig. 5) with respect to the configuration without EGR. The additional lobe, during the inlet phase of the cylinder under examination, permits briefly opening the exhaust valve generating recirculation due to the exhaust gases returning caused by the lower pressure created in the inlet phase inside the cylinder.
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
18
TROUBLESHOOTING Problems Engine does not start.
Possible Problem 1. Battery partially discharged. 2. Battery terminal corroded or loose.
Engine stalls.
Solutions Check and recharge Replace if necessary.
batteries.
connections Clean, inspect and tighten terminal nuts. Replace terminals and nuts if excessively corroded.
3. Injection pump timing incorrect.
Adjust injection pump timing on the engine.
4. Impurities or water in fuel lines.
Disconnect fuel lines from injection pump and clean thoroughly. If necessary clean and dry the fuel tank.
5. No fuel in tank.
Fill tank.
6. Fuel supply pump malfunction.
Check and necessary.
7. Air in fuel system.
Check fuel lines, unions, supply pump, filters and injection pump for air, then bleed system; then bleed the air from the circuit.
8. Starter motor faulty.
Repair or replace starter motor.
9. Thermostarter faulty.
Check and replace thermostarter if necessary.
1. Slow idling speed too low.
Adjust slow idling speed.
replace
pump
if
2. Injection pump delivery irregular. Check delivery on the test bench. 3. Impurities or water in fuel lines.
Disconnect fuel lines from injection pump and clean thoroughly. If necessary clean and dry the fuel tank.
4. Fuel filters clogged.
Replace the filter cartridges.
5. Incorrect valve -- rocker arm Adjust the clearance between the clearances. rocker arms and the valves. 6. Burnt or cracked valves.
Replace the valves.
7. Air in fuel system.
Check fuel lines, unions, supply pump, filters and injection pump for air, then bleed system; then bleed the air from the circuit.
8. Injection pump drive mechanism Replace damaged parts. damaged. (continued)
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
19 (overleaf)
Problems Engine overheating.
Possible Problem
Solutions
1. Coolant pump malfunction.
Overhaul pump necessary.
and
replace
if
2. Thermostat faulty.
Replace thermostat.
3. Radiator inefficient.
Remove internal deposits by flushing. Check for leaks and repair.
4. Deposits in cylinder head and Flush out coolant system. crankcase coolant passages. 5. Coolant pump and fan drive belt Check and adjust belt tension. slack. 6. Coolant level low.
Top up expansion tank with specified coolant mixture.
7. Incorrect engine timing.
Check and adjust engine timing.
8. Injection pump calibration Calibrate pump on test bench to incorrect -- delivering too much or values specified in calibration tables. too little fuel. 9. Air filter clogged.
Clean the assembly and, if necessary, replace the filtering element.
Engine lacks power and 1. Injection pump timing incorrect. runs unevenly. 2. Auto advance regulator injection pump damaged.
Adjust injection pump timing on the engine.
in Overhaul injection pump and adjust on test bench to values specified in calibration table.
3. Control valve journal worn.
Overhaul injection pump and adjust on test bench to values specified in calibration table.
4. Injection pump delivery irregular. Overhaul injection pump and adjust on test bench to values specified in calibration table. 5. All--speed governor damaged.
Overhaul injection pump and adjust on test bench to values specified in calibration table.
6. Injectors partially obstructed or Clean, overhaul damaged. injectors. 7. Impurities or water in fuel lines.
and
calibrate
Disconnect fuel lines from injection pump and clean thoroughly. If necessary clean and dry the fuel tank. (continued)
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
20
(overleaf)
Problems
Possible Problem 8. Fuel supply pump damaged.
Solutions Replace fuel supply pump.
9. Incorrect valve -- rocker arm Adjust the clearance between the clearances. rocker arms and the valves. 10. Cylinder compression low.
Test compression and engine if necessary.
overhaul
11. Air filter clogged.
Clean the assembly and, if necessary, replace the filtering element.
12. Tie--rod in linkage between Adjust to correct length. accelerator and injection pump incorrectly adjusted. 13. Fast idling speed screw on Adjust fast idling speed screw. injection pump incorrectly adjusted. The engine makes anomal- 1. Injectors partially obstructed or Clean, overhaul ous knocking noises. damaged. injectors.
and
calibrate
2. Impurities accumulating in fuel Clean fuel lines and replace severely lines. dented pipes; clean injection pump if necessary. 3. Injection pump timing incorrect.
Adjust injection pump timing on the engine.
4. Crankshaft knocking due to Re--grind crankshaft journals and excessive play in one or more crankpins. Fit oversize shell bearings main or big--end bearings or and thrust washers. excessive endfloat. 5. Crankshaft out of balance.
Check crankshaft alignment and balance; replace if necessary.
6. Flywheel bolts loose.
Replace any bolts that have worked loose and tighten all bolts to the specified torque + angle values.
7. Connecting rod axes not parallel. Straighten connecting rods, check axes parallelism; replace con rods if necessary. 8. Pistons knock due to excessive Rebore cylinder liners and fit oversize wear. pistons. 9. Noise caused by excessive play Fit oversize gudgeon pin, rebore of gudgeon pins in small--end and piston seats and small--end bushings. piston bushings. Loose fit of Replace with new bushings. small--end bushing. 10. Excessive tappet / valve noise.
Check for broken springs or excessive play between valve stems and guides, tappets and bores; adjust the clearance between valves and rocker arms. (continued)
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
21 (overleaf)
Problems
Possible Problem
Solutions
The engine produces 1. Maximum delivery of injection Calibrate pump on test bench to abnormal smoke: black or pump too high. values specified in calibration tables. dark grey. 2. Injection pump delivery Adjust injection pump timing or check excessively retarded or automatic advance regulator. automatic advance regulator damaged. 3. Injection pump excessively advanced. 4. Injectors partially obstructed or adjusted.
delivery Adjust injection pump timing on the engine.
or totally Clean, overhaul and calibrate incorrectly injectors; replace them if necessary.
5. Air filter clogged.
Clean the assembly and, if necessary, replace the filtering element.
6. Loss of engine compression due Replace damaged parts or, to: necessary, overhaul the engine. -- piston rings sticking; -- cylinder liner wear; -- worn or incorrectly adjusted valves. 7. High--pressure damaged.
fuel
if
lines Inspect and replace if necessary.
Blue, grey--blue or grey-- 1. Injection pump delivery Adjust injection pump timing or check white smoke. excessively retarded or automatic advance regulator. automatic advance regulator damaged. 2. Injectors obstructed or damaged. Clean, overhaul and calibrate injectors, replace if necessary. 3. Oil leaking past piston rings due Replace damaged parts or, to sticking rings or cylinder liner necessary, overhaul the engine. wear.
if
4. Oil leaking through the inlet valve Overhaul cylinder head. guides due to guide or valve stem wear. 5. Engine does not reach correct Replace thermostat. operating temperature (thermostat faulty). Engine runs switching off.
on
after 1. Engine stop damaged.
electromagnet Replace electromagnet.
2. All--speed governor damaged.
Overhaul injection pump and adjust on test bench to values specified in calibration table.
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
22
Op. 10 001 10 ENGINE Removal--Installation
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 1. Remove the bonnet as described in operation 90 100 22. 2. Extract the fixing pin and remove the ballast (1); unscrew the retaining screws and retrieve the ballast support (2).
6 3. If the tractor is a T4040 Supersteer or T4050 Supersteer model, position and secure the bracket 380001613 (1) together with the spacers 50162 (4) on the front axle (3) and associated support (2).
7 4. Unscrew the retaining bolts and remove the side grille (1). Perform this operation on the other side of the tractor too.
8
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
23
5. Unscrew the related retaining bolt and loosen the guide (1), unhook the catch and take out the condenser (2).
9 6. Disconnect the electrical connection from the compressor (1) and unscrew the related retaining bolts. Remove the brackets fixing the pipes of the air conditioning system and take the condenser, compressor and pipes under the transmission without disconnecting the pipes.
10 7. Unscrew the bolts (3) securing the exhaust pipe (1), unscrew the exhaust silencer retaining bolts (2) and remove the entire assembly. Unscrew the retaining bolts and remove the heat shield.
11 8. Remove the guard (1) and disconnect the cables from the starter motor (2).
12 87666787A - 11 - 2007
24
SECTION 10 -- ENGINE -- CHAPTER 1
9. Disconnect the pipes (1) of the cab heating system and drain the engine cooling system.
13 10. Unscrew the plug and drain the oil from the rear transmission casing (the prescribed quantity is 42 litres).
25628
14 11. Disconnect the power steering pipes (2), unscrew the related retaining bolts and remove the bracket (1).
15 12. Disconnect the electrical connection from the brake fluid reservoir (1), unscrew the retaining bolts and remove the reservoir from the supporting bracket.
16 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
25
13. Unscrew the retaining bolts and remove the bonnet bracket (1).
17 14. Disconnect: the main electrical connections (1), the connection of the steering sensor and the cab ground, disconnect the throttle cable (2) from the injection pump.
18 15. Disconnect the diesel pipes (1) from the injection pump. Disconnect the pipe (2) from the pump.
19 16. Disconnect: the transmission oil cooler pipes (1) and the front axle differential lock pipe (2).
20 87666787A - 11 - 2007
26
SECTION 10 -- ENGINE -- CHAPTER 1
17. If the tractor is a T4040 Supersteer or T4050 Supersteer model, unscrew the front and rear retaining bolts, unscrew the front pivot pin retaining screw and remove the bracket (1). Unscrew the relative retaining bolts and remove the rear guard.
21 18. If the tractor is a T4040 Deluxe or T4050 Deluxe model, unscrew the front, central and rear retaining bolts and remove the guard on the propeller shafts (1).
27801
22 19. Remove the circlip (2) and move the front sleeve (1) backwards in order to free it from the groove on the front axle.
1
2
25647
23 20. Remove the circlip (2) and move the rear sleeve (1) in order to release it from the groove on the drive.
1
2
25646
24 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1 21. Remove the propeller shaft central support (1) retaining bolts and extract the shaft together with the support.
27
1
25648
25 22. Loosen the retaining bolt and turn the bracket (1) through 90°.
26 23. For models fitted with brakes on the front axle it is necessary to drain the brake fluid tank and disconnect the pipes (1, 2 and 3) from the block.
27 24. Unscrew: the retaining bolts of the pipe (1) delivering oil to the pump and the bolts retaining the pipe (2) to the filter support.
28 87666787A - 11 - 2007
28
SECTION 10 -- ENGINE -- CHAPTER 1
25. Loosen the related clamps and remove the sleeve (2) from the pipe (1) and remove the transmission oil inlet pipe together with the above--mentioned sleeve.
29 26. Unscrew the retaining bolts and remove the guard (1). Do this on both sides.
30 27. Unscrew the retaining bolts and remove the cab mat guard (2). Remove the plastic pedal (1).
31 28. Unscrew the bolts (1) (on both sides), extract the spring pin (2) and remove the throttle pedal (3).
32 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
29
29. Raise the front part of the cab mat; remove the two plastic plugs and, through the hole (1), unscrew the four upper bolts securing the engine to the clutch casing.
33 30. Place a stand under the clutch casing, attach the rear portion of the engine to a hoist, using chains (1).
34 31. Unscrew the remaining bolts (1) securing the engine to the clutch casing and separate the engine with the front axle from the clutch casing.
35 32. Disconnect the connections (1) from the clogged air filter sensor.
36 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
30
33. Place a stand under the rear portion of the bevel drive casing (T4040 Supersteer or T4050 Supersteer) or two stands: one under the axle support at the rear and the other under the front side. (models with standard front axle). Keeping the chains (1, fig. 34) connected, join one chain (5) to the front of the engine. Unscrew the clamps and remove: the engine oil vapour recirculation pipe (3), turbocharger intake pipe (2), and the intake air cooler pipes (1 and 4).
37 34. Disconnect the lower (1) and upper sleeves from the radiator, remove the bracket (2) fastening the power steering pipe.
38 35. For the T4040 Deluxe or T4050 Deluxe models, insert a wooden wedge on each side between the axle support and the axle itself. For all models, unscrew the bolts (1) on both sides and separate the engine from the axle--support assembly with the radiator and battery. 36. Rest the engine on an adequate support. 37. To re--fit the engine, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Apply the torque settings listed on page 12.
--
Connect the engine, with chains, to the hoist.
87666787A - 11 - 2007
39
SECTION 10 -- ENGINE -- CHAPTER 1 --
Refit the engine to the axle--support assembly with the radiator, battery, coolers: intake air and transmission oil.
--
31
--
Connect the upper and lower sleeves of the radiator to the engine.
If the tractor is a T4040 Supersteer or T4050 Supersteer model, unscrew the retaining bolts and remove the bracket 380001613 with the spacers 50612.
--
Connect the differential lock control pipe.
--
Secure the power steering pipes.
--
--
Before refitting the engine to the clutch box carefully clean the mating surfaces and apply sealing compound (2 mm diameter), according to the diagram shown Section 21, Chapter 1, page 30.
Connect the pipes to the transmission oil cooler pipes.
--
Connect the fuel supply and return lines to the injection pump.
--
Connect the delivery pipe to the power steering pump.
--
Connect all the electrical connections between the cab and engine.
--
Position and secure the ground cable between the cab and engine.
--
Position and secure the throttle control rod.
--
Position the engine on the clutch casing and secure it with the specific bolts.
--
Fit the plastic plugs on the cab floor.
--
Move the cab mat into the right position and secure it with the two bolts on the upright (do this on both sides).
--
Fit the throttle pedal with the plastic part.
--
--
Position and secure the guard of the cab mat (do this on both sides).
Position the upper engine bracket with the heat guard and secure it.
--
--
Fit the two lower guards of the control panel (do this on both sides).
Connect the front pipes to the rear pipes delivering coolant to the cab heater.
--
--
Position, connect and secure the oil delivery pipe to the lift.
Position and secure the brake fluid tank and connect the electrical connection to the above--mentioned part.
--
Position, connect and secure the lift control pump oil inlet pipe.
--
Connect the steering control pipes.
--
--
For models fitted with brakes on the front axle it is necessary to connect the pipes to the related block.
Connect the electric cable to the starter motor and fit the relevant protection.
--
Position and secure the heat shield, exhaust silencer to the engine and to the cab.
--
Position and secure the bracket between the clutch housing and engine.
--
Position and secure: the compressor, condenser and related pipes.
--
Position the propeller shaft, secure the central support, slide the two front and rear sleeves and secure them with the circlips.
--
Connect the electrical connection to the compressor.
--
Position and secure the side grille (do this on both sides).
--
Secure: the radiator fixing bracket, engine oil vapour recirculation pipe, inlet pipe and intake air cooler pipes.
--
Connect the clogged air filter sensor pressure switch and steering sensor connections.
--
For models fitted with brakes on the front axle it is necessary to fill the relevant tank (see sect. 00, page 6 for the prescribed product and quantity) and bleed the braking system (see sect. 33).
--
--
--
If the tractor is a T4040 Deluxe or T4050 Deluxe model, position the propeller shaft guard and secure it. If the tractor is a T4040 Supersteer or T4050 Supersteer model, position the propeller shaft rear guard and secure it. If the tractor is a T4040 Supersteer or T4050 Supersteer model, position the propeller shaft front guard and secure it.
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
32 --
--
Screw the plug on the rear transmission casing and fill up with oil (see sect. 00, page 6 for the prescribed product and quantity).
--
Position and secure the ballast support.
--
Position and secure the ballast.
Fill up the engine cooling system (see sect. 00, page 6 for the prescribed product and quantity).
--
Install the bonnet as described in operation 90 100 22.
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
33
Op. 10 001 54
ENGINE Disassembly -- Assembly The figures refer to the F4CE9484M*J601 versions of 71 kW (97 hp) mod. T4050. The revision is to highlight and describe the specific parts of the versions F4CE9484N*J601 of 63 kW (86 hp) mod. T4040 and their respective variants.
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 1. Remove the engine as described in operation 10 001 10, proceed as follows. 2. Drain off the engine oil by removing the plug from the sump and the oil filler plug. 3. Detach the fan unit from the fan pulley. 4. To be able to fit the bracket 380000661 (for fixing the engine to the overhaul stand) to the crankcase, it is necessary to remove the wiring (1) from the left--hand side of the engine.
MIF1103A
40 5. To be able to fit the bracket 380000661 to the crankcase on the right--hand side, remove the starter motor (5), oil filter (3), clamp (4), and turbine oil return pipe (1). 6. Fix the gearbox to the rotating stand 380000301. Detach the oil delivery pipe (2).
MIF1104A
41
87666787A - 11 - 2007
34
SECTION 10 -- ENGINE -- CHAPTER 1
7. Remove the intake manifold (2). 8. Disconnect the engine oil vapour recovery pipe from the blow--by (3). 9. Remove the tappet covers (1). 10. Remove the pipes with the quick--fit coupling (6) and (8). 11. Remove the piping from the LDA system (5). 12. Remove the fuel filter (7). 13. Remove the heater (4). 14. Remove the control unit for the heater (10). 15. Remove the fuel filter support (9).
MIF1105A
42 16. Remove the injector feed pipe (4) from the injection pump (3). 17. Remove the brackets on the cylinder head of the pipe assembly (1), (2) and (6). 18. Replace fuel supply pump (5).
MIF1107A
43 19. Detach the fuel pipe assembly (1) from the injectors. 20. Remove the fuel outlet pipe (2) from the injectors removing the screw (3) and the seal (4).
MIF1108A
44
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
35
21. Remove the screws (2) and the turbine (1). 22. Remove the exhaust manifold (3). 23. Remove the belt (3, fig. 46) of the auxiliary members by loosening the tightener.
MIF1109A
45 24. Remove the alternator (6), fan pulley (2) and the tightener (8). Remove the support (1) of the pulley (2) and the oil cooler (7). 25. Remove the coolant pump (5). 26. Remove the engine cooling system fitting (4) from the crankcase. NOTE: The coolant pump (5) cannot be overhauled. It must be replaced if there is any irregular operation.
MIF1110A
46 27. Lock the flywheel to stop it turning, remove the fixing screws (1) from the pulley (2).
MIF1111A
47 Removing the crankshaft front seal (Op. 28. ÷ 32.) 28. Apply tool 380000665 (4) on the front tang (2) of the crankshaft. 29. Perforate the inner seal (1) with a drill bit (∅ ∅ 3.5 mm) through the guide holes of the tool 380000665 (4), for a depth of 5 mm. 30. Secure the tool 380000665 (4) to the seal (1) with the screws (3) provided. 31. Extract the seal (1) by screwing down the screw (5). MIF0916A
48 87666787A - 11 - 2007
36
SECTION 10 -- ENGINE -- CHAPTER 1
32. Fit the tie rod (3) of the tool 380000669 to the outer seal (1) as shown in the figure 49 and with the lever (4), extract it from the front cover (2).
MIF0917A
49 33. Turn the engine over, take out the screws (2) and remove the oil sump (1).
MIF1117A
50 34. Take out the screws (2) and remove the oil pump (1). NOTE: The oil pump (1) cannot be overhauled. It must be replaced if there is any irregular operation.
MIF1112A
51 35. Using the pin (1), lock the additional counterweights (2) at the T.D.C. Unscrew the retaining bolts (3) and remove the additional counterweights (2).
MIF1113A
52 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
37
36. Before removing the injection pump, do the timing and lock the engine flywheel with cylinder no.1 at T.D.C. as indicated on page 8, using tools 380000988 and 380000732. Then loosen the bolt (2), remove the “ L” spacer (1) and lock the screw (2) in order to keep the pump in time with the engine flywheel.
NOTE: Keep the ”L” spacer with the pump casing.
MIF0920A
53 37. Remove the three nuts (2) (3) (5) securing the injection pump (1) to the crankcase (4) and extract it from its housing.
MIF0922A
54 38. Remove the screws (2) fixing the engine flywheel (1) to the crankshaft.
MIF1115A
55 39. Screw two pins (2) of the appropriate length into the holes in the crankshaft (3). 40. Extract the engine flywheel (1) so it can be slung with the lift and put it away in a specific container.
MIF1116A
56 87666787A - 11 - 2007
38
SECTION 10 -- ENGINE -- CHAPTER 1
Removing the crankshaft rear seal (Op. 41.÷ 44.) 41. Extract the seal, fitting the tool 380000663 (3) on the rear shank (1) of the crankshaft. 42. Perforate the inner seal (5) with a drill bit (∅ ∅ 3.5 mm) through the guide holes of the tool 380000663 (3), for a depth of 5 mm. 43. Secure the tool 380000663 (3) to the seal (5) by screwing down the screws (2) supplied. 44. Extract the seal (5) by screwing down the screw (4). MIF0927A
57 45. Take out the screws (2) and remove the timing gear box (1), retrieving the injection pump gear. NOTE: Note down the assembly position of the screws (2) as they have different sizes.
MIF1125A
58 46. Take out the screws (1) and remove the gears (3) and (4) from the camshaft (2).
MIF1118A
59 47. Take out the bolts (1) and remove the hydraulic pump drive gear (2).
MIF1119A
60 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
39
48. For each cylinder, remove the rocker arm assembly (1) loosen the adjuster nuts (3), unscrew the adjusters (4) and take out the screws (2).
MIF0933A
61 49. Extract the injectors (2) with tool 380000671 (1).
MIF0934A
62 50. Take out the screws (1) fixing the head to the crankcase.
1
MIF1120A
63 51. After fitting the brackets (1) and (2) hook the metal cables and detach the cylinder head from the crankcase with the hoist. NOTE: After removing the cylinder head, remove the brackets (1) and (2).
MIF1121A
64 87666787A - 11 - 2007
40
SECTION 10 -- ENGINE -- CHAPTER 1
52. Valves are removed with tool 380000302 (1), applying pressure on the cap (3) so that, by compressing the springs (4), it is possible to remove the cotters (2). Then remove: the plate (3), springs (4). Repeat this operation on all valves (5).
MIF1122A
65 53. Remove the intake manifold cover and extract the oil seals (1) fitted on the valve stems. To remove the valves, turn the head over. NOTE: Mark the inlet and exhaust valves before removing them.
MIF1123A
66 NOTE: The inlet valves differ from the exhaust valves in the size of the head and there being an additional reference mark (1) on the stem. A = Inlet valve. B = Exhaust valve.
MIF0948A
67 54. Remove the thermostat valve (2) from the governor body (1) taking out the screws (3).
MIF1124A
68 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
41
55. Take out the screws (1) securing the connecting rod caps (2) and remove them. 56. Extract the pistons together with the connecting rods from the top of the crankcase. NOTE: Keep the half bearings in their respective housings since, if they are used, they must be mounted in the position found upon disassembly.
MIF0938A
69 57. Remove the rings (1) from the piston (3) with the pliers 380000221 (2).
MIF0950A
70 58. The piston pin (1) retaining snap rings (2) should be removed using a marking tool (3).
MIF0951A
71 59. Take out the screws (1) and remove the main bearing caps (2).
MIF1126A
72 87666787A - 11 - 2007
42
SECTION 10 -- ENGINE -- CHAPTER 1
60. The penultimate main bearing cap (1) and the related mounting have the half bearing (2) equipped with a shoulder. Remove the pistons with the connecting rods. NOTE: Note down the assembly position of the top and bottom half bearings since, if they are reused, they must be mounted in the position found upon disassembly.
MIF0940A
73 61. Using tool 380000362 (1) and a hoist, remove the crankshaft (2) from the crankcase.
MIF1127A
74 62. Remove the main half bearings (1). 63. Take out the screws (2) and remove the oil nozzles (3).
MIF0942A
75 64. Take out the screws (1) and remove the plate (3) retaining the camshaft (2). NOTE: Note down the assembly position of the plate (3).
MIF1128A
76 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
43
65. Carefully extract the camshaft (1) from the crankcase.
MIF1129A
77 66. Extract the tappets (1) from the crankcase.
MIF0945A
78 67. When disassembling and renewing the front and rear camshaft bushings (1) use the drift 380000667 (2) and grip 380000668 (3).
MIF1130A
79
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
44 GENERAL NOTES ---
--
After disassembling the engine, thoroughly clean the parts. Pages (44รท66) show the assembly operations that require extra attention in order to assemble parts correctly. The torque settings are shown on pages 10รท11.
ALSO REMEMBER THAT: ----
When partially or fully disassembling the engine, all seals must be replaced. Before inserting rotating parts and seals in seats, lubricate the parts with engine oil. When fitting the oil filter, lubricate the seal with engine oil.
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts and use appropriate tools to align fixing holes. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
ENGINE ASSEMBLY ON THE BENCH FITTING THE BUSHINGS
(Disassembly operation 67.) -- To fit and renew the front and rear camshaft bushings (1) use the drift 380000667 (2) and grip 380000668 (3). NOTE: The bushings (1) must be directed so that the lubrication holes coincide with the holes in the seats in the crankcase. MIF1130A
80
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
45
FITTING THE TAPPETS
(Disassembly operation 66.) -- Lubricate the tappets (1) and fit them in their seats in the crankcase.
MIF1131A
81
FITTING THE CAMSHAFT
(Disassembly operation 64. รท 65.) -- Lubricate the bushings supporting the camshaft and mount the camshaft (1) taking care that, during this process, the bushings or the supporting seats do not get damaged.
MIF1129A
82 --
Position the plate (1) retaining the camshaft (2) with the slot facing towards the top of the crankcase and the punchmark facing the operator. Tighten the screws (3) to the prescribed torque stated on page 11.
MIF1132A
83 --
Check that the end float of the camshaft (1) comes within the tolerance range prescribed in Main Data on page 4.
MIF1133A
84 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
46
FITTING THE OIL NOZZLES
(Disassembly operation 63.) -- Fit the nozzles (2) and tighten the retaining bolts (1).
MIF0957A
85
FITTING THE CRANKSHAFT
(Disassembly operations 59. á 62.) -- If any sign of seizure, scoring or ovality is found on the main journals or crankpins, they must be reground. Before reconditioning the pins (1), use a micrometer (2) to measure the pins of the shaft and according to the undersizes given in Main Data on page 4, define the diameter to which the pins must be reduced.
MIF0958A
86 --
--
Check that the toothing of the grooved bushing (1), splined onto the crankshaft (2) is neither damaged nor worn; if it is, remove it with the a suitable extractor (3). When fitting the new grooved bushing it must be heated for 60 minutes in an oven at a constant temperature of 160 °C and spline it onto the crankshaft.
MIF1134A
87 NOTE: If the main journals of the crankshaft are undersized it is necessary to replace the main bearings of the same undersize class made. Do not modify the bearings in any way. The main bearings (1) are supplied as spare parts with an undersized inside diameter of 0.250 -0.500 mm. Carefully clean the main half bearings (1) with a lubrication hole and fit them into their respective seats. The penultimate main half bearing (1) is equipped with semi--circular thrust washers. 87666787A - 11 - 2007
MIF0962A
88
SECTION 10 -- ENGINE -- CHAPTER 1 --
47
Fit the crankshaft (3) with the gear (1) and the grooved bushing (2).
MIF1135A
89 --
Check the clearance between the main journals of the crankshaft and their respective bearings, proceeding as follows: -- Make sure that all parts are perfectly clean and remove all traces of oil. -- Position a length of calibrated wire (3) on the crankshaft journals (4), parallel to the crankshaft centreline. -- Fit the caps (1) complete with half bearings (2) on their supports.
MIF0964A
90 --
Insert the pre--lubricated screws (1) and tighten them in three successive stages. 1st and 2nd phase with a torque wrench to the torque given on page 10.
MIF0965A
--
91
3rd phase with tool 380000304 (1)
positioned as in the figure, further tighten the screws (2) with an angle of 90° ± 5°.
MIF0966A
92 87666787A - 11 - 2007
48
SECTION 10 -- ENGINE -- CHAPTER 1
-- Remove the support caps. The clearance between the main bearings and the relevant journals is measured by comparing the width of the calibrated wire (2), at the point of greatest crushing, with the graduation of the scale on the case (1) containing the calibrated wire. The numbers shown on the scale indicate the mating clearance in millimetres. Check that the clearance is as prescribed in Main Data on page 4, then lubricate the main bearings and permanently mount the supports, tightening the retaining bolts as described above. MIF1075A
93 The crankshaft end float is checked by placing a dial gauge (2) with a magnetic base on the crankshaft (3) as shown in the figure, the normal assembly clearance must come within the tolerance specified in Main Data on page 4. If the clearance is found to be any greater, change the main half bearings of the penultimate rear thrust bearing support (1) and check the clearance again between the crankshaft journals and main half bearings.
MIF1076A
94
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
49
FITTING THE CONNECTING ROD--PISTON ASSEMBLY
(Disassembly operations 57. รท 58.) -- The following references are cut into the crown of the piston: 1. Spare part number and design modification number; 2. Arrow showing the direction of assembly of the piston in the cylinder liner, it must face the front of the crankcase (auxiliary member side). 3. Date of manufacture. 4. Stamping indicating testing of the 1st groove insert. --
MIF0967A
95
Using the pin (3) connect the piston (2) to the connecting rod (4) so that the reference arrow (1) for fitting the piston (2) in the cylinder liner is facing as described in point 2.
MIF0968A
96 --
Insert the rings (2) retaining the pin (1).
MIF1060A
97 --
To fit the rings (1) on the piston (3) use tool 380000221 (2).
NOTE: The piston rings (see Main Data on page 4), are supplied as spare parts in the following sizes: -- standard, marked with yellow paint; -- oversized by 0.5 mm and marked with yellow/green paint.
MIF0969A
98 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
50 --
Fit the half bearings (1) on the connecting rod and cap.
NOTE: If the crankpins of the crankshaft are undersized it is necessary to replace the big end bearings of the same undersize class made. Do not modify the half bearings in any way.
MIF0970A
99
FITTING THE PISTON CONNECTING ROD ASSEMBLIES IN THE CYLINDER LINERS
(Disassembly operation 56.) -- Lubricate the pistons well, including the piston rings and the inside of the cylinder liners. -- With the aid of the ring clamp 380000220 (2), fit the connecting rod--piston assemblies (1) in the cylinder liners.
MIF0971A
100 ----
The ring openings must be staggered apart by 120°; The connecting rod/piston assemblies must all have the same weight; The arrow (1) stamped on the crown of the pistons must face the auxiliary member side of the engine and the recess in the piston skirt must correspond to the position of the oil nozzles.
MIF0972A
101 To measure the clearance proceed as follows: -- Carefully clean the parts and remove all traces of oil; -- Position a length of calibrated wire (2) on the crankshaft journals (1); -- Fit the connecting rod caps (3) with the relevant half bearings (4).
MIF1077A
102 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
51
BIG END CAP ASSEMBLY
(Disassembly operation 55.) -- Tighten the screws (1) previously lubricated with engine oil with a torque wrench (2) to the torque prescribed on page 10.
MIF0973A
103 --
Fit tool 380000304 (1) on the socket wrench and further tighten the bolts (2) as prescribed on page 10.
MIF0974A
104 --
Remove the cap and determine the clearance by comparing the width of the calibrated wire (2) against the graduated scale printed on the packet (1) containing the wire. Check that the clearance is as prescribed in Main Data on page 4, then lubricate the big end half bearings and permanently mount them, tightening the connecting rod cap retaining bolts as described on page 10.
MIF1078A
105 NOTE: Before permanently fitting the connecting rod cap retaining bolts, check that their diameter, measured at the centre of the length of the thread, is no less than 0.1 mm of the diameter measured at approximately 10 mm from the end of the bolt. Check by hand that the connecting rods (1) run axially on the crankshaft journals and their end float measured with a feeler gauge (2) is as prescribed in Main Data on page 4. MIF1079A
106 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
52
FITTING THE THERMOSTAT VALVE
(Disassembly operation 54.) -- Assemble the thermostat valve (2) to its associated body (1) with the screws (3).
MIF1124A
107
FITTING THE CYLINDER HEAD
(Disassembly operations 50. รท 53.) -- Lubricate the valve stem and insert into the relevant valve--guides according to the position marked during disassembly. -- Fit the seals (1).
1
MIF1137A
108 --
Position the following parts on the cylinder head: spring (4) and upper plate (3): using tool 380000302 (1) compress the spring (4) and fit the valve parts (5) using the cotters (2).
MIF1138A
109 ---
Check that the mating surfaces (1) of the cylinder head and crankcase are clean. Do not dirty the cylinder head gasket.
NOTE: Before reusing the cylinder head retaining bolts, check they show no sign of deterioration or deformation and replace them if they do.
MIF1009A
110 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
53
Using the dial gauge 380000228 (1) fitted with its base 380000364 (2), check the protrusion of the pistons (3) at T.D.C. from the cylinder block face is within the tolerance limits specified in Main Data on page 4.
MIF1080A
111 Since there are two type of head gasket, to choose its thickness (1.25 mm Type A and 1.15 mm Type B) make the following measurements: -- for each piston, as shown in the figure, at a distance of 45 mm from the centre of the piston, measure its protrusions S1 and S2 from the top face of the crankcase and then calculate the mean: Scyl1 =
S1 + S2 2
Repeat this operation for pistons 2, 3 and 4 and calculate the mean value: S=
---
MIF1086A
112
Scyl1 + Scyl2 + Scyl3 + Scyl4 4
If S is > 0.40 mm use the gasket type A. If S is < 0.40 mm use the gasket type B. Fit the lifting brackets to the cylinder head. Install the gasket, fit the cylinder head on the crankcase, screwing down the screws (1) without tightening them to torque.
MIF1139A
113 --
Before inserting the control rods, check that the spherical seat (1) of contact with the rocker arm adjuster screw and the spherical end (2) of contact with the tappet show no sign of wear; if there is, then change them. The inlet and exhaust valve control rods are identical and can therefore be interchanged.
MIF1011A
114 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
54 --
Spread LOCTITE 5999 sealant between the cover (2) and the manifold (3) and tighten the screws (1) to the torque prescribed on page 11.
MIF1094A
115
FITTING THE INJECTORS
(Disassembly operation 49.) -- On the injector (1), mount a new seal (2) lubricated with Vaseline and a new washer (3). -- Fit the injectors 2, 3, 4 in the seats on the cylinder head and tighten them to the torque prescribed on page 11.
MIF1063A
116
FITTING THE ROCKER ARM ASSEMBLY
(Disassembly operation 48.) -- Check that the spindle (2) / rocker arm (1) coupling surfaces are neither too worn nor damaged.
Main spindle--rocker arm data (mm)
MIF1012A
117 --
--
Check that the tappet adjusters are unscrewed to prevent them sticking on the rods when fitting the rocker arm assembly (1). Then mount the rocker arm assembly comprising the support and spindles and secure them to the head without tightening the bolts (2) to torque. They will be tightened to torque together with those fixing the cylinder head.
MIF1013A
118 87666787A - 11 - 2007
SECTION 10 − ENGINE − CHAPTER 1
55
FITTING THE TIMING GEAR
(Disassembly operation 46) − Use a marker pen to mark the tooth of the driving gear (1) mounted on the crankshaft (2) on the side of which the reference mark (→) is stamped for timing.
MIF0977A
120 −
Direct the crankshaft (3) and camshaft (4) so that when mounting the driven gear (1) on the camshaft, the marks stamped on the gears (1 and 2) coincide.
MIF0978A
121 −
Place the dial gauge (1) on the timing gear (2) and check that the clearance between the gears (2) and (3) is between 0.076 to 0.280 mm.
MIF1140A
122 −
Insert the screws (1) fixing the gears (2) to the camshaft (3) and tighten them to the torque prescribed on page 10.
MIF1141A
123 87666787A2 − 06 − 2009
SECTION 10 − ENGINE − CHAPTER 1
56 −
Tighten the cylinder head fixing screws in the sequence shown in Figure 125.
MIF1014A
124 −
Tightening sequence diagram for cylinder head bolts. 1st phase of tightening with torque wrench: M12 x 1.75 x 70 bolt: 50 Nm ± 5 Nm (ref. 3−6−11−14) M12 x 1.75 x 140 bolt: 40 Nm ± 5 Nm (ref. 1−2−7−8−9−10−15−16−17−18) M12 x 1.75 x 180 bolt: (ref. 4−5−12−13)
70 Nm ± 5 Nm
2nd phase additional tightening to an angle of 90° for 70 mm long bolts only or 180° for 140 e 180 mm long bolts only. A = fan side −
−
MIF1015A
125
Adjust the clearance between the rocker arms and valves using an Allen wrench (1), box wrench (2) and feeler gauge (3). The working clearance is given in Main Data on page 4. Move the cylinder to the exhaust stroke and measure the clearance; the valves in the cylinder are closed, whilst those on the symmetrical cylinder are rocking. The symmetrical cylinders are 1 − 4 and 3 − 2. − FIRING ORDER 1 − 3 − 4 − 2 Balance valves of cylinder no.
1
3
4
2
Adjust valve clearance of cylinder no.
4
2
1
3
87666787A2 − 06 − 2009
MIF1016A
126
SECTION 10 -- ENGINE -- CHAPTER 1
57
FITTING THE INJECTION PUMP
(Disassembly Operations 37. ) -- Before fitting the injection pump, check that the engine flywheel is still locked and in time with cylinder no.1 at T.D.C. (as indicated in operation 36. page 37), using tools 380000988 and 380000732. -- Do the timing for the injection pump (1, fig. 127) in relation to the drive gear, proceeding as described on page 4.
MIF0920A
126 --
--
Then loosen bolt (2), insert the â&#x20AC;?Lâ&#x20AC;? spacer (1) and lock bolt (2) to make the fuel pump spindle free to turn. Fix the injection pump casing (1) to the seat of the gear box (2) with the screws (3).
MIF0981A
127 --
Spline the gear (1) transmitting drive to the pump.
1
MIF0982A
128
FITTING THE ADDITIONAL COUNTERWEIGHTS
(Disassembly Operations 35.) --
After taking the first cylinder to the top dead centre and doing the timing of the gear of the timing system as described above, do the timing of the additional counterweights, making the marks (A) stamped on the gears coincide as shown in the figure.
MIF1142A
129 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
58 --
Insert the retaining pin in the hole (B) on the additional counterweight assembly to block rotation during the subsequent installation phase.
MIF1143A
130 --
Fit the additional counterweights (2), tighten the screws (3) to the torque prescribed on page 11 and remove the retaining pin (1) from the hole (B).
MIF1113A
131
FITTING THE HYDRAULIC PUMP DRIVE GEAR
(Disassembly operation 47.) -- Insert the gear driving the hydraulic pumps (2) into the seat and tighten the bolts (1).
1 2
MIF1144A
132
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
59
FITTING THE TIMING GEAR CASING
(Disassembly operation 45.) -- Carefully clean the timing gear box (1) and the crankcase. Cleaning the surface to seal is both necessary and unavoidable in order to obtain an effective seal. Apply LOCTITE 5205 sealant onto the box to form a bead with a diameter of a few mm as shown in fig. 133. It must be uniform (no lumps), with no air bubbles, thin areas or breaks. Any flaws must be corrected in as short a time as possible. Avoid using excess material to seal the joint. Too much sealant would tend to come out on both sides of the joint and clog the lubricant passageways. After applying the sealant, the joints require immediate assembly (max minutes). -- Refit the box (1) to the crankcase. -- Tighten the retaining bolts (2) in the position found during disassembly.
1
MIF1136A
133
MIF1147A
134
FITTING THE CRANKSHAFT REAR SEAL
(Disassembly operations 41.÷ 44.) -- Fit part (6) of tool 380000664 on the rear shank (3) of the crankshaft. Secure it with the screws (1) and spline the new seal (2) onto it. -- Position part (5) on part (6), screw down the nut (4) until the seal (2) is completely fitted in the flywheel casing.
MIF1145A
135
FITTING THE FLYWHEEL
(Disassembly operations 38.÷ 40.) -- Check the clutch plate mating surface; turning is required if there is any scoring. -- Check the state of the teeth of the crown gear (2). If you find any breakage or excessively worn teeth, replace it. Mount the new one, previously heated to a temperature of 150 °C for 15÷20 min. NOTE: The nominal thickness of the engine flywheel is 70.5 mm. MIF0990A
136 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
60 --
Screw two pins (2) of the appropriate length into the holes in the shaft (3) and, using the sling, mount the engine flywheel (1).
MIF1116A
137 ---
Spline the flywheel (1) onto the crankshaft, tightening the screws (2) by hand. Lock the flywheel appropriately before tightening the relevant screws to torque.
MIF1115A
138 --
Tighten the bolts (1) securing the engine flywheel (2) in two stages as described on page11: 1st phase, tightening with torque wrench to a torque of 30 ± 5 Nm; nd 2 stage, angle closed 60° ± 5°.
NOTE: Angle closing is performed with tool 380000304.
MIF1146A
139
FITTING THE OIL PUMP
(Disassembly operation 34.) -- Insert the seal. -- Fit the oil pump (1). -- Insert the tightening screws (2) and tighten them to the torque prescribed on page 11.
MIF1149A
140 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1 FITTING THE OIL SUMP
(Disassembly operation 33.) -- Place the new seal on the crankcase. -- Fit the oil sump (1). -- Insert the screws (3) and tighten them to the torque prescribed on page 11. -- Tighten the drain plugs (2) to the torque prescribed on page 11.
61
2
1
MIF1117A
141
FITTING THE CRANKSHAFT FRONT SEAL
(Disassembly operations 28. รท 32.) -- Fit part (4) of tool 380000666 on the front shank (3) of the crankshaft. Secure it with the screws (5) and spline the new seal (6) onto it. Position part (1) on part (4), screw down the nut (7) until the seal (6) is completely fitted in the front cover (2).
MIF1001A
142
FITTING THE CRANKSHAFT FRONT PULLEY
(Disassembly operation 27.) -- Spline the pulley (2) onto the crankshaft and tighten the screws (1) to torque and angle (see page 11), using tool 380000304.
MIF1111A
143
FITTING THE COOLING SYSTEM UNION
(Assembly operation 26.) -- Position the cooling system fitting so that the pins (3 and 4) are against the crankcase. -- Tighten the screws (1 and 2).
MIF1005A
144 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
62
FITTING THE COOLANT PUMP
(Assembly operation 25.) -- Fit a new seal (2) onto the coolant pump (1).
MIF0997A
145 ---
Mount the coolant pump (1). Screw down the screws (2) and tighten them to the torque prescribed on page 11.
MIF1150A
146
FITTING THE FAN--ALTERNATOR PULLEY
(Disassembly operation 24.) -- Fit the coolant temperature sensor (1) screwing it down with a torque wrench. -- Fit the fan pulley support (2) with the screws (3), tightening them to the torque given on page 11.
MIF1151A
147 --
--
Fit on the crankcase: a new gasket (1), the cooler (2), a new gasket (3) and the oil filter mounting (5). Insert the screws (4) and tighten them to the torque prescribed on page 11.
MIF1152A
148 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1 --
63
Refit the bracket (1) to secure the alternator (2) to the crankcase. Tighten the alternator fixing screws (3) to the torque specified on page 11.
MIF1006A
149 --
Fit the fan pulley (2) on the support (1) with the screws (3), tightening them to torque.
MIF1153A
150 --
Fit the tightener (1), tightening the bolts (2) and the tightener nut as directed on page 11.
MIF1154A
151
87666787A - 11 - 2007
64
SECTION 10 -- ENGINE -- CHAPTER 1
FITTING THE AUXILIARY MEMBER DRIVE BELT
(Disassembly operation 23.) -- Fit the Poly--V belt (3) on the pulleys of the crankshaft, tightener (5) of the coolant pump (4), alternator (1) and fan (2). NOTE: Tension the belt correctly as indicated in operation 10 414 10.
MIF1155A
152
FITTING THE EXHAUST MANIFOLD -TURBINE
(Disassembly operations 21. and 22.) -- Mount the exhaust manifold (4) and tighten the screws (3) to the torque prescribed on page 11. -- Fit the turbine (1) with the screws (2).
MIF1156A
153
FITTING THE INJECTOR FEED PIPES
(Assembly operations 19. รท 20.) -- Fit the injector feed pipe assembly (1). Fit the injector fuel outlet pipes (2), using the seals (4) and tighten the screws (3).
MIF1108A
154
FITTING THE FUEL PUMP -- FEED PIPES
(Disassembly operations 16. รท 18.) -- Fit the fuel pump (5). -- Fit the injector feed pipes (4) of the injection pump (3), secure the brackets fixing the pipe assembly (1), (2) and (6) on the cylinder head.
MIF1107A
155 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
65
FITTING THE PIPES BETWEEN THE FUEL SUPPLY AND INJECTION PUMPS, PRE--HEATING SYSTEM AND TAPPET COVER ----------
Fit the fuel filter mounting (9). Fit the control unit for the heater (10). Fit the heater (4). Fit the fuel filter (7). Fit the LDA system piping (5). Connect the pipes with the quick--fit coupling (6) and (8). Fit the tappet covers (1). Connect the engine oil vapour recovery pipe to the blow--by (3). Fit the intake manifold (2).
MIF1105A
156
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SECTION 10 -- ENGINE -- CHAPTER 1
66
FITTING THE STARTER MOTOR ---
Fit the oil delivery pipe (2). Fit the turbine oil return pipe (1), the clamp (4), oil filter (3) and starter motor (5).
MIF1104A
157 -----
Fit the wiring (1). Fit the fan unit to the fan pulley. Add engine oil through the filler plug. Install the bonnet as described in operation 90 100 22.
MIF1103A
158
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SECTION 10 -- ENGINE -- CHAPTER 1
67
CHECKS, MEASUREMENTS AND REPAIRS (CRANKCASE, CYLINDER LINERS)
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Checks and measurements After disassembling the engine, thoroughly clean the crankcase assembly. Use the specific lifting rings for transporting the assembly. Carefully check the crankcase is not cracked. Check the condition of the plugs (3, fig. 162) on the crankcase. If they are rusty or if there is the slightest doubt about their seal, change them. Examine the surfaces of the cylinder liners; they should show no scoring, ovality, taper or excessive wear. To check the internal diameter of the cylinder liners for ovality, taper and wear, use the bore gauge (1), fitted with a dial gauge zero--set on the ring gauge (2) of the diameter of the cylinder liner. NOTE: If the ring gauge is not available, use a micrometer.
MIF1030A
159 Measurements must be taken for each single liner at three different points on the liner and on two perpendicular faces: one parallel to the longitudinal axis of the engine (A) and the other perpendicular (B); maximum wear is generally found on this face in correspondence with the first measurement. If you find any ovality, taper or general wear outside the tolerance given in Main Data on page 4, bore and recondition the cylinder liners. The cylinder liners must be reground in relation to the diameter of the pistons supplied as spare parts (oversized by 0.5 mm over the nominal value) and to the assembly clearance prescribed in Main Data on page 4.
MIF1031A
160
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68
SECTION 10 -- ENGINE -- CHAPTER 1
MIF1032A
161 TOLERANCES
CHARACTERISTIC SUBJECT OF TOLERANCE
SHAPE
Cylindricity
ORIENTATION
Perpendicularity
POSITION
Location
/f/
--
NOTE: If regrinding, all the liners must have the same oversize (0.5 mm). Check the main bearing seats, proceeding as follows: -- fit the main bearing caps on the supports without bearings; 87666787A - 11 - 2007
GRAPHIC SYMBOL
tighten the retaining bolts to the prescribed torque; -- using an appropriate dial gauge for interiors, check that the diameter of the seats is as prescribed in Main Data on page 4. If the measurement is any greater, change the crankcase.
SECTION 10 -- ENGINE -- CHAPTER 1
69
Check that the head mating surface, on the cylinder block, has no deformation. This check can be made, after taking out the grub screws (2), with a calibrated rule (1) and feeler gauge (4). After having located deformed areas, level off the mating surface using a grinding machine. The flatness error must be no greater than 0.075 mm. NOTE: The crankcase can be faced only after making sure that, after machining, the protrusion of the piston from the cylinder liner is no greater than as prescribed in Main Data on page 4.
MIF1033A
162
Check the condition of the crankcase plugs (3); if they are rusty or if there is the slightest doubt about their seal, change them. After facing, restore the bevel of the cylinder liners as shown in Figure 161.
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70
CHECKS, MEASUREMENTS AND REPAIRS CRANKSHAFT
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Crankshaft Clean all parts carefully. If even slight cracks are found, replace the crankshaft. --
If any sign of seizure, scoring or ovality is found on the main journals or crankpins, they must be reground. Before reconditioning, use a micrometer (2) to measure the pins of the shaft (1) to define the diameter to which the pins must be reduced.
NOTE: It is advisable to note the values on a chart. See figure 164. --
The undersize classes are 0.250--0.500 mm. MIF0958A
163
MIF0959A
164 Chart on which to note the measurements of the main journals and crankpins (* Nominal value) All the main journals and crankpins must be ground to the same undersizing marked with a stamp on the side of the crank arm No. 1.
87666787A - 11 - 2007
Undersized crankpins with the letter M. Undersized main journals with the letter B. Undersized crankpins and main journals with the letters MB.
SECTION 10 -- ENGINE -- CHAPTER 1
71
MIF1158A
165 *
Measured on a radius greater than 45.5 mm.
** ↗ 0.50 between adjacent main journals.
MAIN CRANKSHAFT TOLERANCES TOLERANCES SHAPE ORIENTATION POSITION OSCILLATION
CHARACTERISTIC SUBJECT OF TOLERANCE Circularity Cylindricity Parallelism Perpendicularity Straightness Concentricity or coaxiality Circular oscillation Total oscillation Taper
CLASS OF IMPORTANCE ASSIGNED TO PRODUCT CHARACTERISTICS
CRITICAL
GRAPHIC SYMBOL f /f/ //
GRAPHIC SYMBOL
IMPORTANT SECONDARY
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72
CHECKS, MEASUREMENTS AND REPAIRS -- CONNECTING RODS
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Main data (mm) of the connecting rod, piston pin bushing and half bearings *
Inside diameter to be measured after installing in the small end and regrinding with a reamer. ** Cannot be measured free. NOTE: The connecting rod -- connecting rod cap mating surfaces are knurled for a better coupling. It is therefore recommended not to remove the knurling. Each connecting rod is marked: -- On the body and cap with a number indicating their coupling and the cylinder in which it is mounted. -- In the event of replacement, number the new rod with the same number as the replaced connecting rod. On the body of the connecting rod with a letter indicating the weight class of the connecting rod mounted in production: -- V, 1600g รท 1640g (marked in yellow); -- W, 1641g รท 1680g (marked in green); -- X, 1681g รท 1720g (marked in blue). Connecting rods are supplied as spare parts in class W and marked in green. Removing material is not permissible.
MIF1043A
166
Bushings Check that the bushing in the small end has not come loose and shows no sign of scoring or seizure. If this is not so, change it. Disassembly and assembly are performed with a suitable drift. When driving in, make sure that the oilways in the bushing and small end coincide. Using a boring machine, regrind the bushing to obtain the prescribed diameter.
MIF1044A
167
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73
Checking connecting rods Check the parallelism of the connecting rod (2) axes using instrument 380001003 (4) as follows. Fit the connecting rod (2) on the self--centring spindle (3) of tool 380001003 (4) and lock it with the screw (5). Put the spindle (3) on the Vâ&#x20AC;? prisms, setting the connecting rod (2) on the stop bar (1).
MIF1045A
168 Checking twisting Check the twist of the connecting rod (2) by comparing two points (A and B) of the pin (4) on the horizontal plane of the connecting rod axis. Position the support (1) of the dial gauge (5) so that this pre--loads by â&#x2C6;ź 0.5 mm on the pin (4) at point A and reset the dial gauge (5). Move the spindle (3) with the connecting rod (2) and on the opposite side (B) of the pin (4) compare the difference: the variance between A and B must be no greater than 0.08 mm.
MIF1046A
169 Checking bending Check the bend of the connecting rod (3) by comparing two points (C and D) of the pin (4) on the vertical plane of the connecting rod axis. Position the vertical support (2) of the dial gauge (1) so that this rests on the pin (4) at point C as shown in the figure. Swing the connecting rod to and fro, seeking the highest position of the pin and reset the dial gauge (1) in this condition. Move the spindle with the connecting rod (3) and on the opposite side D of the pin (4) repeat the check for the highest point. The difference between points C and D must be no greater than 0.08 mm.
MIF1047A
170 87666787A - 11 - 2007
74
SECTION 10 -- ENGINE -- CHAPTER 1
CHECKS, MEASUREMENTS AND REPAIRS PISTONS
2.560 2.605
105384
171 Normal dimensions (mm) piston data
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SECTION 10 -- ENGINE -- CHAPTER 1
75
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Clean all parts carefully before proceeding with any type of operation. Measuring the piston diameter Using a micrometer (2) measure the diameter of the piston (1), and check the cylinder liners to determine the state of wear of the liners and pistons (see Main Data on page 4). If the clearance is not within the tolerances, it will be necessary to ream and rebore the liners and fit oversize pistons and rings (see Main Data on page 4). NOTE: The diameter must be measured at a distance of 61 mm from the base of the piston skirt.
MIF1035A
172
Clearance between the piston and the cylinder liner can be measured with a feeler gauge (1), as shown in the figure 173.
MIF1036A
173 Piston pins Measuring the piston pin (2) diameter using a micrometer (1). Fit the pins on the pistons checking that the clearance between the piston pin and its bore in the piston is within the tolerance specified in Main Data on page 4.
MIF1037A
174
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76
Conditions for correct pin--piston coupling Lubricate the pin (1) and the piston pin boss seat with engine oil; the pin must go into the piston with a light pressure of the fingers and must not drop out.
MIF1038A
175 Piston rings Using a micrometer (1) check that the thickness of the 1°--2°--3° ring (2) comes within the tolerances stated in Main Data on page 4.
MIF1039A
176 Using a feeler gauge (2), check that the clearance between the rings and their seats on the piston come within the tolerances prescribed in Main Data on page 4.
MIF1040A
177 Measuring the clearance X of the V--ring Due to the special shape of the first seal with a trapezoidal cross--section, the clearance between the groove and the ring should be measured as follows; make the piston (1) protrude from the crankcase so that the ring (3) at issue comes approximately halfway out of the cylinder liner (2). In this position, using a feeler gauge, check the clearance (X) between the ring and the groove: this clearance must be as prescribed in Main Data on page 4. MIF1041A
178 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
77
Measure the clearance between the ends of the piston rings (2) introduced in the cylinder liner (3) using a feeler gauge (1), checking it is as prescribed in Main Data on page 4.
MIF1042A
179
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78
CHECKS, MEASUREMENTS AND REPAIRS -- VALVES AND CAMSHAFT
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Clean all parts carefully before proceeding with any type of operation. Dimensions (mm) of valves and valve guides. A = Exhaust valve. B = Inlet valve.
MIF1048A
180 Decarbonizing, checking and grinding valves Remove all carbon deposits from the valves (2) using a wire brush (1). Check that the valves show no sign of seizure, cracks or burns. If necessary, grind the bevels on the valve heads using a grinding machine, removing as little material as possible.
MIF1049A
181 Using a micrometer (2) measure the valve stem (1) and check it comes within the range of tolerance given in Main Data on page 4.
MIF1050A
182
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79
MIF1052A
183 Dimensions (mm) valve seats
MIF1051A
Dimensions (mm) valve seat housings If the valve seats cannot be reconditioned by just regrinding, they can be replaced with the ones supplied as spare parts. Using a specific tool and taking care not to nick the cylinder head, remove as much material as possible from the valve seats until it is possible to extract them from the cylinder head with the aid of a punch.
184
Heat the cylinder head to 80 á 100 °C and, using a suitable drift, insert the new valve seats, previously cooled. Then regrind the valve seats according to the values given in Figure 183. A = Exhaust valve. B = Inlet valve.
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80
After regrinding, with the base 380000364 (2) and dial gauge 380000228 (1), check that the valve recessing (3) in relation to the top face of the cylinder head comes within the tolerance prescribed in Main Data on page 4.
MIF1053A
185
VALVE SPRINGS The figure shows the main data for checking the inlet and exhaust valve springs. Before assembly, check the valve spring flexibility using tool 380000976. Compare the elastic deformation and load data with those of the new springs stated in the following table.
H(free) H1 H2
Lift mm 63.50 49.02 38.20
Under a load of N No load P1 329 P2 641
MIF1054A
186
Tappets The figure gives the main data, in mm, of the tappets and their seats in the crankcase.
MIF1055A
187
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81
Camshaft
MIF1056A
188 Camshaft data The data refer to the normal journal diameter (dimensions mm) The support journal surfaces on the shaft and cams must be finely honed; if there are signs of seizing or scoring, replace the shaft and relative bushings. Checking cam lift and pin alignment Set the shaft on tailstocks and, using a dial gauge with a 1/100 mm scale placed on the central support, check that the alignment error is no greater than 0.04 mm; change the shaft if it is. Check the diameter of the supporting pins of the camshaft (2) with the micrometer (1) on two perpendicular axis.
MIF1057A
189
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82
CHECKS, MEASUREMENTS AND REPAIRS -- CYLINDER HEAD
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Use tool 380000302 to remove and refit valve springs. Clean all parts carefully before proceeding with any type of operation. Checking the cylinder head mating surface The mating surface of the head (1) with the cylinder block should be checked with a rule (2) and a feeler gauge (3). The deformation measured on the full length of the cylinder head must be no greater than 0.20 mm. If it is any higher, regrind the cylinder head according to the dimensions and warnings given in the following figure.
MIF1058A
190
Cylinder head thickness The nominal thickness A of the cylinder head is 95 ± 0.25 mm the maximum permissible amount of metal removed must not exceed the thickness B of 0.13 mm. NOTE: After regrinding, check the valve recessing and if necessary regrind the valve seats to obtain the recessing prescribed in Main Data on page 4.
MIF1059A
191 TOLERANCES
CHARACTERISTIC SUBJECT OF TOLERANCE
SHAPE
Flatness
Cylinder head hydraulic seal check Check the hydraulic seal using the appropriate tools. Using a pump, introduce water heated to ∼ 90°C at a pressure of 2 ÷ 3 bar. If there is any leakage from the cup plugs, replace them, using a suitable drift for their disassembly -assembly.
87666787A - 11 - 2007
GRAPHIC SYMBOL
NOTE: Before fitting the plugs (3, fig. 162) apply a water--reactive sealant on their sealing surface. If you find any leakage from the cylinder head, it must be changed.
SECTION 10 -- ENGINE -- CHAPTER 1 LOW OIL PRESSURE Functional checks
INDICATOR
83
--
The device is composed of the control switch (1, fig. 192), engine oil pressure gauge (1, fig. 193) and the ”Stop” indicator (1). This indicator light (1) together with the red “Stop” indicator light (1) indicates the engine oil pressure is too low. Switch off the engine and look for the cause of the trouble. The indicator comes on under the following circumstances: --
low oil pressure (the indicator (1) lights up normally without there being any trouble, even with the engine warm and at low speed);
--
control switch (1, fig. 192) malfunction.
192
If the red lamp fails to illuminate when the engine is stopped and the ignition switch is turned to the power ON position, the possible causes are: --
blown fuse;
--
blown lamp;
--
interruption in wire to the control switch.
193
NOTE: When the engine oil pressure is too low, the indicator light comes on with the ignition key on B (ready for starting).
OIL FILTER -- Replacement The oil filter is of the integral paper cartridge type. If the filter gets too clogged, the safety valve opens to enable the oil to by--pass the filter, keeping the engine lubricated, albeit with non--filtered oil. Replace the cartridge periodically (every 800 operating hours), remembering to: --
oil the outer part of the seal in contact with the mounting on the crankcase;
--
screw on the new cartridge until the seal is up against the mounting on the crankcase;
--
tighten the cartridge, by hand only, through a further 3/4 turn.
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84
CHECKS, MEASUREMENTS AND REPAIRS -- COOLING SYSTEM Clean all parts carefully before proceeding with any type of operation. The cooling system is fitted with a permanent coolant mixture consisting of water and ”AMBRA AGRIFLU” antifreeze (50% in volume). This mixture prevents freezing down to the following temperatures: Degrees °C
--8
--15
--25
--35
% in volume of ”AMBRA AGRIFLU”
20
30
40
50
When overhauling, remove deposits of lime scale in the radiator by means of a solution of water and descaling agent in the proportions shown on the container. It is never advisable to limit flushing to the radiator only -- always extend this operation to the entire cooling circuit. Top up the engine with the solution referred to above. Run the engine for about an hour (with the engine off) in order to drain the solution through the drain plug. If the system is leaking, check the radiator seal by immersing it in a tank of water at a temperature of 20 ÷ 40 °C, blowing air into the radiator at a pressure of 0.98 bar (1 kg/cm2) for approx. two minutes (repeat the test at least three times).
This mixture also has anti--oxidant, anti--corrosion, anti--foaming and anti--scaling properties to ensure long--term protection of the cooling system.
COOLANT THERMOMETER -- Check
The same mixture can be kept in the cooling system for a maximum of 2 years or 1200 operating hours, whichever comes sooner; after which it must be changed.
If malfunction is suspected, immerse the bulb of the thermometer in water and check the readings against a test thermometer (repeat the test a number of times with different water temperature to be sure).
RADIATOR -- Flushing and checks Two valves are built into the radiator cap, one compression valve and one depression valve. Check the correct operation of the valves periodically.
THERMOSTAT VALVE -- Replacement The thermostat valve is fitted in the cylinder head coolant outlet union. As calibration operations are not possible, the thermostat valve assembly will need to be replaced when it no longer satisfies the temperature data shown in the General Specifications tables on page 3.
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85
Op. 10 102 70 CRANKSHAFT FRONT SEAL Replacement
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted. To access the seal, proceed as follows: 1. Remove the bonnet as described in operation 90 100 22. 2. Remove the engine radiator, as indicated in operation 10 406 10. 3. Move the tightener (2) away to slacken the belt (1) and then remove it.
194 4. Remove the six retaining bolts (1), the pulley (2) governing the accessory assemblies and the fan--alternator--coolant pump pulley (3).
195
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86
5. Apply tool 380000665 (4) on the front tang (2) of the crankshaft. 6. Perforate the inner seal (1) with a drill bit (â&#x2C6;&#x2026; â&#x2C6;&#x2026; 3.5 mm) through the guide holes of the tool 380000665 (4), for a depth of 5 mm. 7. Secure the tool 380000665 (4) to the seal (1) by screwing down the screws (3) supplied. 8. Extract the seal (1) by screwing down the screw (5). MIF0916A
196 9. Fit the tie rod (3) of the tool 380000669 to the outer seal (1) as shown in the figure and with the lever (4), extract it from the front cover (2). 10. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
MIF0917A
197 To fit the front seal on the crankshaft, proceed as follows: --
Fit part (4) of tool 380000666 on the front shank (3) of the crankshaft. Secure it with the screws (5) and spline the new seal (6) onto it. Position part (1) on part (4), screw down the nut (7) until the seal (6) is completely fitted in the front cover (2).
--
Fit the fan--alternator--coolant pump pulley, the accessory assembly pulley and the six retaining bolts.
--
Refit the transmission belt on the pulleys, adjust it with the tensioning screw and lock the tightener, tightening the two retaining and pivot screws.
--
Refit the engine radiator as described in operation 10 406 10.
--
Install the bonnet as described in operation 90 100 22.
87666787A - 11 - 2007
MIF1001A
198
SECTION 10 -- ENGINE -- CHAPTER 1
87
Op. 10 102 74 CRANKSHAFT REAR SEAL Replacement
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted. To access the seal, proceed as follows: 1. Remove the clutch as described in operation 18 110 10.
199 2. Remove the eight screws (1) fixing the engine flywheel (2).
200 3. Screw two pins (2) of the appropriate length into the holes in the crankshaft (3). Slightly extract the engine flywheel (1) so it can be slung and then and put down in a specific wooden container with the hoist.
MIF1116A
201
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88
4. Apply tool 380000663 (3) on the rear shank (1) of the crankshaft. 5. Perforate the inner seal (5) with a drill bit (∅ ∅ 3.5 mm) through the guide holes of the tool 380000663 (3), for a depth of 5 mm. 6. Secure the tool 380000663 (3) to the seal (5) by screwing down the screws (2) supplied. 7. Extract the seal (5) by screwing down the screw (4).
MIF0927A
202 8. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
To fit the front seal on the crankshaft, proceed as follows: 9. Fit part (6) of tool 380000664 on the rear shank (3) of the crankshaft. Secure it with the screws (1) and spline the new seal (2) onto it. Position part (5) on part (6), screw down the nut (4) until the seal (2) is completely fitted in the flywheel casing.
MIF1145A
203 10. With a hoist and appropriate slinging, insert the engine flywheel (1) on the pins (2) described above, pushing it into contact with the crankshaft (3).
MIF1116A
204
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89
11. Manually tighten the bolts (2) retaining the flywheel (1) to the crankshaft.
MIF1115A
205 12. Tighten the bolts (1) securing the engine flywheel (2) in two stages as described on page 10: -- 1st phase, tightening with torque wrench to a torque of 30 ± 4 Nm; -- 2nd stage, angle closed 60° ± 5°. NOTE: Angle closing is performed with tool 380001001.
MIF1146A
206 13. Refit the clutch as described in operation 18 110 10.
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90
Op. 10 106 12 ADJUSTING VALVE/ROCKER ARM CLEARANCE Adjustment
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 1. Remove the bonnet (1) as described in operation 90 100 22. 2. Disconnect the power steering pipes (2), unscrew the related retaining bolts and remove the bracket (1).
207 3. Disconnect the electrical connection from the brake fluid reservoir (1), unscrew the retaining bolts and remove the reservoir from the supporting bracket.
208 4. Unscrew the retaining bolts and remove the bonnet bracket (1).
209
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91
5. Loosen the clamp and disconnect the engine oil vapour recovery pipe from the blow--by. Unscrew the relevant bolts and remove the tappet covers (1, 2 and 4).
210 6. After taking off the covers, adjust the clearance between the rocker arms and valves using an Allen wrench (1), box wrench (2) and feeler gauge (3). The working clearance should be: -- inlet valves = 0.25 Âą 0.05 mm -- exhaust valves = 0.50 Âą 0.05 mm. 7. Take the cylinder where the clearance is to be adjusted into the end--of--compression phase; the valves in the cylinder are closed, whilst those on the symmetrical cylinder are rocking.
MIF1016A
211 --
The symmetrical cylinders are 1 -- 4 and 3 -- 2.
--
FIRING ORDER 1 -- 3 -- 4 -- 2 Balancing valves of cylinder no.
1
3
4
2
Adjust valve clearance of cylinder no.
4
2
1
3
Refit the parts that were removed, proceeding as follows. --
Respect the tightening torques prescribed on page 11.
--
Position the tappet covers with the seals and secure them.
--
Reconnect the engine oil vapour recovery pipe to the blow--by.
--
Position the upper engine bracket with the heat guard and secure it, connect the power steering pipes.
--
Position the brake fluid tank and secure it to the upper engine bracket, connect the related electrical connection.
--
Install the bonnet as described in operation 90 100 22.
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SECTION 10 -- ENGINE -- CHAPTER 1
92 Op. 10 218 30
INJECTORS Removal--Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows: 1. Remove the bonnet (1) as described in operation 90 100 22. 2. Disconnect the power steering pipes (2), unscrew the related retaining bolts and remove the bracket (1).
212 3. Disconnect the electrical connection from the brake fluid reservoir (1), unscrew the retaining bolts and remove the reservoir from the supporting bracket.
213
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93
4. Unscrew the retaining bolts and remove the bonnet bracket (1).
214 5. Loosen the clamp (2), unscrew the retaining bolts and remove the exhaust silencer (1); the exhaust pipe remains secured to the cab.
215 6. Loosen the clamp and disconnect the engine oil vapour recovery pipe (3) from the blow--by. 7. Unscrew the relevant bolts and remove the tappet covers (1, 2 and 4). 8. Detach the fuel recirculation pipe from the injectors (5). 9. Disconnect the injector delivery pipes (6).
216 10. Remove the injectors (2) with tool 380000982 (1) and extract them from the cylinder head.
MIF1062A
217 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
94
11. To refit the injector, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
On the injector (1), mount a new seal (2) lubricated with Vaseline and a new washer (3).
--
Fit the injectors in the seats on the cylinder head and tighten them with a torque wrench to the torque prescribed on page 11.
--
Fit the new seals on the injector delivery pipe unions.
--
Connect the delivery pipes to the injectors.
--
Refit the tappet covers with their seals.
--
Reconnect the engine oil vapour recovery pipe to the blow--by.
--
Connect the injector fuel recovery pipe.
--
Position and secure the exhaust silencer.
--
Position the upper engine bracket with the heat guard and secure it, connect the power steering pipes.
--
Position the brake fluid tank and secure it to the upper engine bracket, connect the related electrical connection.
--
Install the bonnet as described in operation 90 100 22.
87666787A - 11 - 2007
MIF1063A
218
SECTION 10 -- ENGINE -- CHAPTER 1
95
Op. 10 246 14 BOSCH INJECTION PUMP Removal--Installation, timing and air bleeding
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Remove the bonnet as described in operation 90 100 22. 2. Disconnect the fuel inlet pipe (1), return pipe (3), delivery pipe (4) and the pipe (1) from the injection pump. Disconnect the electrical connections (5 and 6).
219 3. Disconnect the fuel recirculation pipe (1) from the injectors. Unscrew the retaining bolts and remove the throttle control cable bracket (2). Disconnect the injector delivery pipes (3).
220
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96
4. Disconnect the hydrostatic steering control valve supply pipe (1) and unscrew the injector delivery pipe bracket retaining bolt (2), disconnect the pipes from the injectors and remove them.
221 5. Before removing the pump, do the timing at T.D.C. as indicated on page 98 loosen the bolt (2), remove the ”L” spacer (1) and lock the screw (2) in order to keep the pump in time with the engine flywheel. NOTE: Keep the ”L” spacer with the pump casing.
MIF0920A
222 6. Remove the three nuts (2) (3) (5) securing the injection pump (1) to the crankcase (4) and extract it from its housing. 7. To refit the injection pump, proceed as follows. 8. Respect the tightening torques prescribed on page 11.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. MIF0922A
--
Keep to the timing described on page 98.
--
Make sure there are the disassembly conditions: at T.D.C. with the flywheel locked by tool 380000988 then position the injection pump on the crankcase and secure it with the specific bolts.
--
Loosen the screw (2, fig. 222) and insert the ”L” spacer (1).
--
Position and connect the delivery pipes to the injectors.
87666787A - 11 - 2007
223
SECTION 10 -- ENGINE -- CHAPTER 1
97
--
Disconnect the hydrostatic steering control valve supply pipe.
--
Connect the electrical connections for stopping the engine and for the advance device.
--
Position and secure the throttle control rod retaining bracket.
--
--
Connect the recirculation pipe from the injectors to the injection pump.
Connect the piping for the fuel supply pump, return to the tank and for connecting the fuel supply pump and the injection pump.
--
Install the bonnet as described in operation 90 100 22.
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98
SECTION 10 -- ENGINE -- CHAPTER 1
Checking injection pump timing 1. If it is necessary to change the fuel pump, it is supplied already pre--set as a spare part. 2. Remove the starter motor (2), taking out the bolts (1).
MIF1172A
224 3. Fit the bracket of tool 380000988 (1) retaining the flywheel together with the rotation wheel 380000732 (3). 4. Carefully turn the flywheel in its direction of rotation to cancel the clearances of the gears. 5. Turn the engine until the pin (2) supplied with tool 380000988 engages through the slot in the flywheel (4).
MIF1173A
225 6. Unscrew the retaining bolts (2) and remove the priming pump (1) from the crankcase (3).
MIF1174A
226 7. Check through the seat of the priming pump that the camshaft (1) is in step (at TDC) using the reference marks (2) on the shaft. If the marks are not evident, withdraw the pin from the flywheel and rotate the engine 360° until the reference marks are visible. Re--insert the pin to lock.
MIF1175A
227 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
99
8. When fitting the fuel pump on the engine, it is necessary to bring about the condition of T.D.C. on cylinder No. 1 as described on the previous page 9. Fit the injection pump casing (1), preset, in the seat of the gear box (2) and secure it, without tightening, with the screws (3).
ATTENTION The seal removed at the time of pump disassembly must not be reused. Always use genuine spare parts. MIF0981A
228 10. Partly unscrew the bolt (1) locking pump spindle rotation and insert the spacer washer (2). Tighten the screw locking the above--mentioned washer: in this way, the fuel pump spindle is free to turn. 11. Extract the pin of the engine flywheel locking tool. 12. Remove tool 380000988 for flywheel locking/rotation; place the starter motor in its seat.
MIF1176A
229 13. With the injection pump in position but with the mounting bolts loose, remove the plug on the pump cover. 14. Fit the dial gauge 380001004 (2) and the associated tool 380000229 (1), pre--loading the shaft by 2.5 mm. 15. Turn the crankshaft to move from the condition of 1st cylinder at TDC. Reset the dial gauges and turn the crankshaft in the opposite direction to bring it back into the condition of the 1st cylinder at TDC in the phase of the end of compression. In this position the dial gauge on the pump must read off a value of 1.15 Âą 0.05 mm. 16. Turn the pump anti--clockwise if the plunger has completed a shorter stroke, and clockwise if the stroke is longer, repeating the test until the correct stroke is obtained. 17. Verifying these conditions, lock the pump by tightening the relevant nuts to the torque shown on page 11.
MIF1165A
230
87666787A - 11 - 2007
100
SECTION 10 -- ENGINE -- CHAPTER 1
18. Fit the priming pump (1) on the crankcase (3) and tighten the retaining bolts (2) to the prescribed torque.
MIF1174A
231
BOSCH INJECTION PUMP Fuel circuit air bleeding 19. Take out the bleed screw (1) on the filter. 20. Operate the fuel pump lever (2) until fuel (without bubbles) comes out of the filter then put the screw (1) back in.
MIF1166A
232 21. Loosen the injector delivery union (1), start the engine and, after having checked that there are no air bubbles, tighten the union (1).
1
MIF1167A
233
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SECTION 10 -- ENGINE -- CHAPTER 1
101
Op. 10 402 10
COOLANT PUMP Removal--Installation
DANGER
Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted. 1. Remove the engine radiator as indicated in operation 10 406 10. 2. Retrieve the duct (1), unscrew the retaining bolts and remove the fan (2).
234 3. Move the tightener (2) away to slacken the belt (1) and then remove it.
235 4. Disconnect the heater pipe (1) and remove it.
236
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102
5. Unscrew the relevant retaining bolts and remove the coolant pump (1).
237 6. To install the coolant pump, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Respect the tightening torques prescribed on page 11.
--
Fit a new seal (2) onto the coolant pump (1).
--
Position and secure the coolant pump.
--
Position and secure the heater pipe.
--
Position the belt and adjust its tension.
--
Position and secure the fan.
--
Position the duct.
--
Refit the engine radiator as described in operation 10 406 10.
87666787A - 11 - 2007
MIF0997A
238
SECTION 10 -- ENGINE -- CHAPTER 1
103
Op. 10 402 30 THERMOSTATIC VALVE Removal/Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
1. Raise the bonnet. Unscrew the retaining bolts and remove the side grille (1).
239 2. Unscrew the plug (1) to drain off some of the coolant.
240 3. Loosen the clamp (1) and detach the sleeve (2) from the thermostat valve (3).
241
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SECTION 10 -- ENGINE -- CHAPTER 1
104
4. Remove the bolts (1) retaining the thermostat valve cover. 5. Remove the governor body (2), thermostat valve cover seal (3) and thermostat valve (4).
MIF1169A
242 6. To refit the thermostat valve, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Respect the tightening torques prescribed on page 11.
--
Position the thermostat valve, seal and cover, lock it all with the screws.
--
Connect and secure the sleeve to the thermostat valve.
--
Screw the plug onto the lower union.
--
Position and secure the side grille.
--
Fill up the engine cooling circuit (see sect. 00, page 6 for the prescribed product and quantity).
87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
105
Op. 10 406 10
RADIATOR Removal--Installation
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted. 1. Remove the bonnet (1) as described in operation 90 100 22. 2. Unscrew the retaining bolts and remove the side grille (1). Perform this operation on the other side of the tractor too.
243 3. Loosen the clamps (2) and (3), remove the sleeves (1) and (4) from the radiator and drain the fluid from the cooling circuit, leave the sleeves detached.
244 4. Unscrew the related retaining bolt and loosen the guide (1), unhook the catch and take out the condenser (2).
245
87666787A - 11 - 2007
106
SECTION 10 -- ENGINE -- CHAPTER 1
5. Disconnect the connection (1) from the clogged air filter sensor pressure switch. Disconnect the intake sleeve from the air cleaner.
246 6. Unscrew the retaining screw (1) and remove the air cleaner (2).
247 7. Detach the maxi fuses (1) from the related bracket.
248 8. Unscrew the related clamp and detach the pipe (2), unscrew the fixing screws and disconnect the expansion tank (1).
249 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
107
9. Unscrew the clamps and disconnect the pipes (1), (2), (3) and (4) from their seats.
250 10. Unscrew the retaining bolts and remove the cooler (1).
251 11. Unscrew the relative bolt and remove the bracket (1) securing the power steering pipes.
252 12. Unscrew the retaining bolt and remove the bracket (1) from the radiator.
253 87666787A - 11 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
108
13. Unscrew the duct retaining bolts, unscrew the retaining bolts (1) and remove the radiator. 14. To refit the radiator, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
Respect the tightening torques listed on pages 10 and 11.
--
Position the radiator and secure with the relevant bolts.
--
Connect the two upper and lower sleeves to the radiator.
--
Secure the duct to the radiator.
--
Lock the retaining bracket to the radiator.
--
Position and secure the cooler.
--
Position the guide and the condenser and secure it all.
--
Secure the power steering pipes.
--
Position and secure the air cleaner.
--
Connect the engine vapour recirculation pipe.
--
Connect the intake sleeve to the rigid air cleaner pipe.
--
Connect the cooler pipes.
--
Connect the clogged air filter sensor pressure switch connection.
--
Position and secure the expansion tank and connect its pipe to the radiator.
--
Position and secure the maxi fuses.
--
Position and secure the supporting bracket and the side grille (do this on both sides).
--
Fill up the engine cooling system (see sect. 00, page 6 for the prescribed product and quantity).
--
Install the bonnet as described in operation 90 100 22.
87666787A - 11 - 2007
254
SECTION 10 -- ENGINE -- CHAPTER 1
109
Op. 10 414 10
4--CYLINDER COOLANT PUMP AND GENERATOR DRIVE BELT Tension adjustment (Disassembly operation 23.)
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Polyvee belt tensioning instructions
255
To adjust the Polyvee belt (1) governing the fan -coolant pump -- oil pump and alternator pulleys, proceed as follows: 1. Check that the belt (1) is correctly positioned on the belt tensioning device and on the pulleys. 2. Loosen the screws (2) and (3) retaining and pivoting the tightener to the cover (6). 3. Loosen the locking nut (5) and the screw for tensioning the belt (4), checking that its thread is not defective and has no oxidized/painted parts that would affect its rotation in its seat in the cover (6). 4. Turn the screw (4) and lightly tension the belt (1) with the tightener. 5. Using a torque wrench, adjust the tensioning screw of the belt (4) to the torque settings: 3.8 รท 4.4 Nm.
87666787A - 11 - 2007
110
SECTION 10 -- ENGINE -- CHAPTER 1
6. Using a torque wrench, tighten the M10 nut (5) to a torque of 55 Nm (5.6 kgm). 7. Check the tension of the Polyvee belt in the position (1), shown in the figure 257 below, using the belt tension gauge 380001268, bearing in mind that the data measured must remain within the following tolerances: --
Assembly tension 1100 รท 1300 Nm
--
Frequency measured with gauge 380001268 158 รท 170 Hz 256
8. If the measured data are out of tolerance, repeat operations 5 รท 7 described above and check that the measurements come within the prescribed tolerances. 9. Using a torque wrench, tighten the M10 nut (3) to a torque of 55 Nm (5.6 kgm). 10. Using a torque wrench, tighten the M8 nut (2) to a torque of 25 Nm (2.6 kgm).
NOTE: When fitting a new belt, check the tension again after 50 hours of running the engine.
87666787A - 11 - 2007
257
SECTION 10 - ENGINE - CHAPTER 2
1
SECTION 10 - ENGINE
Chapter 2 - Engine (mod. T4020 and T4030) CONTENT Section
Description
Page
10 000
General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10 001 10
Engine Removal-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
NOTE: For the main data, tightening torques, tools, diagrams, lubrication and cooling diagrams, fault diagnosis, disassembly-assembly, checks and overhauling, see the Repairs Manual print no. 87736552A - Italian; Print No. 87736548A - English; Print No. 87736549A - French; Print No. 87736551A - Spanish; Print No. 87736550A - German.
87666787A1 - 03 - 2008
2
SECTION 10 - ENGINE - CHAPTER 2
GENERAL SPECIFICATIONS Engine, technical type: -
mod. T4020 - type F5AE9484A*A (BOSCH pump) . . . . . .
-
mod. T4030 - type F5AE9484B*A (BOSCH pump) . . . . . .
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
diesel, 4-stroke
Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct
Number of cylinders in line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Piston diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99 mm
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104 mm
Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3200 cm3
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17,5 ± 0,5:1
Maximum Power Output: -
mod. T4020 - type F5AE9484A*A . . . . . . . . . . . . . . . . . . . . .
48 kW (65 Hp)
-
mod. T4030 - type F5AE9484B*A . . . . . . . . . . . . . . . . . . . . .
57 kW (78 HP)
Maximum power speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2300 rpm
-
Maximum torque: mod. T4020 - type F5AE9484A*A . . . . .
290 Nm
-
Maximum torque: mod. T4030 - type F5AE9484B*A . . . . .
330 Nm
Maximum torque speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1250 rpm
Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Sump pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
structural, cast iron
Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
forced, with lobe pump
Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
from crankshaft
Oil filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mesh screen on oil pick-up and filter cartridge in delivery line
Normal oil pressure with motor warmed-up at fast idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 bar
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
coolant circulation
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 lines of vertical pipes with copper fins
Fan, attached to the pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
intake, in plastic with 11 blades
Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
centrifugal vane-type
Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
via thermostat valve
-
initial opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
79 ± 2 °C (overleaf)
87666787A1 - 03 - 2008
SECTION 10 - ENGINE - CHAPTER 2
3 (overleaf)
GENERAL SPECIFICATIONS Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by tappets, rods and rocker arms via the camshaft located in the engine block; the camshaft is driven by the crankshaft using straight-tooth gears Intake: -
start: Before T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19° ± 30'
-
end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37° ± 30'
Exhaust: -
start: before B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61° ± 30'
-
end: after T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21° ± 30'
Clearance between valves and rocker arms with engine cold: -
intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.25 ± 0.05 mm
-
exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.50 ± 0.05 mm
Power supply Air filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
dual cartridge dry air filter, with clogged filter indicator with centrifugal pre-filter and automatic dust ejector
Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with double diaphragm
Fuel filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
through wire filter in fuel supply pump, and replaceable cartridge on delivery line to injection pump
Cam operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
via engine timing
BOSCH Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rotating distributor type
All-speed governor, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
centrifugal counterweights
Automatic advance regulator, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
hydraulic
Turbocharger: -
type
........ .....................................
Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOLSET rotating distributor with speed governor and advance variator incorporated
BOSCH pump: -
mod. T4020 - type F5AE9484A*A . . . . . . . . . . . . . . . . . . . . .
VE 4/12 F1150-504246316
-
mod. T4030 - type F5AE9484B*A . . . . . . . . . . . . . . . . . . . . .
VE 4/12 F1150-504246318
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
clockwise
Injection order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3-4-2 (for all models)
87666787A1 - 03 - 2008
4
SECTION 10 - ENGINE - CHAPTER 2
Operation 10 001 10 ENGINE Removal-Installation
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no-one is in the vicinity of the load to be lifted.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 1. Remove the bonnet as described in operation 90 100 22. 2. Extract the fixing pin and remove the ballast (1); unscrew the retaining screws and retrieve the ballast support (2).
1 3. If the tractor is a T4020 Supersteer or T4030 Supersteer, position and secure the bracket 380001613 (1) together with the spacers 50162 (4) on the front axle (3) and associated support (2).
2 4. Unscrew the retaining bolts and remove the side grille (1). Perform this operation on the other side of the tractor too.
3
87666787A1 - 03 - 2008
SECTION 10 - ENGINE - CHAPTER 2
5
5. Disconnect the pipes (1) of the cab heating system and drain the engine cooling system.
4 6. Unscrew the plug and drain the oil from the rear transmission casing (the prescribed quantity is 42 litres).
25628
5 7. Unscrew the retaining bolts and remove the exhaust pipe and silencer.
6 8. Disconnect the connections (1) from the clogged air filter sensor.
7 87666787A1 - 03 - 2008
6
SECTION 10 - ENGINE - CHAPTER 2
9. Disconnect the connection (1) and remove the cable. Unscrew the bolts and detach the fixing blocks (2 and 3) of the air-conditioning system pipes.
8 10. Disconnect the fixing clamps and detach: the vapour recirculation pipe (2), the pipe (1) connecting the turbo charger to the cooler, the pipe (3) connecting the turbo charger to the air filter and the upper sleeve (4) from the engine radiator.
9 11. Unscrew the fixing clamp and detach the lower sleeve (1) from the engine radiator.
10 12. Unscrew the relative bolt and remove the block (1) securing the power steering pipes.
11 87666787A1 - 03 - 2008
SECTION 10 - ENGINE - CHAPTER 2
7
13. Unscrew the relative bolt and remove the block (1) securing the power steering pipes.
12 14. Disconnect the hydrostatic steering piping (1).
13 15. Unscrew the related bolts and remove the bracket (1) retaining the radiator.
14 16. Unscrew the clamp and remove the pipe (1) connecting the turbo charger to the cooler.
15
87666787A1 - 03 - 2008
8
SECTION 10 - ENGINE - CHAPTER 2
17. Slightly raise the front of the tractor and completely remove the condenser (1) of the air-conditioning system from the brackets. Lower the tractor.
16 18. Unscrew the compressor fixing screws (1), block retaining bolt (2) and bring the condenser, compressor and piping inside the cab.
17 19. Disconnect the four electrical connections (1).
18 20. Disconnect the electrical connection from the brake fluid reservoir (1), unscrew the retaining bolts and remove the reservoir from the supporting bracket.
19 87666787A1 - 03 - 2008
SECTION 10 - ENGINE - CHAPTER 2
9
21. Disconnect the cab ground (1).
20 22. Disconnect the throttle cable (1) from the injection pump. Disconnect the delivery pipe (2) from the hydraulic pump.
21 23. Disconnect the hoses (1), of the transmission oil cooler, from the pipes. Disconnect the front axle differential lock pipe (2).
22 24. Remove the guard (1) and disconnect the cables from the starter motor (2).
23
87666787A1 - 03 - 2008
10
SECTION 10 - ENGINE - CHAPTER 2
25. Disconnect the power steering return pipe (1).
24 26. Disconnect the pipes (1 and 2) respectively from the injection pump and from the fuel pump.
25 27. For models fitted with brakes on the front axle it is necessary to drain the brake fluid tank and disconnect the pipes (1, 2 and 3) from the block.
26 28. Using a hoist and sling (1) raise the rear part of the tractor, position a fixed support stand under the towing hook, then remove the right-hand (2) and left hand wheels.
27837
27 87666787A1 - 03 - 2008
SECTION 10 - ENGINE - CHAPTER 2
11
29. If the tractor is a T4020 Supersteer or T4030 Supersteer unscrew the front and rear retaining bolts, unscrew the front pivot pin retaining screw and remove the bracket (1). Unscrew the relative retaining bolts and remove the rear guard.
28 30. If the tractor is a T4020 Deluxe or T4030 Deluxe unscrew the front, central and rear retaining bolts and remove the guard on the propeller shafts (1).
27801
29 31. Remove the circlip (2) and move the front sleeve (1) backwards in order to free it from the groove on the front axle.
1
2
25647
30 32. Remove the circlip (2) and move the rear sleeve (1) in order to release it from the groove on the drive.
1
2
25646
31
87666787A1 - 03 - 2008
12
SECTION 10 - ENGINE - CHAPTER 2
33. Remove the propeller shaft central support (1) retaining bolts and extract the shaft together with the support.
1
25648
32 34. Disconnect: the tie rod (2) governing engagement of the power take-off synchronized with the gearbox, the PTO speed selection link rod and the parking brake tie rod (1).
33 35. Disconnect: the gearbox link rod (1), the range gear link rod (2) and the Dual Command (2 Speed Power Shift) electrical connection (3) (where applicable).
34 36. Disconnect: the lift link rods (1) and the lift-o-matic link rod (2).
35 87666787A1 - 03 - 2008
SECTION 10 - ENGINE - CHAPTER 2
13
37. Disconnect the auxiliary control valve link rods (1).
36 38. Remove the plastic guard (3), if necessary remove the grips (1 and 2).
37 39. Disconnect the PTO clutch control tie-rod (1).
38 40. Disconnect the brake pipes (1) located on the front left-hand side of the cab.
39
87666787A1 - 03 - 2008
14
SECTION 10 - ENGINE - CHAPTER 2
41. Unscrew the screws (1) and lower the fuel tank by 8-10 mm and unscrew the front screws securing the cab (on both sides).
40 42. Position tool 380000294 (1) inside the cab 18-20 centimetres from the central upright (cab centre line) and, by means of a hoist, tighten the nylon ropes (2).
27672
41 43. Unscrew the cab rear retaining bolt (1) (on both sides). Lift the cab taking care that there are no connected or jammed parts. Check that the doors are locked in the open position, to prevent contact between the windows and the tool 380000294. Position the cab on a suitable support.
42 44. Unscrew the clamps and transmission oil inlet sleeve (1).
detach
the
43 87666787A1 - 03 - 2008
SECTION 10 - ENGINE - CHAPTER 2
15
45. Disconnect the piping (1).
44 46. Disconnect the pipes (1 and 2) and remove the front of the pipe (1). On the other side of the tractor, disconnect the pipes of the transmission oil cooler and differential lock.
45 47. Unscrew the related retaining bolts and remove the bracket (1).
46 48. Position a stand under the clutch casing. Connect the engine to the hoist using chains (1) and tighten them. 49. Unscrew the bolts fastening the engine to the transmission and separate the two assemblies.
47
87666787A1 - 03 - 2008
16
SECTION 10 - ENGINE - CHAPTER 2
50. Place a stand under the rear portion of the bevel drive casing (T4020 Supersteer or T4030 Supersteer) or two stands: one under the axle support at the rear and the other under the front side. (models with standard front axle). 51. For the T4020 Deluxe or T4030 Deluxe models, insert a wooden wedge on each side between the axle support and the axle itself. For all models, keeping the chains taut (1, fig. 47), unscrew the bolts (1) on both sides and separate the engine from the axle-support assembly with the radiator and battery. 52. Rest the engine on an adequate support. 53. To re-fit the engine, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
-
Respect the tightening torques prescribed on page 12.
-
Connect the engine, with chains, to the hoist.
-
Refit the engine to the axle-support assembly with the radiator, battery, coolers: intake air and transmission oil.
-
Before refitting the engine to the clutch box carefully clean the mating surfaces and apply sealing compound (2 mm diameter), according to the diagram shown Section 21, Chapter 1, page 30.
-
Position the engine on the clutch casing and secure it with the specific bolts.
-
Position the bracket on the engine and secure it.
-
Connect the transmission oil cooler pipes and the differential lock pipe.
-
Connect the transmission oil inlet and delivery pipes.
-
Position the cab on the transmission and secure it with the bolts.
-
Raise the fuel tank and secure it with the bolts.
87666787A1 - 03 - 2008
48
SECTION 10 - ENGINE - CHAPTER 2
17
-
Connect the brake piping.
-
Position and secure the throttle control rod.
-
Connect the PTO clutch control tie rod and mount the plastic guard.
-
Connect the transmission oil delivery pipe.
-
-
Connect the auxiliary control valve tie rods.
Position and secure the ground cable between the cab and engine.
-
Connect the lift and lift-o-matic control tie rods.
-
-
Connect the main and range gear levers and connect the Dual Command (2 Speed Power Shift) connections (where applicable).
Position the brake fluid tank, secure it and connect the related electrical connection.
-
Connect all the electrical connections between the cab and engine.
-
Position and secure: the compressor, condenser and related pipes.
-
Position and secure the pipes of the air cooler and turbo charger.
-
Position the radiator bracket and secure it.
-
Connect the steering control pipes and secure them.
-
Connect the top and bottom sleeves to the radiator and secure them.
-
Connect the electrical connection to the compressor.
-
Connect the clogged air filter sensor connection.
-
If the tractor is a T4020 Supersteer or T4030 Supersteer model, unscrew the retaining bolts and retrieve the bracket 380001613 with the spacers 50612.
Position and secure the exhaust silencer and the pipe.
-
Screw the plug on the rear transmission casing and fill up with oil (see sect. 00, page 6 for the prescribed product and quantity).
-
Position and secure the rear wheels.
-
Position and secure the cab heater pipes.
-
For models fitted with brakes on the front axle it is necessary to fill the relevant tank (see sect. 00, page 6 for the prescribed product and quantity) and bleed the braking system (see sect. 33).
-
Position and secure the side grille (on both sides).
-
Connect the fuel supply and return lines to the injection pump.
Fill up the engine cooling system (see sect. 00, page 6 for the prescribed product and quantity).
-
Position and secure the ballast support.
-
Connect the power steering return pipe.
-
Position and secure the ballast.
-
Connect cables to the starter motor.
-
-
Connect: the hoses of the transmission oil cooler and the front axle differential lock pipe.
Install the bonnet as described in operation 90 100 22.
-
Connect the synchronised PTO engagement link rod, the PTO speed selection link rod and the parking brake tie rod.
-
Position the propeller shaft, secure the central support, slide the two front and rear sleeves and secure them with the circlips.
-
-
-
-
-
If the tractor is a T4020 Deluxe or T4030 Deluxe model, position the propeller shafts guard and secure it. If the tractor is a T4020 Supersteer or T4030 Supersteer model, position the propeller shafts guard and secure it. If the tractor is a T4020 Supersteer or T4030 Supersteer model, position the propeller shafts front bracket and secure it.
87666787A1 - 03 - 2008
18
87666787A1 - 03 - 2008
SECTION 10 - ENGINE - CHAPTER 2
SECTION 18 -- CLUTCH -- CHAPTER 1
1
SECTION 18 -- CLUTCH Chapter 1 -- Clutch CONTENT Section
Description
Page
18 000
General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
18 110 10
Clutch -- Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
18 110 30
Dual disk clutch 11”/11” Test bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
18 110 30
Single disk clutch 11” (fitted with Power--Shuttle) Test bench overhaul . . . . . . . . . . . . . . . 20
18 100 40
Clutch adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
LUK 11”/11” CLUTCH -- GENERAL SPECIFICATIONS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
single disk, dry plate dual clutch unit
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical: pedal operated for main transmission clutch; hand lever operated PTO clutch
Engagement and release mechanism . . . . . . . . . . . . . . . . . . . . . . .
single Belleville spring
Driven plate lining material for main transmission clutch: . . . . . . .
Ceramettallic
Driven plate lining material for PTO clutch . . . . . . . . . . . . . . . . . . .
Ceramettallic
Driven disc thickness: --
main clutch (9, fig. 2): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
9.6 ÷ 10.4
--
PTO clutch (11, fig. 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
”
7.3 ÷ 7.9
--
wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
”
see pages 21 and 22
Clearance between main transmission clutch release sleeve and housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearance between PTO clutch release sleeve and housing . . . .
0.050 ÷ 0.151 mm
0.060 ÷ 0.136
Release lever coplanarity adjustment . . . . . . . . . . . . . . . . . . . . . . .
see pages 22 and 23
Clutch control adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
see page 24
87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
2
LUK 11” CLUTCH -- GENERAL SPECIFICATIONS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
single dry plate clutch
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
operation with pedal
Engagement and release mechanism . . . . . . . . . . . . . . . . . . . . . . .
Belleville spring disk
Driven plate lining material for PTO clutch . . . . . . . . . . . . . . . . . . .
cerametallic pads
Driven plate thickness for PTO clutch (1, fig. 2) . . . . . . . . . . . . . . . --
Driven plate wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance between clutch release sliding sleeve and support . . .
mm
7.3 ÷ 7.9
”
see page 21
mm
0.050 ÷ 0.151
BOLT TORQUES PARTS TO BE TIGHTENED
Thread
11”/11” clutch/flywheel retaining bolts . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torque Nm
kgm
M 8 x 1.25
20 ÷ 25
2 ÷ 2.5
Release command fork securing bolt (7, fig. 1)
M 16 X 1.5
136 ÷ 165
13.9 ÷ 16.1
Clutch housing/engine retaining nuts . . . . . . . . . . . . . . . . . . . . . . . .
M 12 x 1.25
117 ÷ 129
11.6 ÷ 13.1
Nut for sleeve cover fixing stud (6, fig. 1) . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
20 ÷ 25
2 ÷ 2.5
SPECIAL TOOLS Warning -- The operations described in this section cannot be carried out without the ESSENTIAL tools marked with an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual. List of specific tools required for the various operations described in this Sect. X 380001612
Pin for centering and adjustment of 11”/11” clutches.
X 380000293
Clutch adjustment gauge (with 380001612).
380000256
Set of wrenches for adjustment of levers in 11”/11” LUK clutches.
X 380001613
Axle--engine support bracket (with 50162) for models fitted with supersteer front axle.
87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1 50169
3
Guide pin for fitting the engine to the clutch housing (see sect. 21).
Spacer to be made for securing axle--engine assembly, for models fitted with supersteer front axle (mark the tool with no 50162 -- Measurements in mm) Make in Fe 42C material. Make no. 4 spacers.
27821
1
Longitudinal section of 11â&#x20AC;?/11â&#x20AC;? LUK clutch 1. PTO clutch release lever adjuster. 2. Belleville spring disk. 4. PTO clutch release levers. 8. Main clutch release levers. 9. Main clutch disk. 10. Main clutch release lever adjuster. 11. PTO clutch disk. D = 97.5 mm. Nominal distance of release levers (8) from clutch contact surface on flywheel. D1 = 139.5 mm. Nominal distance of release levers (4) from clutch contact surface on flywheel.
NOTE: During installation, apply sealing compound to surfaces X as shown in Section 21, Chapter 1, page 30.
2
87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
4
Longitudinal section of 11â&#x20AC;? LUK clutch 1. Main clutch disk. 2. PTO clutch release levers. D1 = 139.5 mm. Nominal distance of release levers (2) from clutch contact surface on flywheel.
NOTE: When refitting the clutch, check that the clutch disks are positioned as in the drawing.
NOTE: During installation, apply sealing compound to surfaces X as shown in Section 21, Chapter 1, page 30.
3
87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
5
CLUTCH TROUBLESHOOTING Problems The clutch slips
Possible Problem
Solutions
1. Worn disks 11 and 9, page 3, Check and compare the data given on disk 1, page 4 on pressure the pages indicated, replace any plates and flywheel. parts which are worn up to or over the limit and adjust levers and clutch control linkage. 2. Belleville spring disk (2, page Replace the Belleville spring. 3) distorted or damaged. 3. Oil or grease contaminating the friction lining of disks 11 and 9, page 3) and disk (1, page 4).
The clutch jerks
Replace the disks, identify and eliminate the source of the lubricant inside the clutch housing and thoroughly clean the friction surfaces.
1. Partial seizure of the external Check rod pivots and lubricate. control linkage. 2. Clutch disk deformed.
(9,
page
3) Replace the disk and adjust the clutch control lever.
3. Clutch disk (9, page 3) with Replace disk. damaged hub springs or loose hub rivets. 4. Oil or grease contaminating the friction lining of disks (11 and 9, page 3) and disk (1, page 4). Clutch sticks and drags
Replace the disks, identify and eliminate the source of the lubricant inside the clutch housing and thoroughly clean the friction surfaces.
1. Clutch disks (11 and 9, page 3) Replace and adjust disks. and disk (1, page 4) deformed. 2. Seizure of external control Check, replace faulty parts and lubrilinkage. cate. 3. Controls incorrectly adjusted. Adjust the controls (see. page 19).
Clutch noisy when engaged and/or disengaged
1. Thrust bearing worn.
Replace bearing
2. Clutch disk (9, page 3) with Replace disk. hub springs damaged. Clutch pedal too stiff
1. Partial seizure of the external Check rod pivots and lubricate. control linkage. 2. Partial seizure of pedal pivot.
Check pivot and lubricate.
87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
6
Op. 18 110 10 CLUTCH -- Removal--Installation
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Carry out operation 90 100 22 Bonnet, only removal (see section 90). 2. If the tractor in question is a model fitted with a supersteer front axle, detach the front ballast (3), if fitted, using a hoist and two steel cables (1), extract the pin (2) and remove the ballast.
27786
4 3. If the tractor in question is a model fitted with a supersteer front axle, attach bracket 380001613 (1) together with spacers 50162 (see page 3).
27787
5 4. Unscrew the cap (1), drain off a few litres of coolant and replace the cap. 5. Carry out operation 10 254 44 Exhaust pipe, only removal (see Section 10).
27749
6
87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
7
6. Loosen the clamp retaining bolts (1) and detach the red and black pipes (2) of the cab heating system. 7. Carry out operation 90 110 14 Instrument panel lower guard, only removal (see Sect. 90).
27647
7 8. Loosen the nut (1) and remove the PTO clutch control cable (2). NOTE: For models with mechanical gears, remove the clutch control cable.
27650
8 9. Remove the accelerator control cable (1) from the injection pump. 10. Unscrew the speedometer/tachometer control cable, if applicable (version with analog control panel).
27660
9 11. Detach the four hoses (1) from the power steering circuit pipes.
27662
10 87666787A - 11 - 2007
8
SECTION 18 -- CLUTCH -- CHAPTER 1
12. Remove the conditioning system pipe retaining clamps. 13. Disconnect the electrical connection, remove the retaining bolts, remove the conditioning system compressor (1) without disconnecting the piping, and place in the cab.
27123
11 14. Remove the retaining bolt, remove the filter/dryer (1) without disconnecting the piping, and place in the cab.
27663
12 15. Remove the retaining wing nut, extract the conditioning system condenser (1) from the bracket on the engine radiator, without disconnecting the piping. NOTE: If necessary, also remove the bracket fitted on the radiator.
27664
13 16. Position the condenser (1) on the cab floor, together with the other conditioning system components that were disassembled in operations 11 and 12. Anchor them to the brake pedals so as to prevent damage when lifting to remove the cab. NOTE: The pipes must not be disconnected in order to avoid refilling the system.
27665
14 87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
9
17. Drain off the brake fluid and disconnect the brake control pipes (2) from the block (1). 18. Disconnect the control pipes that go from the block (1) to the rear transmission, on the brakes.
27125
15 19. Disconnect the brake feed pump pipes (2) from the relative tank (1).
27126
16 20. Remove the four retaining bolts and the hood rear support (1).
17 21. Disconnect all electrical connected to the cab.
connections
(1)
27124
18 87666787A - 11 - 2007
10
SECTION 18 -- CLUTCH -- CHAPTER 1
22. Disconnect: the connections (1) on the brake priority block, the thermostarter connection (2), steering sensor connection, engine stop connection on the injection pump and starter motor connection.
27789
19 23. Disconnect the earth connection (1), engine coolant temperature connection (2), engine oil pressure connection and the connections on the alternator.
27790
20 24. Unscrew the clamps and disconnect the fuel return pipe (1) from the thermostarter and the fuel supply pump inlet pipe (2).
27791
21 25. Unscrew the plug and drain the oil from the rear transmission casing (the prescribed quantity is 42 litres).
25628
22 87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
11
26. Loosen the clamps, detach the hoses (1) from the rigid piping (2) and attach to the air filter support to facilitate access.
27793
23 27. Unscrew the retaining bolt and detach the bracket (2) clamping the piping (1).
27794
24 28. Unscrew and disconnect the filter (2) piping (1). 29. Disconnect the union (3) on the front differential lock control pipes and loosen the clamp (4).
27795
25 30. Unscrew the clamp (1) and detach the sleeve on the oil intake piping, unscrew the fitting (2) and remove the lift oil feed piping.
27796
26 87666787A - 11 - 2007
12
SECTION 18 -- CLUTCH -- CHAPTER 1
31. Unscrew: the union (1), bolt (2) and remove the front differential lock piping (3).
27797
27 32. If the tractor in question is a model fitted with a supersteer front axle, unscrew the screws and remove the guard (1).
27798
28 33. If the tractor in question is a model fitted with a supersteer front axle, extract the snap ring (2) and slide back sleeve (1).
27799
29 34. If the tractor in question is a model fitted with a supersteer front axle, unscrew: the pin (1) and the 4 bolts (2), recovering the pin and lower bracket.
27800
30 87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
13
35. If the tractor in question is a model fitted with a standard front axle, unscrew the front, central and rear retaining bolts and remove the guard on the propeller shafts (1).
27801
31 36. If the tractor in question is a model fitted with a standard front axle, extract the rear snap ring and slide back sleeve (1) on the grooved shaft.
27802
32 37. Fit an additional hitching bracket (1) if the engine is only provided with one bracket. 38. Position a fixed stand under the clutch casing and attach a chain to the hoist and the brackets (1), put the chain under tension.
27803
33 39. Unscrew the screws and remove the cab floor covering (1).
27804
34 87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
14
40. Raise the cab floor covering, remove the foam rubber and, using a wrench (1) placed through the two holes on the cab platform, unscrew the 4 upper screws securing the clutch casing to the engine. Unscrew the remaining screws securing the clutch casing to the engine.
27805
35 41. Make sure that the hoisting slings (1) are tensioned and, working on the front wheels, detach the engine--front axle assembly from the clutch casing.
27806
36 42. Using tool 380001612 (1), unscrew the retaining bolts and remove the clutch (2). 43. To refit the engine to the clutch casing, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Apply the torque settings listed on page 20.
27785
37 --
Before refitting the engine to the clutch box carefully clean the mating surfaces and apply sealing compound (2 mm diameter), according to the diagram shown Section 21, Chapter 1, page 30.
--
Refit the clutch to the flywheel, using tool 380001612.
--
Using a hoist, position the engine--front axle assembly and secure in position. Screw the upper bolts through the holes on the cab platform.
87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1 --
Position the foam rubber covering, the mat and guard.
--
If the tractor in question is a model fitted with a standard front axle, position the sleeve correctly, securing with the snap ring, then assemble and secure the propeller shafts guard.
--
If the tractor in question is a model fitted with a supersteer front axle, assemble and secure the lower bracket and pin.
15
--
Connect all brake priority terminal piping (see page 6, Sect. 00 for prescribed products and quantities).
--
Correctly position the compressor, the radiator and conditioning system dehydrator filter, then secure.
--
Connect the hydrostatic steering piping.
--
Connect the accelerator cable to the injection pump.
--
If the tractor in question is a model fitted with a supersteer front axle, position the sleeve correctly, securing it with the snap ring.
--
Connect the rev counter cable (if fitted).
--
If the tractor in question is a model fitted with a supersteer front axle, assemble and secure the propeller shafts guard.
--
Connect the PTO cable to the relative lever.
--
Connect the clutch cable (if fitted).
--
Connect and secure the front differential lock piping.
--
Carry out operation 90 110 14 Instrument panel lower guard, only installation (see Section 90).
--
Connect the lift intake and delivery piping.
--
Connect the heating system piping.
--
Connect the Power Shuttle filter and front differential lock piping, then secure together with the clamp.
--
Carry out operation 10 254 44 Exhaust pipe, only assembly (see section 10).
--
If the tractor in question is a model fitted with a supersteer front axle, remove bracket 380001613 together with spacers 50162.
--
Assemble the front ballast, if fitted.
--
Carry out operation 90 100 22 Bonnet, only installation (see section 90).
--
Complete filling the engine cooling system (see page 6, Sect. 00 for prescribed products and quantities).
--
Screw the plug on the rear transmission casing and fill up with oil (see page 6, Sect. 00 for prescribed products and quantities).
--
Connect the heat exchanger hose to the rigid piping.
--
Connect the thermostarter and fuel pump piping.
--
Connect the connections: alternator, engine oil pressure, engine coolant temperature and intake manifold ground.
--
--
Connect the connections: of the starter motor, injection pump, steering sensor, thermostarter, on the brake priority block and all those of the cab. Assemble the bonnet rear support.
87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
16
Op. 18 110 30 11”/11” DUAL DISK CLUTCH -- Test bench overhaul
1
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Unscrew the three PTO clutch lever adjustment nuts (1). 2. Recover the pressure plate (1) with the three coil springs (2) and the three washers.
24791
38
1
2 24792
39 3. Position three clamps (1) at intervals of 120ٛ on the clutch body and gradually and carefully squeeze the Belleville spring disk.
1
24793
40 4. Extract the six spring retaining pins (1) from their seats.
1
24794
41 87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1 5. Remove the three clamps and extract the Belleville spring disk (1).
17
1
24975
42 6. Loosen the three locknuts (1) on the main clutch lever adjustment screws.
1
24976
43 7. Remove the three main clutch lever adjustment screws (1).
1
24977
44 8. Extract the main clutch pressure plate (1).
1
24978
45 87666787A - 11 - 2007
18
SECTION 18 -- CLUTCH -- CHAPTER 1
9. Extract the main clutch disk (1).
1
24979
46 10. Remove the springs (1) on the PTO clutch control levers.
1
24980
47 11. Extract the pivot pins (1) on the PTO clutch control levers.
1
24981
48 12. Remove the springs (1) on the main clutch control levers.
1
24982
49 87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1 13. Extract the pivot pins (1) on the main clutch control levers.
19
1
14. To refit the clutch, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Refit the lever pivot pins and the relative springs.
--
Refit the main clutch disk in the clutch housing.
--
Install the main clutch pressure plate, securing to the pins with the bolts.
--
Install the Belleville spring disk, carefully position the three clamps and evenly and progressively compress the spring. Insert the six pins, making sure that they are securely inserted in their respective seats, then remove the clamps.
--
Install the PTO clutch disk; fit the three washers and the coil springs on the pins and secure with the three nuts.
24983
50
87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
20
Op. 18 110 30 SINGLE DISK CLUTCH 11â&#x20AC;? (fitted with Power--Shuttle) -- Test bench overhaul
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Unscrew the three clutch lever adjustment nuts (1). 25963
51 2. Remove the pressure plate (1) with the coil springs (2) on the levers.
25964
52 3. Unscrew the six retaining bolts (1) of the Power Shuttle gear control disk and remove (2). 4. To refit the clutch, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Refit the Power Shuttle gear control disk in the clutch housing.
--
Install the pressure plates and secure to the spring coils.
--
Tighten the lever adjustment nuts.
87666787A - 11 - 2007
25965
53
SECTION 18 -- CLUTCH -- CHAPTER 1
21
CHECKS, MEASUREMENTS AND REPAIRS -- DUAL DISK CLUTCH
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Minimum permissible dimensions after refacing of parts subject to wear in the 11”/11” dual clutch
25966
A ≥ 15.5 mm; B ≥ 22.7 mm; D ≥ 15.8 mm. 1. Flywheel. 2. PTO clutch pressure plate. 3. Main clutch pressure plate. 4. Clutch cover.
54
Minimum permissible dimensions after refacing of parts subject to wear in the 11” single clutch A ≥ 15.5 mm; C ≥ 15.8 mm. 1. Flywheel. 2. PTO clutch pressure plate. 3. Clutch cover.
--
--
Check for wear on the Power take--off (11, fig. 1 and 1, fig. 2) and main (9) clutch disks and replace if the retaining rivets are worn or approaching the friction material. Replace the disc when the oil has soaked into the organic agglomerate surfaces.
25967
55
Minimum permissible dimensions after refacing of parts subject to wear in the 11”/11” dual clutch and 11” single clutch. --
Check the friction surface conditions of the pressure plates and the clutch casing. Generally, by means of turning, up to 1 mm of material can be removed from the cast iron friction surfaces of the clutch cover (3), the pressure plate ring (2) and the flywheel (see section 10 chap. 1, page 56). When parts (1), (2), (3) and (4) ( figs. 54 and 55) are to be repaired by removing material, proceed as follows:
87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
22 --
If it is necessary to reface the friction surfaces on the PTO clutch pressure plate (2, fig. 54 and 55), remember that the amount removed in relation to the nominal thickness (A), must also be removed from the base of the flywheel housing (4, fig. 34 and 35) in order to regain the original position of the pressure plate (2) in relation to the flywheel.
The position indicated by (C) of the clutch cover (4, see fig. 54 and 55) must be calculated using the following formula: C = 71.4 + A Where: A = Thickness of the pressure plate after refacing. C = Height of the clutch cover after refacing. --
When the friction surfaces of the main clutch pressure plate ring (3, fig. 54) or the clutch cover (4), need refacing, remember that the removal of material cannot be compensated by turning the clutch cover (4) on the flywheel side.
--
Therefore the least possible material should be removed from parts (3 and 4), for longer clutch life.
NOTE: If, after having refaced parts (3 and 4, fig. 54), several times, the main clutch disk starts to slip, the entire clutch assembly must be replaced. --
Refit the clutch assembly as shown on page 6.
COPLANARITY ADJUSTMENT OF 11â&#x20AC;?/11â&#x20AC;? DUAL CLUTCH RELEASE 1. After overhauling the clutch, fit the centering pin 380001612 (1) and fit the entire clutch assembly to the flywheel, tightening the bolts (2).
25968
56
87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
23
2. Fit gauge 380000293 (1) on the centering pin and, using a feeler gauge, adjust the main clutch release levers (2) to obtain a clearance of 0.1 mm.
25969
57 3. Rotate the gauge 380000293 (1) and, with the aid of a feeler gauge, adjust the PTO clutch release levers (2) to obtain a clearance of 0.1 mm.
25970
58
COPLANARITY OF 11â&#x20AC;? SINGLE PLATE CLUTCH RELEASE LEVERS 4. After overhauling the clutch, fit centring pin 380001612 (1), gauge 380000293 (2), and fit the entire clutch assembly to the flywheel, tightening the bolts (3).
25971
59 5. Using a feeler gauge, adjust the coplanarity of the clutch release lever to obtain a clearance of 0.1 mm.
25972
60 87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
24
Op. 18 100 40 GEAR CLUTCH CONTROL ADJUSTMENTS 1. If the position of the clutch pedal (1) requires adjustment, or after a clutch overhaul, check that main clutch pedal travel (A), is 150 Âą 2 mm. If not adjust as follows:
25973
61 ----
Loosen the locknut (2) and turn the nut (1) anticlockwise. Check that travel is 150 Âą 2 mm. Tighten the locknut (1).
25974
62 -----
Operate the unit four or five times. Check that the clutch pedal (1) travel is as prescribed. If necessary, reset to the correct value (A), as previously described. After having correctly adjusted pedal travel, check that the entire distance is travelled with a maximum load of 19 daN (19.3 kgm).
25975
63
87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
25
PTO CLUTCH CONTROL ADJUSTMENTS
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 1. Remove the left--hand guard under the control panel. 2. Loosen the locknut (2) and unscrew nut (1) until there is a play of 30 á 40 mm on the control lever (4). 64 3. Fully raise the lever (1), hold in position and tighten nut (1, fig. 64) until the lever (4, fig. 64) makes contact with the rubber stop (3, fig. 64). 4. Make 2 or 3 engagement and disengagement movements to bed in the PTO clutch control system. 5. Check that the control lever (4, fig. 64) goes against the stop (3, fig. 64): if it doesnâ&#x20AC;&#x2122;t, repeat step 3. 6. Unscrew nut (1) on face No. 8 faces of the hexagon and lock with the locknut (2, fig. 64).
65
7. Check that there is play on the control lever (4, fig. 64) without load. 8. Refit the left--hand guard.
87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
26
PTO CLUTCH SERVO CONTROL
66 Cross--section of PTO servo control 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Discharge oil pipe. Oil delivery pipe to control piston. Pressurized oil pipe, from pump. Dust ring. O -- Ring. Control valve drive pin. PTO clutch lever. Locknut. Flexible protective sleeve. Piston housing.
87666787A - 11 - 2007
11. 12. 13. 14. 15. 16. 17. 18. 19.
Seals. Control piston. Retaining ring. Control valve lever, connected by cable to control lever in cab. Lever control linkage (7). Retaining ring. O -- Ring. Spring. Control valve body.
SECTION 18 -- CLUTCH -- CHAPTER 1
27
2
1
3 4 5
2 8 3 7 1 6
MDE0552A
Pressurised oil
Discharge oil 67
DESCRIPTION AND OPERATION ENGAGING THE PTO CONTROL CLUTCH The PTO clutch control system consists of a control lever (in the cab) and a cable connecting the lever to the servo control unit. The servo control unit consists of a hydraulic control valve and piston. When the PTO clutch is engaged with the control lever in the cab, the connecting cable acts on the lever (8) which, as it moves, pushes up the control valve drive pin (4).
When the pin (4) moves up it closes the hole leading to the oil discharge pipe (1). The oil from the pump passes through line (3), line (2), and acts on the piston (6). The piston (6), under an oil pressure of 15.7 (16) bar (kg/cm2) moves and, by means of tie--rod (7), moves lever (5), engaging the PTO clutch.
87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
28
2 1 3 4 5
9
2
8
3
7
1
MDE0553A
6
Pressurised oil
Discharge oil
DISENGAGING THE PTO CONTROL CLUTCH When the PTO clutch is disengaged with the lever in the cab, the linkage releases the clutch control lever (5). The spring (9) moves the control valve drive pin (4) down to stop the oil pumped in through pipe 3 from going into pipe (2).
87666787A - 11 - 2007
68 In this position, the pipe (2) that delivers the oil to the piston (6) communicates with the discharge pipe (1) so that the oil can flow away from the piston. When the piston (6) lowers it moves lever (5) with the linkage (7) and disengages the PTO clutch.
SECTION 18 -- CLUTCH -- CHAPTER 1
PTO CLUTCH SERVO CONTROL ADJUSTMENT
ATTENTION
29
2. Push the clutch lever (1) up.
69
3. Connect the fork (2) to the lever (1) by unscrewing the lever so that the control piston (5) goes against the bottom of the cylinder (6).
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
4. Unscrew the fork (2) one turn (1.25 mm) so that there is an internal clearance between the clutch control sleeve and levers.
1. Detach the protective sleeve (4) from the fork pin (2) and unscrew the locknut (3).
5. Tighten the locknut (3) and attach the protective sleeve (4) to the fork pin (2).
87666787A - 11 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
30
ADJUSTING THE PTO ENGAGED SWITCH
ATTENTION
70 2. Unscrew the screws (1) retaining the PTO engaged switch (2) and move away from the control valve lever (3).
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
3. Move the switch (2) towards the control valve lever (3 )until the switch trips.
1. Check that the PTO clutch is disengaged.
4. Lock the switch (2) in this last position with the screws (1).
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
1
SECTION 21 -- GEAR TRANSMISSION Chapter 1 -- Mechanical transmission CONTENT Section
Description
Page
21 000
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
21 118 10
Rear transmission casing--gearbox. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . 14
21 118 12
Rear transmission casing--gearbox. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . 14
21 118 85
Gearbox transmission casing. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
21 130 10
Gearbox control lever. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
21 130 11
Range gear control lever. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
21 130 52
Shuttle control lever. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10 216 10
Fuel tank. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REVERSER DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mechanical type with spur gearing, located between the main clutch and the gearbox.
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
hand lever located on left--hand side of operator
CREEPER UNIT DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordinary gear train with spur gearing, located between the main clutch and the gearbox, up stream from the shuttle. Providing 28 forward gears and 16 reverse gears
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
hand lever located on left--hand side of the operator (continued)
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
2
TRANSMISSION AND RANGE GEAR DATA (overleaf)
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 speed, constant--mesh, with synchronisers on all gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
helical
Reduction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ordinary gear train with 4 ranges for a total of 16 speeds.
--
gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
spur
Gearbox and reduction unit controls . . . . . . . . . . . . . . . . . . . . . . . . .
independent, by means of lever located on right--hand side of operator
Thickness of gearbox driving shaft adjustment ring (4, page 8) .
mm
0.5 -- 0.75 -- 1.0 -- 1.25 -- 1.5 -1.75 -- 2.0 -- 2.25
Thickness of gearbox driven shaft adjustment ring (12, page 8) .
mm
0.5 -- 0.75 -- 1.0 -- 1.25 -- 1.5 -1.75 -- 2.0 -- 2.25
Springs for detent balls on gearbox and range gear control rods: --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
42
--
length of spring under load of 75.5 ÷ 83.3 N (7.7 ÷ 8.5 kg) . .
mm
35
Springs (1, page 10) for gearbox and range gear control levers: --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
44
--
spring length under load of 31.4 ÷ 35.3 N (3.2 ÷ 3.6 kg)
mm
35
BOLT TORQUES PARTS TO BE TIGHTENED
Thread
Sleeve cover retaining nuts (C1, page 3) . . . . . . . . . . . . . . . . . . . . .
Tightening torque Nm
kgm
M 8 x 1.25
20 ÷ 25
2.0 ÷ 2.5
Gearbox driving and driven shafts bearing cover screws (C2) . . .
M 10 x 1.25
84 ÷ 93
8.6 ÷ 9.5
Retaining bolts securing creeper clutch casing to rear transmission/gearbox (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 12 x 1.25
117 ÷ 129
11.9 ÷ 13.1
Driven gear shaft locknut (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 32 x 1.5
280 ÷ 309
28.5 ÷ 31.5
Drive gear housing cover retaining screws (C5) . . . . . . . . . . . . . . .
--
43 ÷ 51
4.4 ÷ 5.2
Pressure switches (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
51 ÷ 72
5.2 ÷ 7.3
Parking brake inspection cover, gearbox and range control relay levers support cover retaining screws (C7) . . . . . . . .
M 10 x 1.25
43 ÷ 51
4.4 ÷ 5.2
Bolts or nuts securing creeper clutch casing to the engine (C8) .
M 12 x 1.25
117 ÷ 129
11.9 ÷ 13.1
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
3
BOLT TORQUES
C1 -- 20÷25 Nm
25612
C3 -- 117÷129 Nm
C4 -- 280÷309 Nm
C5 -- 43÷51 Nm
C2 -- 84÷93 Nm
C6 -- 51÷72 Nm
25614
C7 -- 43÷51 Nm
C8 -- 117÷129 Nm 27928
1
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
4 SPECIAL TOOLS
Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual. List of specific tools required for the various operations described in this Sect. 380000227
Clutch casing lift hook.
380000301
Turning stand for overhaul.
X 380001614
Tool for gearbox driving and driven shafts adjustment.
X 380001615
Driving shaft rod for lifting unit.
X 380001616
Driven shaft retaining tool.
X 380001617
Pliers for gearbox shafts circlips.
380001618
Driving shaft fitting guide.
X 380001619
Driven shaft fitting guide.
X 380001610
Adjuster handle (with 380001620 and 380001609).
X 380001620
Power take--off drive shaft seal splining tool (with 380001610).
X 380001609
Power take--off drive shaft roller bearings splining tool (with 380001610).
50091
Tool for removal--installation final drives (see section 27).
25618
Guide pin for re--fitting the gearbox in the casing. (Mark part with no. 50158 -- Measurements in mm) Make in C 40 material.
87666787A - 11 - 2007
2
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
5
26258
Tool to be made for removal--installation of the final drives, to be used with a part of 50091. (Mark the tool with no. 50114 -- Measurements in mm) Make in Fe 42 C material -- (*) Measurement according to hoist seat.
3
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
6
(1)
27940
4 Bracket to be made for gearbox overhaul on rotating stand. (Mark part with no. 50160 -- Measurements in mm) 1. Rotating stand shaft. Make in Fe 42C material.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
7
27941
5 Bracket to be made for gearbox overhaul on rotating stand. (Mark part with no. 50160 -- Measurements in mm) Make in Fe 42C material.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
8
1
2
3
4
5
6
7
8
X X 25619
13
12
11
10
9 6
Longitudinal cross--sectional view of gearbox and gear range 1. 2. 3. 4. 5. 6. 7.
Seal. Power take--off shaft support roller bearings. Reverser control synchroniser. Gearbox driving gear clearance adjusting thickness. Power take--off shaft. Gearbox driving gear. Selector sleeve for high or medium--low speeds.
Bevel Pinion Shaft. Selector sleeve for low or medium--high speeds. Synchroniser for 1st and 2nd speed. Synchroniser for 3rd and 4th speed. Gearbox driven shaft gear clearance adjusting thickness. 13. Gearbox driven shaft. 8. 9. 10. 11. 12.
NOTE: When fitting apply sealing compound to surfaces X as shown on page 30.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
9
7 Cross--sectional view of gearbox and range gear 1. 2. 3.
Shuttle control external rod. Gear control external rod spring. Gear control external rod.
4. 5.
Gear selector internal rods. Shuttle selector internal rod.
NOTE: When fitting apply sealing compound to surfaces X as shown on page 30.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
10
3 4 5
25622
6
25623
8 Cross--sectional view of gearbox and range gear 1. 2. 3. 4.
Range gear control external rod spring. Range gear control external rod. Reverser control fork. Shuttle selector synchroniser.
5. 6. 7. 8.
Shuttle relay gear (reverse gear) Detent ball and spring. Lubricating oil external pipes. Lubricating oil internal pipes.
NOTE: When fitting apply sealing compound to surfaces X as shown on page 30.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
11
9 Longitudinal cross--sectional view of creeper unit for gearbox 1. 2.
Creeper unit selector sleeve. Creeper unit driving shaft--gear.
3. 4.
Creeper unit driven gear. Shuttle selector synchroniser.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
12
DESCRIPTION AND OPERATION Gearbox and shuttle 4--speed gearbox with constant--mesh helical gears controlled by two synchronizers. The range gear has cascade--type constant--mesh spur gears. The range gear provides 4 forward ranges. The gearbox and the range gears are controlled by two independent levers located on the right--hand side of the operator. The shuttle is a mechanical device providing 16 forward gears and 16 reverse gears. It is controlled by a lever located on the cab platform to the left of the operator. The reverser is composed of a group of three spur gears: reverser driving gear, reverser driven gear and intermediate gear, engagement is by means of a synchroniser located in the gear unit.
The reverser is installed inside the clutch casing, between the clutch and the gearbox. Lubrication is by means of the oil in the rear transmission/gearbox. Creeper unit The creeper unit is a mechanical device providing 28 forward speeds and 16 reverse speeds. The creeper unit only intervenes in slow, medium slow and medium fast ranges, a mechanical interlock prevents creeper engagement in the fast ranges. The creeper unit is composed of a group of three spur gears: a sliding control gear, a driving gear shaft and a driven gear. The creeper unit is installed upstream from the reverser and is controlled by the same control lever as the reverser, located on the left--hand side of the operator.
GEARBOX, CREEPER UNIT AND SHUTTLE TROUBLESHOOTING
Problems
Possible Problem
Solutions
Spontaneous disengagement of 1. External levers and relay rods Adjust correctly. incorrectly adjusted. gearbox, creeper or shuttle. 2. Control lever retaining springs Replace springs. damaged. 3. Synchroniser teeth or Remove the transmission/gearbox selection sleeves damaged. and replace the synchronisers or the engagement sleeves. 4. Engagement incomplete.
stroke Eliminate the cause and restore full engagement travel. (continued)
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
13
GEARBOX, CREEPER UNIT AND SHUTTLE TROUBLESHOOTING (overleaf)
Problems
Possible Problem
Solutions
Difficulty in engaging the gearbox, 1. External levers and relay rods Adjust correctly. incorrectly adjusted. creeper or reverser units. 2. Stiffness and/or partial Check rod pivots and lubricate. seizure of external levers and relay rods. 3. Main clutch dragging.
See Sect. 18.
4. Synchronisers or selection Remove the transmission / gearbox sleeves damaged. and replace the synchronisers or engagement sleeves. 5. Internal controls do not slide Overhaul the controls. easily: rods, forks and sleeves. Excessive noise in creeper or reverser.
gearbox, 1. Worn or damaged internal Remove the transmission--gearbox parts. casing and replace the damaged parts.
CREEPER UNIT TROUBLESHOOTING Problems
Possible Problem
Solutions
Spontaneous disengagement of 1. External levers and relay rods Adjust correctly. creeper unit. incorrectly adjusted. 2. Engagement incomplete.
stroke Eliminate the cause and restore full engagement travel.
Difficulty in engaging the creeper 1. External levers and relay rods Adjust correctly. unit. incorrectly adjusted. 2. Stiffness and/or seizure of Check rod pivots and lubricate. external levers and rods. 3. Main clutch dragging.
See Sect. 18.
4. Selector sleeve damaged.
Remove the clutch--gearbox casing and replace the sleeve.
5. Internal controls do not slide Overhaul the controls. easily: rods, forks and sleeves. Excessive noise in creeper.
1. Internal components worn or Remove the clutch casing and defective. replace the damaged parts.
87666787A - 11 - 2007
14
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
Op. 21 118 10 -- 21 118 12 REAR TRANSMISSION--GEARBOX CASING Removal--Installation
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that the units or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted. Proceed as follows. 1. Carry out operation 90 150 10: Cab with platform unit, only removal (see Section 90, Chapter 1). 2. Carry out operation 23 101 26: Transmission shafts and guard, only removal (see Section 23, Chapter 1). 3. Carry out operation 10 216 10: Fuel tank, only removal (see Section 10, Chapter 1). 4. Lock the front wheels using chocks. 5. Remove the top link of the third point. 6. Using a hoist and sling (1) raise the rear part of the tractor, position a fixed support stand under the towing hook, then remove the right--hand (2) and left hand wheels.
27837
10 7. Unscrew the plug and drain the oil from the rear transmission casing (the prescribed quantity is 42 litres).
25628
11 8. Unscrew the stabiliser strut bracket retaining bolts (1).
27840
12
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
15
9. Attach tool 50091 (1) and adapter 50114 (2) to the final drive body.
27841
13 10. Position a hydraulic jack (2) under the gear unit, unscrew the retaining bolts and, using the jack (2), remove the right--hand gear unit (1) and the spacer. 11. Detach and remove the vertical rods, complete with the lower arms.
27842
14 12. Remove the pick--up bar, connect the pick--up hitch hook (2), using a chain (1), to the hoist, loosen the retaining bolts and detach the hook.
1
2
25627
15 13. Disconnect and remove the lift auxiliary control valve control pipes (1) and trailer brake control (2).
1
2
25449
16 87666787A - 11 - 2007
16
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
14. Unscrew the retaining bolts and extract the Lift--O--Matic control lever (1).
1
25450
17 15. Unscrew the retaining bolts on the lift (1) and recover the trailer brake control pipes support bracket. Disconnect the power take--off speed sensor connections, if necessary.
1 25451
18 16. Attach the lifting hook 380000227 (1) to the lift (2) and, by means of a hoist, raise and remove the lift.
1
2
25452
19 17. Unscrew and remove the filter pipes (2) and the transmission--gearbox casing pipes. 18. Disconnect the union (3) on the front differential lock control pipes and loosen the clamp.
27795
20 87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
17
19. Unscrew the clamp (1) and detach the sleeve on the oil intake pipes, unscrew the union (2) and remove the lift oil feed pipes, detach and remove the two transmission gearbox casing pipes.
27796
21 20. Disconnect the brake control pipes (1) from the brake block and the rear transmission casing and remove. 21. Unscrew the union and the retaining bolt, then remove the pipes (2).
22 22. Disconnect the unions on the heat exchanger pipes (1).
1
25640
23 23. Disconnect the unions (2) and remove the pipes (1 and 3). 24. Unscrew the retaining bolts and remove the cab support bracket (on both sides).
1
2
3
25642
24 87666787A - 11 - 2007
18
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
25. Position a fixed stand (1) under the engine.
1
27943
25 26. Screw on the four hooks (1) and, using a chain, connect them to a hoist, unscrew the retaining bolts that secure the clutch casing to the engine and detach the engine, together with the rear transmission.
1
27944
26 27. Position the rear transmission--clutch unit on a workbench. Unscrew the retaining bolts and recover the services control valve (1).
1
25654
27 28. Extract the pin (3), detach the external lever (1), unscrew the retaining bolts and remove the support (2), complete with control levers.
1
2 3
25655
28 87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1 29. Disconnect: the parking brake control lever (5), the drive gear control oil union (4) and the electric sensors (1, 2 and 3).
1
19
3
2
4 5 25656
29 30. Position two nylon slings (1) under the clutch casing (2) and attach to the hoist. Unscrew the retaining bolts that secure the clutch casing to the transmission casing and remove. 31. To refit the rear transmission--gearbox casing, proceed as follows.
1
2
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. ---
-----
---
For the correct orientation of the various parts, refer to the illustrations on pages 8, 9, 10 and 11. Before refitting casings, supports and covers, thoroughly clean and degrease the mating surfaces and apply a strip of sealing compound of about 2 mm diameter as shown in the diagram on page 30. Respect the tightening torques prescribed on page 2. Re--fit the clutch casing on the rear transmission--gearbox case. Fit the electric sensors, the drive gear oil union and the parking brake control external lever. Fit the support complete with creeper--shuttle control lever, remembering to attach the lever (2) to the bracket (1) and to insert the unit positioned in an anticlockwise direction, then straighten--up the unit when it comes into contact with the casing, to facilitate the insertion of the lever (2) in the relative teeth. Assemble the creeper--reverser external control lever. Fit the services control valve.
25657
30
1 2
27945
31
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
20 --
Refit the rear transmission--gearbox case and clutch casing to the engine.
--
Attach the cab mounting.
--
Connect all of the services control valve pipes.
--
Connect the brake and services control pipes.
--
Connect the heat exchanger pipes.
--
Fit the rear transmission--gearbox case oil intake pipes.
--
Connect the trailer brake and lift control pipes.
---
--
Fit the towbar and towing hook.
--
Re--connect the vertical rods to the lift arms.
--
Fit the brake disks, the differential axle shafts and final drives.
--
Fit the rear wheels and remove the support stands.
--
Carry out operation 90 150 10: Cab with platform unit, only installation (see Section 90, Chapter 1).
--
Connect all of the lateral filter and front differential lock control pipes.
Carry out operation 23 101 26: Propeller shafts and guard, only installation (see Section 23, Chapter 1).
--
Tighten the rear transmission--gearbox oil drainage plug.
Carry out operation 10 216 10: Fuel tank, only installation (see Section 10, Chapter 1).
--
Fill up the rear transmission--gearbox casing (see page 6, Sect. 00 for prescribed products and quantities).
--
Assemble the hydraulic lift.
--
Fit the Lift--O--Matic control lever.
--
Assemble and connect the auxiliary control valve support and trailer brake valve pipes.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
21
Op. 21 118 85 GEARBOX TRANSMISSION CASING Disassembly--Assembly
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Attach the transmission--gearbox casing on the rotating stand 380000301 using brackets 50160 (see pages 6 and 7). 2. Remove the drive gear casing, following the instructions in Sect. 23. 3. Unscrew the retaining bolts and remove the cover (1) with the gearbox lever and gear unit. 4. Detach the power take--off control shaft following the instructions in Sect. 31.
25717
32
5. Remove the parking brake casing cover and extract the circlip (1) that secures the parking brake control lever.
25718
33 6. Extract the parking brake control lever (2) and retrieve the sleeve--cam (1).
25721
34
87666787A - 11 - 2007
22
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
7. Loosen the retaining bolt and remove the cover (1).
25734
35 8. Remove the circlip (2) and recover the unit (1) composed of the brake disk and the relative friction sectors.
25735
36 9. Fit tool 380001615 (1) on the driving shaft and lock in position, insert tool 380001616 (2) on the gearbox driven shaft and tighten.
NOTE: If the gearbox is the standard version, screw in a bolt M 12 x 1.25 x 40 together with a washer â&#x2C6;&#x2026; 12 x â&#x2C6;&#x2026; 45 and 3 mm shim in place of the tool 380001616 (2).
25736
37 10. Remove the circlip from the front side of the casing and, using an extracting tool, extract the final drive driven shaft and recover the driven gears (1).
25737
38 87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
23
11. Extract the lubrication pipe (1) from the gearbox.
25738
39 12. Remove the circlip (1) and the union (2), complete with the lubrication pressure adjustment valve.
25739
40 13. Unscrew the lubrication union (1) from the left--hand side of the casing.
25740
41 14. Remove the union (2) and the lubrication sleeve (1).
25741
42 87666787A - 11 - 2007
24
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
15. Enlarge the circlip (1) that secures the gearbox driving shaft.
25742
43 16. From the drive gear case, enlarge the circlip (1) that secures the gearbox driven shaft.
25744
44 17. Unscrew the gearbox retaining bolts (1) and remove, using a hoist.
25743
45 18. Fit tool 380001614 (2) in a vice and remove the mobile part (1) of the tool.
25774
46 87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
25
19. Fit the gearbox unit to the tool 380001614 (1) and re--fit the mobile part (2) of the tool.
25775
47 20. Remove the pins (1) to free the gearbox control forks (on one side).
25776
48 21. Extract the pins (1) on the other side of the gearbox and remove: the upper part (1) of tool 380001614, tool 380001615 (2) from the driving shaft and retaining tool 380001616 from the driven shaft.
25777
49 22. Remove the driving (1) and driven (2) shafts.
25778
50 87666787A - 11 - 2007
26
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
23. From the opposite side, remove the rod stop ring (2), extract and recover the shuttle control fork (1).
25779
51 24. Extract the circlip synchroniser (2).
(1)
and
recover
the
25780
52 25. Unscrew the retaining bolt (2) and recover the pin (3), relay gear (1) and relative bearings and thrust washers.
25781
53 26. Enlarge the circlip (3) that secures the driven gear (1) to the gearbox support (2) and remove the gear (1).
25782
54 87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
27
27. Enlarge the circlip (1) and extract the gearbox driven shaft (2). 28. To re--fit the transmission--gearbox casing, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
25783
55 --
For the correct orientation of the various parts, refer to the illustrations on pages 8, 9, 10 and 11.
--
Before refitting casings, supports and covers, thoroughly clean and degrease the mating surfaces and apply a strip of sealing compound of about 2 mm diameter as shown in the diagram on page 30.
--
Respect the tightening torques prescribed on page 2.
--
Carry out the gearbox driven and driving shaft adjustments noted on page 29.
--
Fit the gearbox driving shaft on the relative support.
--
Fit the gearbox driven gear on the relative support.
--
Fit the reverse drive gear complete with thrust washer, bearing and retaining bolt.
--
Assemble the synchroniser and circlip.
--
Fit the shuttle control rod, fork and stop circlip.
--
Assemble the driven and driving shafts, the control forks and lock in position by means of tools 380001616 and 380001615, fit the mobile part of tool 380001614.
--
Fit the control forks to the rods using the pins.
--
Detach the mobile part of the tool 380001614 and remove the gearbox unit from the tool.
--
Fit tools 380001618 and 380001619 (1) on the driving shaft lock circlip and the driven shaft lock circlip respectively.
25784
56
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
28 --
Using a hoist, fit the gearbox unit in the casing and recover the tools 380001618 (1) and 380001619 (the latter must be recovered from the drive gear casing). Secure in position with the bolts.
--
Fit the lubrication union and sleeve.
--
Fit the lubrication pressure adjustment valve, complete with the union and circlip.
--
Assemble the lubrication pipes.
--
Fit the driven shaft and gears.
--
Remove tools 380001615 and 380001616 from the driving and driven shafts respectively.
--
Fit the parking brake unit, comprising brake disks and friction sectors.
--
Fit the cover (1) and secure with the bolt (2).
25785
57
NOTE: Apply Loctite 242 thread locker to the thread on bolt (2) and tighten to a torque setting of 19,6 Nm (2 kgm). --
Assemble the parking brake control lever, complete with cam sleeve and circlip.
--
Fit the parking brake cover. 25786
--
Assemble the power take--off control shaft, following the instructions in Section 31.
--
Fit the cover with the gearbox control lever and final drive.
--
Fit the drive gear, following the instructions in Section 23.
--
Detach the transmission--gearbox casing from the rotating stand.
87666787A - 11 - 2007
58
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
29
TRANSMISSION--GEARBOX CASING Gearbox driving and driven shafts end float adjustment.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. NOTE: When fitted, the driving and driven shaft gears must provide an axial clearance of 0.8 mm in order to guarantee correct synchroniser operation.
25787
59
29. Using tool 380001614 (1) clamped in the vice, attach the gearbox support complete with the driving and driven shafts without the respective adjustment shims (4 and 12, page 8), fit the mobile part (2) on the tool. 30. Using a depth gauge, measure the distance (L) between the top of the tool 380001614 (1) and the circlip (3) on the driving shaft bearing. 31. Measure the distance (L1) between the top of the tool 380001614 (1) and the circlip (2) on the driving shaft bearing. 32. The adjustment shim (4, page 8) to fit on the driving shaft is given by: S = L -- 46.5 -- 1.0 where L = measurement read 46.5 = theoretical measurement of tool 380001614 1.0 = synchronizer operating clearance. Round down the value. 33. The adjustment shim (12, page 8) to fit on the driven shaft is given by: S1 = L1 -- 36 -- 1.0 L1 = measurement read 36 = theoretical measurement of tool 380001614 1.0 = synchronizer operating clearance. Round down the value
25788
60
Example: L = 48.8 mm. Measurement read L1 = 37.8 mm. Measurement read 46.5 = Theoretical measurement of tool 380001614 36 = Theoretical measurement of tool 380001614 1.0 = synchronizer operating clearance. S = 48.8 -- 46.5 -- 1.0 = 1.3 mm (adjustment shim 4, page 6). S1 = 37.8 -- 36 -- 1.0 = 0.8 mm (adjustment shim 12, page 6). The adjustment shims are listed on page 2. Round down the value. 87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
30
27152
61 Sealing compound application diagram for transmission--gear box casing The types of sealing compound are listed on page 1, Sect. 00.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
31
Op. 21 130 10 GEARBOX CONTROL LEVER Removal -- Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Unscrew the four retaining bolts and the guard retaining flange. 2. Raise the guard (2), remove the gearbox control lever retaining bolt and the gearbox control lever (1).
NOTE: If a POWER SHUTTLE gearbox is fitted, disconnect the electrical contact located on the gear lever.
27654
62 3. To refit the gearbox control lever, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
NOTE: If a POWER SHUTTLE gearbox is fitted, connect the electrical contact located on the gear lever. --
Fit the gearbox control lever (1, fig. 62), complete with guard (2) on the control sleeve.
--
Fit the lever retaining bolt to the control sleeve, lower the guard, fit the four guard retaining flange retaining bolts.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
32
Op. 21 130 11 RANGE GEAR CONTROL LEVER Removal -- Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Unscrew the four retaining bolts and the guard retaining flange. 2. Raise the guard (2), remove the range control lever retaining bolt and the range control lever (1).
27653
63 3. To refit the range control lever, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Fit the range control lever (1, fig. 63), complete with guard (2) on the control sleeve.
--
Fit the lever retaining bolt to the control sleeve, lower the guard, fit the four guard retaining flange retaining bolts.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
33
Op. 21 130 52 SHUTTLE CONTROL LEVER Removal -- Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Unscrew the four guard retaining flange bolts, raise the guard and remove the reverser control lever retaining bolt. 2. Unscrew the reverser control lever (1), complete with the guard (2). 3. To refit the shuttle control lever, proceed as follows.
27651
64
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Fit the reverser control lever (1, fig. 64), complete with guard (2) on the control sleeve.
--
Fit the reverser lever retaining bolt to the control sleeve, lower the guard, fit the four guard retaining flange retaining bolts.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
34
Op. 10 216 10 FUEL TANK Removal -- Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Lock the front wheels using chocks. 2. Using a hoist, slightly raise the rear part of the tractor and position a stand under the left--hand lateral gear unit casing, then remove the rear left--hand wheel. 3. Unscrew the plug (1) and drain the fuel from the tank into a suitable container (capacity: 75 litres).
27792
65 4. Loosen the clamp and detach the fuel intake pipe (1).
27946
66 5. Disconnect the connections (1).
two
fuel
level
indicator
67
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
35
6. Unscrew and remove the fuel return pipe (1).
68 7. Loosen the clamp (1) and remove the tank fuel intake pipe union (2).
69 8. Position a hydraulic jack under the tank, unscrew the retaining bolt and remove the clamp (1), unscrew the front bracket retaining bolt (2), lower the hydraulic jack and remove the tank. 9. To refit the fuel tank, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Position and secure the fuel tank.
--
Fit and secure the tank fuel intake pipe union.
--
Connect the fuel return pipe.
--
Connect the electrical connections to the fuel gauge.
--
Connect the fuel inlet pipe.
--
Fit the left--hand wheel and remove the support stand.
--
Fill up the fuel tank (prescribed quantity: 75 litres).
70
87666787A - 11 - 2007
36
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 2
1
SECTION 21 -- GEAR TRANSMISSION Chapter 2 -- Mechanical transmission and splitter CONTENT Section
Description
Page
21 000
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
21 160 31
Splitter device gearbox, shafts and bearings. Removal -- Installation . . . . . . . . . . . . . . . . . 8
REVERSER DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mechanical type with spur gearing, located between the main clutch and the gearbox.
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
hand lever located on left--hand side of operator
CREEPER UNIT DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordinary gear train with spur gearing, located between the main clutch and the gearbox, up stream from the shuttle. Providing 44 forward speeds and 16 reverse speeds
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
hand lever located on left--hand side of the operator (continued)
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 2
2
TRANSMISSION AND RANGE GEAR DATA (overleaf)
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 speed, constant--mesh, with synchronisers on all gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
helical
Reduction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ordinary gear train with 4 ranges for a total of 16 speeds.
--
gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox and range gear controls . . . . . . . . . . . . . . . . . . . . . . . . . . .
spur independent, by means of lever located on right--hand side of operator
TRANSMISSION AND RANGE GEAR DATA For missing data see Chapter 1, page 2
SPLITTER MAIN DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordinary gear train with helical gears, located up stream from the creeper unit, providing two different speeds within the same gear. This device cannot be inserted when the creeper unit is selected.
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Creeper control lever on left--hand side of operator.
BOLT TORQUES See Chapter 1, page 2
SPECIAL TOOLS See Chapter 1, pages 4, 5, 6 and 7
87666787A-- 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 2
25745
1
2
6
5
3
4
3
X
X
1 Longitudinal cross--sectional view of gearbox, gear range and splitter 1. 2. 3.
Gearbox driving shaft. Splitter device driving gear. Splitter device driven gear.
4. 5. 6.
Splitter device control synchroniser. Thrust washer. Circlip.
NOTE: On assembly apply sealant to surfaces X following the indications in Chapter 1.
Warning -- For missing data see Chapter 1, page 8.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 2
4
1
2
3
9
8
7
25746
6
5
4
2 Longitudinal cross--sectional view of splitter and creeper unit 1. 2. 3. 4. 5.
Gearbox driving shaft. Splitter device driving gear. Creeper unit driving gear. Thrust washer. Creeper unit driven gear.
87666787A-- 11 - 2007
6. 7. 8. 9.
Splitter device or creeper unit control synchroniser. Splitter device driven gear. Thrust washer. Circlip.
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 2
1
2
3
5
4 25748
A
5
25749
5
B
25747
8
7
6
25750
5
C 3
Cross--sectional view of gearbox with splitter and creeper unit A. Position of two stop rings (5) on control rod for fitting with splitter device. B. Position of two stop rings (5) on control rod for fitting with splitter device and creeper unit. C. Position of two stop rings (5) on control rod for fitting with creeper unit. 1. Spring. 2. Poppet ball.
3. 4. 5. 6. 7. 8.
Reverser control rod. Safety pawl. Control rod stop rings on splitter device and creeper unit. Splitter device and creeper unit control rod. Poppet ball. Spring.
87666787A - 11 - 2007
6
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 2 DESCRIPTION AND OPERATION
Gearbox and shuttle 4--speed gearbox with constant--mesh helical gears controlled by two synchronizers. The range gear has cascade--type constant--mesh spur gears. The range gear provides 4 forward ranges. The gearbox and the range gears are controlled by two independent levers located on the right--hand side of the operator. The shuttle is a mechanical device providing 16 forward gears and 16 reverse gears. It is controlled by a lever located on the cab platform to the left of the operator. The reverser is composed of a group of three spur gears: reverser driving gear, reverser driven gear and intermediate gear, engagement is by means of a synchroniser located in the gear unit. The reverser is installed inside the clutch casing, between the clutch and the gearbox. Lubrication is by means of the oil in the rear transmission/gearbox Creeper unit The creeper unit is a mechanical device providing 28 forward speeds and 16 reverse speeds.
87666787A-- 11 - 2007
The creeper unit only intervenes in slow, medium slow and medium fast ranges, a mechanical interlock prevents creeper engagement in the fast ranges. The creeper unit is composed of a group of three spur gears: a sliding control gear, a driving gear shaft and a driven gear. The creeper unit is installed upstream from the reverser and is controlled by the same control lever as the reverser, located on the left--hand side of the operator. Splitter The splitter is a mechanical device that provides two different speeds in the same gear, obtaining 32 forward speeds and 16 reverse speeds, or 44 forward speeds and 16 reverse speeds in the fitting with the splitter and the creeper unit. The splitter device only acts on the 16 forward speeds in the gearbox, and cannot be inserted with the shuttle or creeper unit inserted, a mechanical lock prevents this action. The splitter device is composed of two helical gear units: driving and driven gears and the control synchroniser. The splitter device is located up stream from the creeper unit and is controlled by the same lever that controls the creeper and shuttle unit, on the left--hand side of the operator.
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 2
7
GEARBOX, CREEPER UNIT AND SHUTTLE TROUBLESHOOTING See Chapter 1, pages 12 and 13
CREEPER UNIT TROUBLESHOOTING See Chapter 1, page 13
SPLITTER DEVICE TROUBLESHOOTING Problems
Possible Problem
Solutions
Spontaneous disengagement of splitter device
1. Engagement stroke incomplete.
Difficulty in engaging the splitter device
1. Stiffness and/or seizure of Check rod pivots and lubricate. external levers and rods. 2. Main clutch dragging. 3. Engagement damaged.
Eliminate the cause and restore full engagement travel.
See Sect. 18.
synchroniser Detach the transmission gearbox casing and replace the engagement synchroniser.
4. Internal controls do not slide Overhaul the controls. easily: rods, forks and sleeves. Splitter device excessively noisy
1. Worn or damaged internal Detach the transmission gearbox parts. casing and replace the damaged parts.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 2
8
Op. 21 160 31 SPLITTER DEVICE AND CREEPER UNIT GEARBOX, SHAFTS AND BEARINGS Removal--Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Carry out operation 90 150 10: Cab with platform unit, only removal (see Section 90, Chapter 1). 2. Carry out operation 21 118 10 or 21 118 12: Rear transmission--gearbox, only removal (see Section 21, Chapter 1). 3. Carry out operation 21 118 85 Gearbox transmission casing, only removal of gearbox from casing (see Section 21, Chapter 1). 4. Fit tool 380001614 (1) in a vice and lock the gearbox unit in position by means of the bolts. 5. Unscrew the lubrication line (3) and remove tool 380001616 (2) and tool 380001615 from the driving shaft.
25752
4
6. Extract the pin in order to release the splitter device and creeper unit fork (1).
25753
5 7. Remove the circlip (1) and remove the splitter device driving gear (2).
25754
6
87666787A-- 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 2
9
8. Remove the circlip (1) and recover the thrust washer (2), the splitter driven gear (3), the cotter and the synchroniser stop ring.
25755
7 9. Extract the stop ring (1).
25770
8 10. Extract the synchroniser hub (3) together with the engagement sleeve (2) and control fork (1).
25771
9 11. Remove the stop ring (1).
25772
10 87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 2
10
12. Extract the thrust washer (2), creeper unit driven gear (1) and recover the bearing thrust washer. 13. Remove the circlip (4) and the grooved pin (3). 14. To refit the splitter device and creeper unit, proceed as follows.
ATTENTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. --
Refer to the illustrations on pages 3, 4 and 5.
--
Respect the tightening torques prescribed on page 2, Chapter 1.
--
Fit the grooved pin, creeper unit driven gear and the relative thrust washers, lock in position using the stop ring.
--
Fit the synchroniser, the stop ring and the control fork.
--
Assemble the splitter driven gear, the cotter, the synchroniser engaging ring and circlip.
--
Assemble the splitter driving gear and relative circlip.
--
Fit the splitter driving gear and circlip.
--
Fit the lubrication line
--
Fit tools 380001616 and 380001615 (respectively) on the driven and driving shafts.
--
Carry out operation 21 118 85: Transmission gearbox, only installation of gearbox in housing (see Section 21, Chapter 1).
--
Carry out operation 21 118 10 or 21 118 12: Rear transmission housing--gearbox, only installation (see Section 21, Chapter 1).
--
Carry out operation 90 150 10: Cab with platform unit, only installation (see Section 90, Chapter 1).
87666787A-- 11 - 2007
25773
11
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
1
SECTION 21 -- GEAR TRANSMISSION Chapter 3 -- Power Shuttle transmission with HI LO function CONTENT Section
Description
Page
21 000
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cross--sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
21 118 85
Gearbox transmission casing. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
21 134 46
Power shuttle control valve. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
21 134 62
Accumulator. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
21 134 70
Gearbox control valve solenoid valves. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . 19
21 154 34
Clutch casing. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
21 154 60
Clutch casing. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REVERSER DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mechanical type with spur gearing, located between the main clutch and the gearbox.
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
hand lever located on the left--hand side of the steering wheel
CREEPER UNIT DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordinary gear train with spur gearing, located between the main clutch and the gearbox, up stream from the shuttle. Providing 28 forward gears and 16 reverse gears
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
hand lever located on left--hand side of the operator
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
2
TRANSMISSION AND RANGE GEAR DATA Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 speed, constant--mesh, with synchronisers on all gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
helical
Reduction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ordinary gear train with 4 ranges for a total of 16 speeds.
--
gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
spur
Gearbox and reduction unit controls . . . . . . . . . . . . . . . . . . . . . . . . .
independent, by means of lever located on right--hand side of operator
For missing data see Chapter 1, page 2. POWER SHUTTLE MAIN DATA Number of driven plates in each clutch . . . . . . . . . . . . . . . . . . . . . .
no.
6
Thickness of driven plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
2.00 ÷ 2.08
Driven plate material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
sintered
Number of driving plates in each clutch . . . . . . . . . . . . . . . . . . . . . .
no.
6
Drive disc thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
2.00 -- 2.20
Driving plate material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thickness of clutch assembly under a load of 1600 N (163.1 kg)
steel mm
24.9 ÷ 25.1 (1)
Clutch piston return spring (4, pages 7 and 8: --
number of springs for each clutch . . . . . . . . . . . . . . . . . . . . . . .
no.
7
--
spring free height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
3.30
--
spring height under a load of 1255 N (128 kg) . . . . . . . . . . . . .
mm
2.62
Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Shuttle and services transmission working pressure (kg/cm@) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mounted on the outer left--hand side of the transmission--rear--gearbox casing, comprising no. 5 control solenoid valves. bar
15.7 (16)
Accumulator spring (3, page 11): --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
122
--
length of spring under load of 325 ÷ 359 N (33.2 ÷ 36.6 kg)
mm
100
By--pass valve spring (6, page 11): --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
35,5
--
length of spring under load of 37.2 ÷ 41.2 N (3.8 ÷ 4.2 kg) . .
mm
25,5
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
paper cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
fixed to the pump body on suction side
Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
the same as used for the hydrostatic steering system (see section 41, Chapter 2)
(1) Value to obtain by varying the thickness of the driving plates.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
3
BOLT TORQUES PARTS TO BE TIGHTENED
Thread
Tightening torque Nm
kgm
1.7 รท 2.8
0.17 รท 0.28
For missing data see Chapter 1, page 2. Solenoid valve retaining nut (C1) (โ ข) . . . . . . . . . . . . . . . . . . . . . . . . .
--
Solenoid valve spool retaining bolt (C2) . . . . . . . . . . . . . . . . . . . . . .
--
Solenoid valve spool retaining bolts (C3) . . . . . . . . . . . . . . . . . . . . .
--
47 รท 54
4.8 รท 5.5
Solenoid valve retaining nut (C4) (โ ข) . . . . . . . . . . . . . . . . . . . . . . . . .
--
5.4 รท 8.1
0.55 รท 0.83
14.9 รท 20.3 1.52 รท 2.07
(โ ข) Apply 1 or 2 drops of LOCTITE 542 before tightening
C1 --14.9รท20.3 Nm
F
C2 --1.7รท2.8 Nm LO
DUMP
REV
HI
FWD
C3 --47รท54 Nm
C4 --5.4รท8.1 Nm 25791
C4 --5.4รท8.1 Nm
C3 --47รท54 Nm
25792
1
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
4 SPECIAL TOOLS
Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual. List of specific tools required for the various operations described in this Sect. 380000227
Clutch casing lift hook.
380000301
Turning stand for overhaul.
X 380001614
Tool for gearbox driving and driven shafts adjustment.
X 380001621
Driving shaft rod for lifting unit.
X 380001616
Driven shaft retaining tool.
X 380001610
Adjuster handle (with 380001620 and 380001609).
X 380001620
Power take--off drive shaft seal splining tool (with 380001610).
X 380001609
Power take--off drive shaft roller bearings splining tool (with 380001610).
X 380001617
Pliers for gearbox shafts circlips.
X 380001618
Driving shaft assembly guide.
X 380001619
Driven shaft fitting guide.
X 380000171
Adaptor (with 380000291).
X 380000291
Tool for hydraulic clutch piston springs (with 380000171).
X 380000240
Hydraulic pressure testing kit.
X 380000278
Hydraulic pressure testing kit.
50091
Tool for removal--installation final drives (see section 27).
25618
2 Guide pin for re--fitting the gearbox in the casing. (Mark part with no. 50158 -- Measurements in mm) Make in C 40 material.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
5
27941
3 Bracket to be made for gearbox overhaul on rotating stand. (Mark tool No. 50157 -- Measurements in mm). Make in Aq 42 material.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
6
(1)
27940
Bracket to be made for gearbox overhaul on rotating stand. (Mark tool No. 50157 -- Measurements in mm) 1. Rotating stand shaft -- Make in Aq 42 material.
87666787A - 11 - 2007
4
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
1
2
3
9
8
7
4
2
3
5
7
6
X
25793
10
5 Longitudinal cross--sectional view of Power Shuttle gearbox 1. 2. 3. 4. 5.
High speed and reverse clutch control piston. Steel disks. Friction disks. Piston return Belleville washer. Low speed clutch control piston.
6. 7. 8. 9. 10.
Driving gear. Driven gear. Low speed clutch control pipes. High speed and reverse clutch control pipes. Lubrication control pipes.
NOTE: When fitting apply sealing compound to surfaces X as shown on page 30, Chapter 1.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
8
2
1
3
2
4
3
5
6
X
25794
10
9
8
7
11
6 Longitudinal cross--sectional view of Power Shuttle and creeper unit gearbox 1. 2. 3. 4. 5. 6.
High speed and reverse clutch control piston. Steel disks. Friction disk. Piston return Belleville washer. Low speed clutch control piston. Driving gear.
7. 8. 9. 10. 11.
Driven gear. Low speed clutch control pipes. High speed and reverse clutch control pipes. Lubrication control pipes. Creeper unit driven gear.
NOTE: When fitting apply sealing compound to surfaces X as shown on page 30, Chapter 1.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
9
A 7 Cross--sectional views of Power Shuttle and creeper unit gearbox A. Cross--sectional view for gearbox fitted with creeper unit. 1. Reverser control pin. 2. Reverser control rod.
3. 4. 5. 6.
Gearbox control rod. Gearbox control external lever. Creeper unit control rod. Creeper unit external control lever.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
10
1
F
LO
7
FWD
DUMP
REV
HI
6
2
5
3 4
25798
8 Power Shuttle control valve 1. 2. 3. 4.
LOW clutch control solenoid valve. HIGH clutch control solenoid valve. Reverse speed control solenoid valve. Dump solenoid valve.
5. 6. 7.
Forward speed control solenoid valve. LOW forward gears clutch pressure control cap. HIGH forward and reverse gears clutch pressure control cap.
CLUTCH CONTROL PRESSURE TEST Unscrew plug (4) or (5) on the clutch to be tested and connect a pressure gauge from kit 380000240 to the relative hole. Start the engine and check the pressure (see page 2). If the pressure is incorrect adjust the shims (4, page 11), increase if the pressure is low and decrease if too high.
87666787A - 11 - 2007
NOTE: Remember that when testing the pressure of the reverse clutch (in reverse function) the indicator that lights up on the control panel (the tortoise) is the LO one, even though the other clutch is engaged (HI and reverse).
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
1
2
3
11
4
5 27084
7
6
9 Cross--sectional view of services control valve 1. 2. 3.
Four wheel drive release solenoid valve. Differential lock solenoid valve. Spring for services control oil pressure adjustment valve.
1
2
4. 5. 6. 7.
Services control oil pressure adjustment shims. By--pass valve spring. By--pass valve. Services control pressure adjustment valve.
3
27085
10 Cross--sectional view of accumulator 1. 2.
Ball valve. Accumulator piston.
3.
Accumulator spring.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
12
DESCRIPTION AND OPERATION Gearbox and shuttle 4--speed gearbox with constant--mesh helical gears controlled by two synchronizers. The range gear has cascade--type constant--mesh spur gears. The range gear provides 4 forward ranges. The gearbox and the range gears are controlled by two independent levers located on the right--hand side of the operator. The reverser is a mechanical device making it possible to obtain 16 forward gears and 16 reverse gears. It is controlled by a lever located on the control panel to the left of the steering wheel. Speed reversal is obtained by means of the lever located on the left--hand side of the steering wheel. It is not necessary to press the clutch pedal, but the engine rpm and tractor speed must be reduced. The reverser is composed of a group of three spur gears: reverser driving gear, reverser driven gear and intermediate gear, engagement is by means of a synchroniser located in the gear unit. The reverser is installed inside the clutch casing, between the clutch and the gearbox. Lubrication is by means of the oil in the rear transmission/gearbox. Creeper unit The creeper unit is a mechanical device allowing reduced speeds to be obtained.
The creeper unit only intervenes in slow, medium slow and medium fast ranges, a mechanical interlock prevents creeper engagement in the fast ranges. The creeper unit is composed of a group of three spur gears: a sliding control gear, a driving gear shaft and a driven gear. The creeper unit is installed upstream from the reverser and is controlled by the same control lever as the reverser, located on the left--hand side of the operator. Power Shuttle unit The Power Shuttle gearbox is controlled by two multi--disk clutches in an oil bath. This provides hydraulic control of 4 gears for each range, both forward and in reverse. Gear and range selection is performed by pressing the clutch pedal and operating the control levers located on the right--hand side of the operator. Two push buttons are located on the gearbox control lever, one marked with a tortoise and the other with a hare. By pressing these push buttons high or low speed can be selected (within the same speed). The operation is carried out hydraulically with tractor in movement. The front clutch controls the high speeds and reverse, the rear clutch controls the low speeds. The Power Shuttle gearbox provides 32 forward speeds and 16 reverse speeds, or 44 forward speeds and 16 reverse speeds in the version with the creeper unit.
GEARBOX, CREEPER UNIT AND SHUTTLE TROUBLESHOOTING See Chapter 1, pages 11 and 12.
GEARBOX, CREEPER UNIT AND SHUTTLE TROUBLESHOOTING See Chapter 1, page 12.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
13
Operation 21 118 85 GEARBOX TRANSMISSION CASING Disassembly--Assembly
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Carry out operation 21 118 12: Rear transmission--gearbox casing, only removal (see Chapter 1). 2. Disconnect the pipes (2) on the accumulator (1), unscrew the retaining bolts and remove the accumulator.
27086
11
3. Unscrew the retaining bolts and recover the services control valve (1).
1
25654
12 4. Unscrew the retaining bolts and detach the Power Shuttle (1) control valve. 5. Attach the transmission--gearbox casing on the rotating stand 380000301 using brackets 50160 (see pages 5 and 6).
27087
13
87666787A - 11 - 2007
14
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
6. Unscrew the retaining bolts (1) on the clutch control pipes (2).
27088
14 7. Rotate and remove the clutch control pipes (1).
27089
15 8. Unscrew the unions (1 and 2) on the clutch control pipes and recover the internal unions.
27090
16 9. Loosen the shuttle control pin (1). 10. Complete the gearbox removal operations by following the instructions in Chapter 1, page 21. 11. To refit the unit, carry out the disassembly operations in reverse order, following the instructions in Chapter 1.
27091
17 87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
15
Operation 21 134 46 POWER SHUTTLE CONTROL VALVE Disassembly -- Assembly
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
With the Power Shuttle control valve on the workbench, proceed as follows. 1. Extract the pin (1) that retains the creeper unit control lever (2).
27109
18
2. Extract the creeper unit control lever (1) and recover the internal lever (2).
27110
19 3. Unscrew the nut (2) and extract the solenoid valve (1).
27111
20
87666787A - 11 - 2007
16
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
4. Unscrew the solenoid valve pin (1). 5. Carry out operations no. 3 and 4 also for the solenoid valve (2).
27112
21 6. Unscrew the nut (2) and extract the solenoid valve (1).
27113
22 7. Unscrew the solenoid valve pin (1). 8. Carry out operations no. 6 and 7 also for solenoid valves (2 and 3).
27114
23 9. Remove the Seeger ring (1).
27115
24 87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
17
10. Remove the plug (1) and recover the shuttle control pin (2).
27116
25 11. Remove the switch (1). 12. To refit the Power Shuttle control valve, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
For the correct orientation of the various parts, refer to the illustrations on page 10.
--
Respect the tightening torques prescribed on page 3.
--
Fit the switch.
--
Assemble the control pin, plug and circlip.
--
Fit the pins and relative solenoid valves then, after having applied 1 or 2 drops of Loctite 542, tighten the nuts.
--
Assemble the internal lever, the creeper unit control lever and the pin.
27117
26
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
18
Operation 21 134 62 ACCUMULATOR Disassembly -- Assembly
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. With the accumulator on the workbench, proceed as follows. 1. Unscrew the cap (1) and recover the spring (2, fig. 28) and piston (3, fig. 28)
27118
27 2. Accumulator parts: cap (1), spring (2), piston (3) and accumulator body (4). 3. To re--fit the accumulator, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
For the correct orientation of the various parts, refer to the illustrations on page 11.
--
Insert the piston and spring in the accumulator body.
--
Tighten the cap.
87666787A - 11 - 2007
27119
28
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
19
Op. 21 134 70 GEARBOX CONTROL VALVE SOLENOID VALVE Removal -- Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. In order to remove a control solenoid valve from the two clutches, the working area must be kept clean. Proceed as follows. 1. Lock the front wheels using chocks. 2. Using a hoist, slightly raise the rear part of the tractor and position a stand under the left--hand lateral gear unit casing, then remove the rear left--hand wheel. 3. Disconnect the solenoid valve connection (1).
29
4. Loosen the nut and remove the solenoid valve (1).
30 5. Unscrew the solenoid valve pin (1). 6. To refit the control valve solenoid, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Screw the pin on the solenoid valve.
--
Fit and secure the solenoid valve.
--
Connect the electrical connection.
--
Fit the left--hand wheel and remove the support stand.
31
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
20
Op. 21 134 70 GEARBOX CONTROL VALVE SOLENOID VALVE Removal -- Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. In order to remove a control solenoid valve from the gearbox, the working area must be kept clean. Proceed as follows. 1. Lock the front wheels using chocks. 2. Using a hoist, slightly raise the rear part of the tractor and position a stand under the left--hand lateral gear unit casing, then remove the rear left--hand wheel. 3. Disconnect the solenoid valve connection (1) and unscrew the retaining nut.
32
4. Remove the solenoid valve (1).
33 5. Unscrew the solenoid valve pin (1). 6. To refit the control valve solenoid, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Screw the pin on the solenoid valve.
--
Fit and secure the solenoid valve.
--
Connect the electrical connection.
--
Fit the left--hand wheel and remove the support stand.
87666787A - 11 - 2007
34
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
21
Operation 21 154 34 -- 21 154 60 CLUTCH CASING Disassembly -- Assembly
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Carry out operation 21 118 12: Rear transmission--gearbox casing, only removal (see Chapter 1). 2. Attach the clutch casing to the rotating stand 380000301 using brackets 50160 (see pages 5 and 6) 3. Unscrew the retaining bolts and remove the clutch control pipes (1).
27092
35
4. Unscrew the retaining bolt and recover the sleeve (1), fork (2) lever (3) and spring (4).
27093
36 5. Unscrew the rear bearing support retaining bolts (1).
27094
37
87666787A - 11 - 2007
22
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
6. Unscrew the front bearing support (2) retaining bolts (1).
27095
38 7. Insert tool 380001621 (1) on the clutch unit (2), secure in position and remove, using a hoist.
27096
39 8. Position the clutch unit (1) on a workbench, remove tool 380001621 (2) and separate the unit into two parts.
27097
40 9. Unscrew the retaining bolts and remove the sleeve (1) for the power take--off clutch engagement sleeve.
27098
41 87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
23
10. Remove the circlip (1) and remove the front bearing support (2).
27100
42 11. Remove the circlip (1) and remove the shaft (2).
27101
43 12. Remove the circlip (1) that secures the clutch disk assembly.
27102
44 13. Extract the gear (1) and recover the clutch disk assembly (2) and the relative clips (3).
27103
45
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3
24
14. Using an extractor (1) and tool 380000291 (2) compress the Belleville washer (3), remove the stop ring (4) and recover the above--mentioned springs and piston.
27104
46 15. Remove the stop ring (1) and extract the clutch body (2).
27105
47 16. Remove the front bearing support (1).
271106
48 17. Remove the circlip (1) and remove the bearing (2). 18. To refit the clutch casing, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. ---
For the correct orientation of the various parts, refer to the illustrations on pages 7, 8 and 9. Respect the tightening torques prescribed on page 3.
27107
49 87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 4
1
SECTION 21 -- GEAR TRANSMISSION Chapter 4 -- Power Shuttle Transmission (8 + 8 and 16 + 16 versions) CONTENT Section
Description
Page
21 000
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 3 Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 3 Removal and disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 3
TRANSMISSION AND RANGE GEAR DATA Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 speed, constant--mesh, with synchronisers on all gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
helical
Range gear (16 + 16 version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ordinary gear train with 4 ranges for a total of 16 speeds.
Range gear (8 + 8 version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ordinary gear train with 2 ranges for a total of 8 gears.
--
gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox and reduction unit controls . . . . . . . . . . . . . . . . . . . . . . . . .
spur independent, by means of lever located on right--hand side of operator
For missing data see Chapter 1, page 2.
POWER SHUTTLE MAIN DATA For missing data see Chapter 1, page 2. Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mounted on the outer left--hand side of the transmission--rear--gearbox casing, comprising no. 3 control solenoid valves.
(1) Value to obtain by varying the thickness of the driving plates.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 4
2
BOLT TORQUES Tightening torque PARTS TO BE TIGHTENED
Thread Nm
kgm
1.7 ÷ 2.8
0.17 ÷ 0.28
For missing data see Chapter 1, page 2. Solenoid valve retaining nut (C1) (•) . . . . . . . . . . . . . . . . . . . . . . . . .
--
Solenoid valve spool retaining bolt (C2) . . . . . . . . . . . . . . . . . . . . . .
--
Solenoid valve spool retaining bolts (C3) . . . . . . . . . . . . . . . . . . . . .
--
47 ÷ 54
4.8 ÷ 5.5
Solenoid valve retaining nut (C4) (•) . . . . . . . . . . . . . . . . . . . . . . . . .
--
5.4 ÷ 8.1
0.55 ÷ 0.83
14.9÷ 20.3 1.52 ÷ 2.07
(•) Apply 1 or 2 drops of LOCTITE 542 before tightening
1
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 4
3
2 Longitudinal cross--sectional view of Power Shuttle gearbox (16 + 16 version) 1. 2. 3.
Forward gear control clutch. Reverse gear control clutch. Forward gear drive shaft.
4. 5.
Reverse drive shaft. Reverse driven shaft.
NOTE: For missing data see Chapters 1 and 3.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 4
4
3 Cross--sectional views of Power Shuttle gearbox 1. 2. 3. 4.
Power Shuttle control valve. Gear control internal rods. Gear control external lever. Pin.
87666787A - 11 - 2007
5. 6. 7.
Pin retaining bolt (4). Reverse intermediate gear. Needle bearing.
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 4
5
4 Longitudinal cross--sectional view of Power Shuttle gearbox (8 + 8 version) 1. 2.
Low gear intermediate gear. Selector sleeve for high gears.
3. 4.
Selector sleeve for low speeds. Pinion Gear.
NOTE: For missing data see Chapters 1 and 3.
87666787A - 11 - 2007
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 4
6
5 Power Shuttle control valve. 1. 2.
Reverse clutch control solenoid valve. Forward clutch control solenoid valve.
3. 4.
Dump solenoid valve. Operating pressure testing plugs.
CLUTCH CONTROL PRESSURE TEST Unscrew plug (4) or (5) on the clutch to be tested and connect a pressure gauge from kit 380000240 to the relative hole. Start the engine and check the pressure (see page 1).
87666787A - 11 - 2007
If the pressure is incorrect adjust the shims (4, page 11, Chapter 3), increase if the pressure is low and decrease if too high.
SECTION 23 -- DRIVE LINES -- CHAPTER 1
1
SECTION 23 -- DRIVE LINES Chapter 1 -- Drive lines CONTENT Section
Description
Page
23 000
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description, operation and hydraulic diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
23 101 26
Propeller shafts and guard. Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
23 101 40
Drive gear assembly. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
23 202 50
Drive gear assembly. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
23 101 42
Drive gear housing removed. Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
23 202 52
Drive gear housing removed. Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
MAIN SPECIFICATIONS -- 4WD ELECTROHYDRAULIC ENGAGEMENT Reduction ratio of drive gear device (on all models) . . . . . . . . . . .
43/28X28/39= 1:1.1
Internal diameter of sliding sleeve (16, fig. 2) . . . . . . . . . . . . . . . . .
mm
35.080 ÷ 35.119
Diameter of coupled shaft (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
34.975 ÷ 35.000
Internal diameter of sliding sleeve (16) . . . . . . . . . . . . . . . . . . . . . .
mm
50.080 ÷ 50.119
Diameter of coupled shaft (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
48.975 ÷ 49.900
Internal diameter of fixed sleeve (15) . . . . . . . . . . . . . . . . . . . . . . . .
mm
22.065 ÷ 22.098
Diameter of coupled shaft (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
21.979 ÷ 22.000
Length of spring (20, with spring free) . . . . . . . . . . . . . . . . . . . . . . .
mm
82
Length of spring (20) under a load of 60.5 ÷ 65.5 kg . . . . . . . . . . .
mm
40
PROPELLER SHAFT DATA Thickness of rings (2, fig. 3) that adjust the position of the front sleeve (3) on the dual transmission shaft . . . . . . . . . . . . . . . . . . . .
mm
1.5 -- 1.9 -- 2.2 -- 2.5 -- 2.8 -- 3 -3.3 -- 3.7 -- 4 -- 4.3
Front sleeve end float (L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
1.0 ÷ 1.5
87666787A - 11 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
2
BOLT TORQUES
C1 --88Nm
27836
C2 -- 98 Nm
C3 -- 49 Nm 25976
1 PARTS TO BE TIGHTENED
Thread
Propeller shaft central support retaining bolt (C1) . . . . . . . . . . . . .
Tightening torque Nm
kgm
M 12 x 1.5
88
9
Drive gear housing retaining bolt (C2) . . . . . . . . . . . . . . . . . . . . . . .
M 12 x 1.25
98
10
Control cylinder oil delivery union (C3) . . . . . . . . . . . . . . . . . . . . . . .
M 18 x 1.50
49
5
87666787A-- 11 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
3
SPECIAL TOOLS Warning-- The operations described in this section cannot be carried out without the ESSENTIAL tools marked with an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual. List of specific tools required for the various operations described in this Sect. X 380001613
Axle--engine support bracket (with 50162) for mod. T4040 Supersteer and T4050 Supersteer.
X 380001622
Drive shaft seal key.
X 380000279
Key for Ă&#x2DC; 50 mm piston.
X 380000280
Key for Ă&#x2DC; 35 mm piston.
X 380000240
Hydraulic pressure control kit (use tool 380000560).
Spacer to be made for securing axle--engine assembly, for mod. T4040 Supersteer and T4050 Supersteer (mark the tool with no. 50162 -- Measurements in mm) Make in Fe 42C material. Make no. 4 spacers.
27821
2
87666787A - 11 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
4
27827
3 Tool to make for drive gear unit spring removal (stamp no. 50161 on the tool -- Measurements in mm) Make in Fe 42C material.
27828
4 Punch to make for gearbox driving shaft disassembly (mark part with No. 50141 on the tool -- Measurements in mm) Construct in C40 material -- Pin 3 x 20 mm.
87666787A-- 11 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
1
3 4
2
5 6 7 8
9 10 11
5
12 13 14 15 16 17 18 19
27
20
26
25
24
27829
22 27831
23 27830
21 5
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Driven shaft. Dust ring. Seal. Circlip. Bearing. Circlip. Metal seal segment. Metal seal segment. Circlip. Bearing. Driving gear. Gear sleeve. Seal. Metal seal segments.
Sectional view of drive gear with electrohydraulic coupling 15. Seals. 16. Mobile coupling. 17. Circlip. 18. Retaining pin. 19. Plate. 20. Four--wheel drive engagement spring 21. Rear axle speed sensor. 22. Transmission oil drainage plug. 23. Front axle speed sensor. 24. Thrust ring. 25. Manifold ring. 26. Circlip. 27. Circlip.
NOTE: On installation, apply sealing compound to the surfaces X (see Section 27, Chapter 1). 87666787A - 11 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
6
20
L
4
3
2
1
25978
6 Control cylinder oil delivery union and front grooved sleeve L. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Axial clearance of sleeve (3). Circlip. Adjustment shim. Sleeve. Circlip. Flat washer. Screw. Plug. Flat seal. Coupling. Flat seal.
87666787A-- 11 - 2007
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Coupling. Seal. ‘O‘ Ring Seal. Rigid piping. ‘O‘ Ring Seal. Manifold ring. ‘O‘ Ring Seal. Rigid piping. ‘O‘ Ring Seal. Drive gear housing.
SECTION 23 -- DRIVE LINES -- CHAPTER 1
1
2
3 4
5
7
6
8
7
9 10 11 12 13
14
27832
10
13
15 16 17 18 27833
7 Sectional view of drive gear with mechanical coupling 1. 2. 3. 4. 5. 6. 7. 8. 9.
Driven shaft. Dust ring. Seal. Circlip. Bearing. Circlip. Circlip. Thrust ring. Bearing.
10. 11. 12. 13. 14. 15. 16. 17. 18.
Driving gear. Thrust ring. Circlip. Coupling sleeve. Transmission oil drainage plug. Control pad. Seal. External control lever. Lever return spring (17).
NOTE: On installation, apply sealing compound to the surfaces X (see Section 27, Chapter 1).
87666787A - 11 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
8
25979
4WD gear engaged
4WD gear disengaged Circuit oil under pressure Circuit oil discharging
8
DESCRIPTION AND OPERATION OF THE 4WD DRIVE GEAR WITH ELECTROHYDRAULIC COUPLING
The electrohydraulically operated 4WD is engaged by pressing the switch on the control panel. By turning on the switch, the electrical impulse to the solenoid valve control relay is deactivated. With the solenoid valve de--energized, the oil supply to the mobile coupling internal chamber is interrupted, causing the parts to engage and the oil to drain from the control circuit.
87666787A-- 11 - 2007
The 4WD is disengaged by turning off the switch on the control panel. This sends an impulse to the relay which, in turn, energises the control solenoid valve. With the solenoid valve energized, oil is supplied to the mobile coupling internal chamber and the 4WD disengages. Lubrication is guaranteed by the oil in the rear transmission gearbox.
SECTION 23 -- DRIVE LINES -- CHAPTER 1
9
DESCRIPTION AND OPERATION The drive gear housing is mounted below the rear transmission gearbox and is driven by the transmission shaft via gear unit (11, fig. 3). Drive is then transmitted from the shaft (1) to the front axle by means of the transmission shaft that connects the two units.
Drive gear engagement and disengagement by means of the switch on the control panel. A light on the control panel illuminates when the drive gear is engaged.
ELECTROHYDRAULIC DRIVE GEAR TROUBLESHOOTING Problems FWD does not engage.
Possible Problem
Solutions
1. Drive gear engage/disengage Replace switch. switch faulty. 2. Solenoid valve control contac- Check relay. Replace if tor faulty. necessary. 3. Drive gear solenoid valve con- Check solenoid valve. Replace if trol jammed in delivery position. necessary.
4WD remains engaged.
4. Spring (20, page 3) deformed.
Overhaul the unit.
1. Transmission oil level low.
Top up oil.
2. Clogged oil filter.
Replace filter.
3. Hydraulic pump inefficient.
Overhaul or replace the pump.
4. Drive gear engage/disengage Replace switch. switch faulty. 5. Lack of power supply to the so- Check electrical connections and lenoid valve: connections loose replace defective parts. or damaged, contactor faulty. 6. Drive gear solenoid valve con- Overhaul or replace solenoid trol jammed in discharge posi- valve. tion. 7. Oil leakage through the seals Replace damaged seals. with consequent pressure drop: hub, piston or delivery union seals, or drive gear shaft seal rings. With electrohydraulic 4WD disengaged, drive cannot be engaged by operating the brake pedals.
1. Brake pump pressure switch Replace pressure switch. faulty.
87666787A - 11 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
10
Operation 23 101 26 TRANSMISSION SHAFTS AND GUARD Disassembly -- Assembly (models T4040 Supersteer or T4050 Supersteer)
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. To remove, proceed as follows. 1. Remove the front ballast (3), if fitted, using a hoist and two steel cables (1), extract the pin (2) and remove the ballast.
27786
9 2. Attach the bracket 380001613 (1) together with the spacers 50162 (see page 3).
27787
10 3. Unscrew the retaining bolts and remove the right and left--hand (1) guards.
27798
11
87666787A-- 11 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
11
4. Extract the rear circlip (2) from the sleeve (1) and move the sleeve back.
27799
12 5. Unscrew: the pin (1) and the 4 bolts (2), recovering the pin and lower bracket.
27800
13 6. Using a hydraulic jack, slightly raise the bracket (1), remove the circlip (2), recover the half bushings (3) and remove the aforementioned bracket (1).
27823
14 7. Unscrew the retaining bolts and remove the propeller shaft rear guard. 8. Extract the rear circlip and slide the sleeve (1) back on the splined shaft. 9. Unscrew the central support bolts and extract the transmission shaft. 10. To re--install the propeller shaft and relative guards, proceed as follows.
27802
15 87666787A - 11 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
12
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Fit the complete transmission shaft and secure in position.
--
Fit the rear guard and secure in position.
--
Fit the front protective bracket and secure in position with the half bushing and relative circlip.
--
Fit the pin and lower staff and secure in position.
--
Fit the left and right--hand guards.
--
Remove the bracket 380001613 together with the spacers 50162.
--
Assemble the front ballast and secure in position.
Operation 23 101 26 PROPELLER SHAFTS AND GUARD Disassembly -- Assembly (Mod. T4040 Deluxe or T4050 Deluxe)
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. To remove, proceed as follows. 1. Unscrew the front, central and rear retaining bolts and remove the propeller shafts guard (1).
27801
16 2. Extract the rear circlip and unscrew the sleeve (1) back on the splined shaft. 3. Unscrew the central support bolts and extract the transmission shaft. 4. To re--fit the transmission shaft and relative guard, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Fit and secure the propeller shaft in position.
--
Fit and secure the guard.
87666787A-- 11 - 2007
27802
17
SECTION 23 -- DRIVE LINES -- CHAPTER 1
13
Operation 23 101 40 -- 23 202 50 DRIVE GEAR HOUSING ASSEMBLY Removal -- Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 1. Carry out operation 23 101 26 Transmission shafts and guard, only removal (see page 8). 2. Remove the drainage plug and collect the oil in a suitable.
25628
18 3. Remove the sensors (1) guard cover on the drive gear housing (electrohydraulic drive gear.
25980
19 4. Unscrew the retaining bolts (1) on the sensors (2) and remove from the drive gear housing (electrohydraulic drive gear. 5. Detach the drive gear engagement control lever (mechanical drive gear).
25981
20
87666787A - 11 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
14
6. Unscrew the eight drive gear housing retaining bolts (1) on the transmission gearbox.
25982
21 7. Remove the drive gear housing (1) from the transmission gearbox. 8. To re--fit the drive gear housing, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Respect the tightening torques prescribed on page 2.
--
Carefully clean the contact surfaces.
--
Apply the sealing compound (approx. 2 mm in thickness), as shown in Section 27, Chapter 1.
--
Fit the drive gear housing on the transmission gearbox.
--
Re--fit the two speed sensors, securing in position with the two retaining bolts (electrohydraulic drive gear).
--
Connect the drive gear engagement control lever (mechanical drive gear).
--
Refit the transmission oil drainage plug.
--
Carry out operation 23 101 26 Propeller shafts and guard, only installation (see page 8).
--
Refill the rear transmission gearbox (for products and quantities, see Section 00, page 6).
87666787A-- 11 - 2007
25983
22
SECTION 23 -- DRIVE LINES -- CHAPTER 1 Op. 42 23 101 DRIVE GEAR HOUSING Disassembly -- Assembly
15
REMOVED
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Carry out operation 23 101 26 : Transmission shafts and guard, only removal (see page 8). 2. Carry out operation 23 101 40 : Drive gear housing, only removal (see page 11). 3. Remove the dust ring (1) and seal (2).
25984
23
4. Remove the circlips and ball bearings (1) from the seating.
25985
24 5. Remove the circlip (5) and washer (4), extract the pin (3) and remove: the external lever (6), the internal lever (2) and the coupling pad (1).
1 2 6
27834
3 4 5 25
87666787A - 11 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
16
6. Extract the coupling sleeve (1), remove the circlip (3) and remove: the washer (4), gear (5) and shaft (2).
1 2
7. To refit the drive gear housing, proceed as follows.
3
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Insert the shaft in the housing, then assemble the gear unit, washer and circlip.
--
Fit the internal lever, the external lever, the coupling pad and secure in position by means of the washer and relative circlip.
--
Fit the bearing and relative circlips.
--
Use tool 380001622 to fit the seal and dust ring (use the spacer to fit the dust ring).
--
Carry out operation 23 101 40 Drive gear housing assembly, only installation (see page 11).
--
Carry out operation 23 101 26 Propeller shafts and guard, only installation (see page 8).
4 27835
5 26
25989
27
87666787A-- 11 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
17
Op. 23 202 52 DRIVE GEAR HOUSING REMOVED Removal -- Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Carry out operation 23 101 26 : Transmission shafts and guard, only removal (see page 8). 2. Carry out operation 23 202 50 : Drive gear housing, only removal (see page 11). 3. Remove the dust ring (1) and seal (2).
25984
28 4. Remove the circlips and ball bearings (1) from the seating.
25985
29 5. Remove the pin (1) fitted on the opposite end of the shaft and slide off the oil delivery union.
25986
30 87666787A - 11 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
18
6. With tool 50141 (see page 4) and an extracting tool applied to the end of the shaft, remove the gears, the bearing, the D.D. coupling unit and the oil delivery manifold. 7. Using a hydraulic press and tool 50161 (see page 4), compress the spring, manipulating the washer, extract the retaining ring and remove the spring. Move the end of the piston (mobile coupling 16, fig. 2) to remove it from the housing.
25988
31 8. To refit the drive gear housing, proceed as follows.
X-
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Check all parts and replace if worn.
--
Check the seals and the metal seal segments, replacing if necessary.
--
Lubricate all parts.
25989
NOTE: The seals (13 and 15, page 3) must be inserted in their respective housings as quickly as possible in order to avoid deformation, using (respectively) tools 380000279 and 380000280. --
Insert the piston in the seating.
--
Using a press and tool 50161 fit the spring, washer and retaining ring.
--
Fit the shaft, the oil delivery manifold, the 4WD coupling assembly and the bearing in the drive gear housing.
--
Fit the oil delivery union and secure the shaft by means of the circlip.
--
Fit the bearing and relative circlips.
--
Use tool 380001622 to fit the seal and dust ring (use the spacer to fit the dust ring).
--
Carry out operation 23 202 50 Drive gear housing assembly, only installation (see page 11).
--
Carry out operation 23 101 26 Propeller shafts and guard, only installation (see page 8).
87666787A-- 11 - 2007
32
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
1
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION Chapter 1 -- Front axle mechanical transmission (Mod. T4040 Supersteer and T4050 Supersteer) CONTENT Section
Description
Page
25 000
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
25 100 30
Front axle assembly. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
25 102 15
Bevel drive support and front axle differential. Removal--Installation . . . . . . . . . . . . . . . . 20
25 102 20
Front axle bevel drive. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
25 102 24
Front axle differential. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
25 104 34
Front axle differential lock clutch assembly. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
25 108 30
Front epicyclic final gear with brake. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . 36
25 108 30
Front epicyclic final drive. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
25 108 38
Wheel hub and steering knuckles. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
25 108 46
Steering knuckle pins and bearings. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
25 108 47
Steering knuckles pins and bearings. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
44 511 80
Leading drive wheels toe--in check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SPECIFICATIONS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
steering, stress--supporting, centrally pivoted
Vertical pivoting angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal pivoting angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11° 21°
Bevel drive -- differential Pinion--crown gear ratio 30 km/h:
8/30= 1:3.75
Pinion--crown gear ratio 40 km/h: Backlash between bevel gear pair: . . . . . . . . . . . . . . . . . . . . . . . . . .
10/30 = 1:3 0.15 ÷ 0.20
mm
(continued)
87666787A - 11 - 2007
2
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 SPECIFICATIONS (overleaf)
Ratio between front wheel revs and rear wheel bevel drive revs 30 km/h: . . . . . . . . . . . . . . . . . . . . . . . .
1.378 (1) -- 1.306 (2)
Ratio between front wheel revs and rear wheel bevel drive revs 40 km/h: . . . . . . . . . . . . . . . . . . . . . . . .
1.374 (1) -- 1.303 (2)
Thickness of bevel pinion position adjustment spacer rings (18, page 10) of bevel pinion position adjuster . . . . . . . . . . . . . . . .
mm
2.5 -- 2.6 -- 2.7 -- 2.8 -- 2.9 -- 3.0 -- 3.1 -- 3.2 -- 3.3 -- 3.4 -- 3.5 -3.6 -- 3.7 --
Thickness of pinion bearing adjustment spacers (17, page 10) . .
mm
2.5 -- 2.55 -- 2.6 -- 2.65 -- 2.7 -2.75 -- 2.8 -- 2.85 -- 2.9 -- 2.95 -3.00 -- 3.05 -- 3.1 -- 3.15 -- 3.2 -3.25 -- 3.3 -- 3.35 -- 3.4 -- 3.45 -3.5 -- 3.55 -- 3.6 -- 3.65 -- 3.7 -3.75 -- 3.8 -- 3.85 -- 3.9 -- 3.95 -4.00 -- 4.05 -- 4.1 -- 4.15 -- 4.2 -4.25 -- 4.3 -- 4.35 -- 4.4 -- 4.45 -4.5 -- 4.55 -- 4.6 -- 4.65 -- 4.7 -4.75 -- 4.8
Thickness of crown wheel position adjustment spacers (8 page 11) mm
0.9 -- 1 -- 1.1 -- 1.2 -- 1.3 -- 1.4 -1.5 -- 1.6 -- 1.7 -- 1.8 -- 1.9 -- 2
Backlash between side pinions and side gears . . . . . . . . . . . . . . .
mm
0.15
Thickness of side pinion thrust washers (2, page 10)
.........
mm
1.470 ÷ 1.530
Thickness of sun pinion thrust washers . . . . . . . . . . . . . . . . . . . . . .
mm
1.5 -- 1.6 -- 1.7 -- 1.8
Diameter of cross pin (5) for side pinions . . . . . . . . . . . . . . . . . . . .
mm
21.939 ÷ 21.960
Diameter of cross pin bore in side pinions (4): . . . . . . . . . . . . . . . .
mm
22.040 ÷ 22.061
Clearance between cross pin and bores . . . . . . . . . . . . . . . . . . . . .
mm
0.080 ÷ 0.122
Differential lock
mm
0.080 ÷ 0.122
Free length of spring (9, page 11): . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
∼75
Spring length under load of 1370 ÷ 1566 N (139.7 ÷ 159.7 kg) . .
mm
∼41
Diameter of outer axle shafts (10, page 10) in correspondence with bushes (11): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
44.975 ÷ 45.000
Inside diameter of installed bushes (11) . . . . . . . . . . . . . . . . . . . . .
mm
45.100 ÷ 45.175(!)
Clearance between axle shafts and bushes . . . . . . . . . . . . . . . . . .
mm
0.100 ÷ 0.200
Bushings to seats fitting interference . . . . . . . . . . . . . . . . . . . . . . . .
mm
0.064 ÷ 0.129
Thickness of steering knuckle bearing adjusters (14) . .
mm
0.10 -- 0.15 -- 0.20 -- 0.25 -- 0.30
Axle--shafts and swivel assemblies
(1) Normal four--wheel drive models. (2) Automatic four--wheel drive models.
87666787A - 11 - 2007
(continued)
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
3
SPECIFICATIONS (overleaf)
Epicyclic final drives Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
12 : (12+60) = 1 : 6
Thickness of driven gear shims (12, page 10) . . . . . . . . . . . . . . . .
mm
0.77 ÷ 0.83
Diameter of front--upper pin (3, page 12) of axle pivot . . . . . . . . .
mm
39.965 ÷ 39.985
Inside diameter of front--upper bush (4) . . . . . . . . . . . . . . . . . . . . . .
mm
39.988 ÷ 40.037 (1)
Clearance between pin (3) and bush (4) . . . . . . . . . . . . . . . . . . . . .
mm
0.003 ÷ 0.072
Diameter of axle pivot front--lower pin (7) . . . . . . . . . . . . . . . . . . . .
mm
39.975 ÷ 40.000
Inside diameter of front--lower bush (6) . . . . . . . . . . . . . . . . . . . . . .
mm
40.416 ÷ 40.221 (1)
Clearance between pin (7) and bush (6) . . . . . . . . . . . . . . . . . . . . .
mm
0.146 ÷ 0.246
Axle pivot
(1) Measurement to be obtained without reaming
87666787A - 11 - 2007
4
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 BOLT TORQUES PARTS TO BE TIGHTENED
Thread
Nut for axle--shaft retaining bolt (C1, page 5) . . . . . . . . . . . . . . . . .
Tightening torque Nm
kgm
M 12 X 1.25
77 ÷ 93
7.8 ÷ 9.5
Crown wheel to differential gearbox retaining bolt (C2) . . . . . . . . .
M 12 X 1.25
119 ÷ 144
12.1÷14.7
Differential locknut safety tab retaining bolt (C3) . . . . . . . . . . . . . .
M 10 x 1.25
36 ÷ 51
3.7 ÷ 5.2
Differential bevel gear support to axle retaining bolt (C4) . . . . . . .
M 12 X 1.25
119 ÷ 144
12.1÷14.7
Bevel pinion shaft locknut (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 35 X 1.5
294
30
Pipe unions on power control hydraulic cylinders (C6) . . . . . . . . .
--
44
4.5
Pipe unions on manifolds for steering control hydraulic cylinders (C7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
25 ÷ 27
2.5 ÷ 2.7
Tie rod ball joint locknuts (C8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
142
14.5
Tie rod ball joint locknuts (C10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
196
20
Steering knuckle pin retaining bolt (C11) . . . . . . . . . . . . . . . . . . . . .
M 10 x 1.25
64
6.5
Rim to hub retaining bolt (C12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 18 X 1.5
170 ÷ 206
17.3 ÷ 21
Epicyclic final drive housing retaining bolt (C13) . . . . . . . . . . . . . . .
M 10 x 1.25
55 ÷ 67
5.6 ÷ 6.8
Wheel hub bearing locknut (C14) . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 70 X 2
392
40
Differential lock device retaining bolt (C1 page 6) . . . . . . . . . . . . .
M 10 x 1.25
60 ÷ 70
6.1 ÷ 7.1
Differential lock control hydraulic fitting (C2) . . . . . . . . . . . . . . . . . .
--
73
7--4
Differential lock control hydraulic fitting (C3) . . . . . . . . . . . . . . . . . .
--
44
4.5
Brake control cylinder retaining bolt (C4) . . . . . . . . . . . . . . . . . . . . .
M 10 x 1.25
66 ÷ 73
6.7 ÷ 7.4
Differential housing support cap bolt (C5) . . . . . . . . . . . . . . . . . . . .
M 12 X 1.25
119 ÷ 144
12.1÷14.7
Upper pivot bearing locknut (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 95 X 2
20
2
Upper pivot pin locknut (C7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 35 X 1.5
290 ÷ 320
29.5÷32.6
Bearing support retaining bolt (C8) . . . . . . . . . . . . . . . . . . . . . . . . . .
M 12 X 1.5
170 ÷ 208
10
Front pivot support retaining bolt (C9) . . . . . . . . . . . . . . . . . . . . . . .
M 14 X 1.5
136 ÷ 165
31.6 ÷ 38.7
Lower pivot pin retaining bolt (C10) . . . . . . . . . . . . . . . . . . . . . . . . . .
M 14 X 1.5
136 ÷ 165
13.8 ÷ 16.8
Axle to engine support retaining bolt (C11) . . . . . . . . . . . . . . . . . . .
M 24 X 2
310 ÷ 380
31.6 ÷ 38.7
Rear pivot pin retaining bolt (C12) . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 18 X 1.5
417 ÷ 504
42.5 ÷ 51.4
Side pinion support to cover retaining bolt (C13) . . . . . . . . . . . . . .
M 12 X 1.25
119 ÷ 144
12.1÷14.7
Rim and cover to hub retaining bolt (C14) . . . . . . . . . . . . . . . . . . . .
M 18 X 1.5
170 ÷ 206
17.3 ÷ 21
Front axle
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
5
BOLT TORQUES
C5 --294 Nm C4 -- 119 ÷ 144 Nm
C6 --44 Nm C7 -- 25 ÷ 27 Nm
25509
C2 -- 119 ÷ 144 Nm C3 -- 36 ÷ 51 Nm C1 -- 77 ÷ 93 Nm
C13 -- 55 ÷ 67 Nm
C10 -- 170 ÷ 206 Nm C11 -- 64 Nm C8 -- 100 ÷ 142 Nm
25510
C12 -- 170 ÷ 206 Nm
C14 -- 392 Nm 1
87666787A - 11 - 2007
6
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
C3 --44 Nm C2 --73Nm
25512
25511
C1 -- 60 รท 70 Nm
C4 -- 66 รท 73 Nm
C14 -- 170 รท 206 Nm
C13 -- 137 Nm 25515
2 87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 SPECIAL TOOLS Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual. List of specific tools required for the various operations described in this Sect. 380000251
Front axle overhaul stand.
X 380001613
Front axle and engine support bracket.
X 380001623
Splined wrench for pinions.
X 380001624
Wrench for pinion nut.
X 380000248
Pinion bearing adjustment tool.
7
380000249
Universal gauge for positioning of front bevel drive pinion.
X 380000252
Wrench for front differential case bearing threaded adjustment ring.
X 380000295
Wrench for front axle wheel hub bearing retaining nut.
X 380000286
Wheel hub seal key (version without front brakes).
X 380000287
Wheel hub seal key (version with front brakes).
X 380000265
Front axle pivot pin removal tool.
X 380000234
Front axle pivot bearing outer ring removal tool.
X 380000235
Tool for measurement of rolling drag torque of front axle bearings.
380000240
Universal kit for testing oil pressure for front axle differential lock engagement.
380001625
Pivot pin unit guide dowel.
Tool to be made for adjustment of bevel drive pinion; to be used in conjunction with tool 380000248 (mark tool No. 50118 -- Measurements in mm). Construct in UNI C40 material.
26135
3 Spacer to be made for securing axle--engine assembly, for models fitted with super steer front axle (mark the tool with no. 50162 -- Measurements in mm). Make in Fe 42C material. Make no. 4 spacers.
27821
4
87666787A - 11 - 2007
8
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
27892
5 Tool to be made for front axle wheel disassembly--assembly (mark tool with No. 50165 -- Measurements in mm) Make in UNI C40 material.
27893
6 Tool to be made for front axle gear unit cover disassembly--assembly (mark tool with No. 50169 -- Measurements in mm) Make in UNI C40 material.
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
9
27919
7 Modification to make to tool 380000302 (Measurements in mm)
87666787A - 11 - 2007
10
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
10
G
11
12
X
G
25517
14
13
15 15
16
17 18
H4
18
X
L
X
25216
9 8
7
6 5
4
3
2
1
8 Cross--sectional views of front axle G
= 0.5 รท 1 mm. Gasket (13) assembly clearance in seat.
H4 = 95 mm. Nominal distance between crown wheel axis and greater diameter of the pinion. 1. Crown wheel bearing adjustment ring nut. 2. Side gear thrust washers. 3. Side gear. 4. Side pinion. 5. Cross pin for side pinions. 6. Crown wheel. 7. Differential cage. 8. Pinion Gear.
Crown wheel bearing adjustment ring nut. Axle shaft. Axle shaft bush (10). Epicyclic reduction unit driven gear shims. Seal. Steering knuckle adjustment plates. Ball joint. Seal. Thickness of bevel pinion bearing adjustment spacer. 18. Thickness of bevel pinion position adjustment spacer. 9. 10. 11. 12. 13. 14. 15. 16. 17.
NOTE: When fitting apply sealing compound to surfaces X as shown on page 31. 87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
11
8
20
G 11
19
X
12
18 17
13
G 25518
16
14 25519
15 Cross--sectional view of front axle with differential lock 10. Differential lock control piston. G = 0.5 รท 1 mm. Gasket (13) assembly clearance in 11. Axle shaft. seat. 12. Axle shaft bush (11). H4 = 95 mm. Nominal distance between crown wheel 13. Epicyclic reduction unit driven gear shims. axis and greater diameter of the pinion. 14. Seals. 1. Crown wheel bearing adjustment ring nut. 15. Steering knuckle adjustment plates. 2. Side gear thrust washers. 16. Pinion Gear. 3. Side gear. 17. Ball joint. 4. Side pinion. 18. Seal. 5. Crown wheel. 19. Thickness of bevel pinion bearing adjustment 6. Cross pin for side pinions. spacer. 7. Differential cage. 20. Thickness of bevel pinion position adjustment 8. Thickness of crown wheel bearings adjustment spacer. shim. 9.
9
Differential lock disengagement spring.
NOTE: When fitting apply sealing compound to surfaces X as shown on page 31. 87666787A - 11 - 2007
12
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
10 Cross--sectional views of front axle pivot 1. 2. 3. 4. 5.
Front pivot bearing ring nut. On assembly the housing must be filled with AMBRA GR 9 grease. Front upper pivot pin. Front upper pivot bush. Drive shaft bearing support.
87666787A - 11 - 2007
6. 7. 8. 9. 10.
Front lower pivot bush. Front lower pivot pin. Universal Joint. Rear pivot bearing. Rear pivot pin.
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
2
3
4
13
5
G G
1
25521
7
6
X
11 Cross--sectional views of wheel hub (version with brake) G. = 1.5 ÷ 2 mm. Gasket (6) assembly clearance in seat. 4. Brake friction disk. 1. Axle shaft. 5. Brake support hub. 2. Brake control pipes. 6. Brake lining. 3. Brake piston. 7. Steering knuckle adjustment plate.
NOTE: When fitting apply sealing compound to surfaces X as shown on page 31.
DESCRIPTION AND OPERATION
The tractors are supplied with rigid front axles, comprising: bevel drive differential, stub axles and stub axles and lateral epicyclic final drives.
The axle can pivot both vertically 11° and horizontally 21° because of the front and rear double pivoting action.
87666787A - 11 - 2007
14
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
Front differential lock disengaged
1
2
25530
1
Front differential lock engaged
Discharge oil
2
Pressurised oil
25531
The front pivot knuckle bearing is installed on the axle support, the rear pivot is installed on the clutch casing. Two spring shock absorbers are attached to the support and axle, that gradually limit the vertical pivoting action and maintain the engine in the vertical position when the tractor is on the level. The drive transmission shaft is supplied with a universal joint, permitting horizontal pivoting. The differential has two planet pinions; drive is transmitted to lateral epicyclic final drive units (installed on the wheel hubs) through universal joints which do not require any maintenance. The front axle can be supplied complete with front teeth type differential locking.
87666787A - 11 - 2007
FRONT DIFFERENTIAL LOCK
12
By operating the relative switch on the control panel, the solenoid valve opens to allow the oil sent from the pump to enter the annular chamber of the control piston (1), overcome the resistance of the spring (2) and thus cause the teeth of the coupling sleeves to mesh and engage the differential lock. In rest conditions the oil inside the annular chamber of the piston(1) is static and not pressurised as the relative solenoid valve is in the discharge position (not energised). In these conditions, the helical spring (2) keeps the teeth of the two coupling sleeves of the differential lock apart.
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
15
FRONT AXLE HYDRAULIC DIFFERENTIAL LOCK TROUBLESHOOTING Problems
Possible Problem
The differential lock fails to 1. Transmission oil level low. engage engage. 2. Clogged oil filter.
Solutions Top up oil. Replace filter.
3. Hydraulic pump faulty.
Overhaul or replace the pump.
4. Faulty differential switch.
Replace switch.
5. Lack of power supply to the Check electrical connections and solenoid valve: connections loose replace defective parts. or damaged, contactor faulty. 6. Differential lock control solenoid Overhaul or replace solenoid valve. valve jammed in discharge position. 7. Oil leakage through the seals with Replace damaged seals. consequent pressure drop: piston seals or delivery pipe seals. Differential disengage.
lock
fails
to 1. Differential lock solenoid valve Overhaul or replace solenoid valve. jammed in delivery position. 2. Differential lock release spring Replace spring. broken. 3. Lack of power supply to the Check electrical connections and solenoid valve: connections loose replace defective parts. or damaged, contactor faulty.
With differential lock engaged 1. Differential lock control switch Replace switch. and the control switch in (connected to LIFT--O--MATIC position 3, when the lift arms device) defective. are raised with the LIFT-O--MATIC the differential lock fails to disengage. With differential lock engaged, 1. Differential lock control switch Replace switch. the differential lock does not (connected to brake pump) disengage when brake pedals defective. are pressed.
87666787A - 11 - 2007
16
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
Op. 25 100 30 FRONT AXLE ASSEMBLY Removal--Installation
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted. Proceed as follows: 1. Carry out operation 10 406 10: Radiator, only removal (see Sect. 10). 2. Carry out operation 23 101 26: Transmission shafts and guard, only removal (see Section 23). 3. Disconnect the electrical connection (2) and remove the steering cylinder control pipe (1) (on both sides).
13
4. Unscrew the brake control piping (1) on the axle from the union (2).
1
2
25543
14 5. Unscrew the differential lock control piping union (1).
27895
15
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
17
6. Loosen the retaining nut and remove the tie rod (1) from the seat.
16 7. Pass a nylon sling (1) under the axle support, attach to the hoist and allow the hoist to take the strain. Position a hydraulic jack under the axle
17 8. Remove the grub screw (2) and unscrew the cover (1).
18 9. Remove the securing ring and unscrew the axle pivot retaining ring nut (1).
19 87666787A - 11 - 2007
18
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
10. Loosen the universal joint bearing support retaining bolts on the axle. 11. Remove tool 380001613 (1) and spacers.
20 12. Move the axle forwards, remove the universal joint (1), complete the removal operation and position a stand (2) under the front axle support.
21 13. Unscrew the retaining bolts (3) on the brackets (1 and 2) and the lower pivot pin (4) retaining bolt, extract the pin and remove the brackets (1 and 2).
2
1
4
3
25554
22 14. Remove the circlip, loosen the retaining bolts and extract the pivot pin (1). Unscrew the retaining bolt, withdraw the hinge pin (2) and retrieve the steering control cylinder (3). Repeat this operation on both steering control cylinders.
1
2
3 25555
23 87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 15. With the axle attached to the sling and supported by the hydraulic jack, remove the wheels (1).
19
1
16. To refit the front axle on the tractor, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. ------------
--
-------
Refer to the instructions on page 12 for the positioning of the various parts. Respect the tightening torques prescribed on page 4. Attach the axle to a hoist and position a hydraulic jack under the rear part of the axle. Fit the wheels. Fit the two steering control cylinders. Attach the brake control pipes and connect them to the central union. Connect the pipes to the steering control cylinder. Assemble the universal joint, securing in position with the ring nut. Screw the tool 380001625 (1) onto the pivot pin (2) to then help insert it into the bearing seat. Fit the universal joint bearing support on the axle support. Raise the tractor from the front using the hoist and nylon sling, position the axle and lock in position with the nut. Fit bracket 380001613 together with the spacers 50162 to prevent pivoting. Screw on the bearing cover to the prescribed torque value and tighten the grub screw. (The cover must be filled with AMBRA GR 9 grease). Fit the steering control tie rod (on both sides). Connect the front differential lock control pipe. Connect the front brake control pipe. Connect the steering sensor electrical connection and the steering control pipe. Carry out operation 10 406 10: Radiator, only installation (see Section 10). Carry out operation 23 101 26 Propeller shafts and guard, only installation (see Section 23).
25556
24
1
2
25557
25
87666787A - 11 - 2007
20
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
Op. 25 102 15 BEVEL DRIVE AND FRONT AXLE DIFFERENTIAL HOUSING Removal--Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
1
2
Proceed as follows. 1. Fit tool 380001625 (2) on the pivot pin, attach a chain (1) to the hoist, place the axle on the stand 380000251 (4) and secure in position. 2. Loosen the retaining bolts and remove the two track rods (3).
3 4 25558
26
3. Remove the plug (1) and drain the oil from the epicyclic final drive. Drain the oil from the axle casing.
1
25559
27 4. Unscrew all of the epicyclic final drive casing retaining bolts (1).
1
25560
28
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 5. Using an extractor (1), fitted on the oil drainage plug, detach the epicyclic final drive casing (2) and remove.
21
2
25561
29 6. Remove the securing ring (1) on the wheel hub bearing lock ring (2).
2
1
25597
30 7. Remove the wheel hub bearing lock ring using wrench 380000295 (1) and recover the final drive fixed gear.
1
25598
31 8. Detach the wheel hub and steering knuckle (1).
1
25566
32 87666787A - 11 - 2007
22
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
9. Loosen the axle--shaft retaining bolt (1).
1
25567
33 10. Extract the axle--shaft (1) complete with the universal joint and bearing housing bush.
1
25568
34 11. Remove the retaining bolts (1) holding the bevel drive--differential housing to the axle casing, inserting two guide pins into the bores.
1
25569
35 12. Connect the bevel drive--differential housing to the hoist and detach from the axle casing. 13. To refit the bevel drive--differential housing to the axle casing, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. ---
Refer to the illustrations on pages 10 and 11 for the positioning of the various parts. Respect the tightening torque values prescribed on page 4.
87666787A - 11 - 2007
25570
36
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 --
Attach the bevel drive--differential to the axle casing after having carefully cleaned and degreased the mating surfaces and apply sealing compound (approx. 2 mm) along the marked line shown in the figure.
--
Refit the axle--shafts, locking in position with the relative bolts.
--
Assemble the wheel hubs, steering knuckles and carry out adjustment operations as described on page 45.
--
Fit the final drive fixed gear, locking in position with the ring nut as described on page 42.
--
Carefully secure the ring nut.
--
Before reassembling the epicyclic final drive casing, carefully clean and degrease the mating surfaces, then apply sealing compound (approx. 2 mm) along the marked line shown in the figure.
--
Fill up the lateral final drives and the axle casing (for recommended products and quantities see page 6, Sect. 00).
--
Fit the track rods.
23
27157
37
87666787A - 11 - 2007
24
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
Op. 25 102 20 FRONT AXLE BEVEL DRIVE Overhaul
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
1
2
If the differential lock is installed it must be removed, following the instructions on page 33. Proceed as follows. 1. Unscrew and remove the ring nut (2) stop tab (1). Using wrench 380000252, loosen the ring nut (2).
25576
38
2. Unscrew the crown wheel -- differential housing cap bolts (1).
1
25577
39 3. Disassemble the crown wheel (2) recovering the adjustment shims (1) positioned on the opposite side from the adjustment ring nut (3).
1
2
3
25578
40
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 4. Remove the securing ring on the drive pinion lock ring and unscrew, using the wrench for nut 380001624 (2) and the pinion spline wrench 380001623 (1).
1
25
2
25579
41 5. Recover: the grease seal ring (1), the ring nut (2), the drive pinion ring nut (3) and the dust seal ring (4).
6. Extract the drive pinion shaft (3, fig. 76) together with the spacer (1) and adjustment shim (2). Remove the ball joint and bush from the rear.
1
2
3
4
25587
42 7. To reassemble the front axle bevel drive assembly, proceed as follows.
1
2
3
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Refer to the illustrations on pages 10 and 11 for the positioning of the various parts.
--
Respect the tightening torque values prescribed on page 4.
--
Carry out the adjustments described on pages 26 รท 32.
--
Fit the drive pinion complete with inner bearing rings, spacers, adjustment shims, ball joint and bush, dust seal ring, pinion ring nut, seal ring and ring nut.
--
Carefully secure the drive pinion ring nut.
--
Fit the crown, complete with adjustment shim and housing cap.
--
Fit the crown wheel bearing adjustment ring nut stop tab.
--
Assemble the differential lock, as described on page 33.
25588
43
87666787A - 11 - 2007
26
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
BEVEL DRIVE ADJUSTMENTS Adjusting the preloading on the bevel drive shaft bearings (17, page 10 and 19, page 11)
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 8. Clamp tool 380000248 (1) in the vice, install the inner rings on the bearings (2 and 4), the spacer (3) and fully tighten the nut on the tool. 44 9. Using the micrometer, measure the distance (H1) between the upper surface and the pin of tool 380000248 (1).
45 10. Disassemble the parts mentioned above, lubricate the bearings with engine oil and then reassemble the parts, excluding the bearing spacer (3, fig. 44), in the bevel drive--differential housing, complete with outer bearing races, held in the vice. 11. Fully tighten the nut on the tool 380000248 (1) whilst turning the tool to ensure that the bearings are seated correctly. 12. Using the micrometer, measure the distance (H2) shown by the tool in this condition. 13. The thickness of the adjustment shim (17 or 19) required is given by: S = H2 -- H1 + 0.05 mm If necessary, round this value up to the nearest 0.05 mm. NOTE: -- On completing the adjustment, do not remove the adjustment tool from the bevel drive--differential housing: leave in place for adjustment of the drive pinion position.
87666787A - 11 - 2007
46
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
27
BEVEL DRIVE ADJUSTMENTS Determining the thickness of the drive pinion position adjustment shim (18, page 10 and 20, page 11) Proceed as follows.
14. Fit tool 380000249 (1) in the bevel drive--differential housing, complete with outer bearing rings, crown wheel bearings adjustment shim, circlip and differential housing caps.
1
2
15. Screw the cones (2) of tool 380000249 (1) in or out in order to position the micrometer shaft in the direction of the inner bearing ring and eliminate end float between the cones and the outer rings of the crown wheel bearings. 16. Adjust the micrometer so that the shaft is in contact with the inner bearing ring and measure the distance (H3) obtained. 17. Determine the correct distance (H5) between the crown wheel axis and the large diameter base of the pinion: H5 = H4 Âą C where: H4 = 95 mm Nominal distance between crown wheel axis and large diameter base of pinion (see pages 10 and 11). C = correction value stamped on pinion preceded by a + or -- sign (if other than 0), to be added to or subtracted from the nominal distance (H4) according to the sign.
25594
47
18. The thickness of the adjustment shim (18, page 10 and 20, page 11) will be given by: S = H3 -- H5 where: H3 = micrometer reading; H5 = corrected nominal distance between the crown wheel axis and the large diameter base of the pinion. Example -- Distance measured using micrometer H5 = 98 mm. -- Nominal distance between crown wheel axis and large diameter base of H4 = 95 mm. -- Correction value C = + 0.2 mm. -- Corrected nominal distance H5 = 95 + 0.2 = 95.2 mm -- Thickness of adjustment shim -- S = 98 -- 95.2 = 2.8 mm. -- Correction value C = -- 0.2 mm. -- Corrected nominal distance H5 = 95 -- 0.2 = 94.8 mm. -- Thickness of adjustment shim 87666787A - 11 - 2007
28 ------
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 S = 98 -- 94.8 = 3.2 mm. Correction value C = 0 mm. Corrected nominal distance H5 = H4 = 95 mm. Thickness of adjustment shim S = 98 -- 95 = 3 mm.
1
2
3
19. Remove tools 380000248 and 380000249 from the bevel drive housing. 20. Install the drive pinion (3) complete with: inner bearing rings, spacer (1), adjustment shims of the previously determined thickness, ball joint and relative bush. Lubricate all parts before installing 21. Position the wrench 380001624 (2) for the pinion nut and the wrench 380001623 (1) for the splined pinion. 22. Using the torque wrench on wrench 380001623 (1) whilst holding the pinion in position by means of wrench 380001624 (2) tighten the pinion nut to a torque value of 382 Nm (39 kgm) while simultaneously rotating the pinion shaft to ensure that the bearings are seated correctly. 23. With torque wrench 380001633 (2) fitted on wrench 380001623 (1), check that the pinion rolling torque, without oil seal (16, page 10 or 18, page 11) and relative dust seal, is 0.5 รท 1 Nm (0.050 รท 0.100 kgm). If the rolling torque is less than the prescribed value, fit a thinner adjustment shim (17, pages 10 or 18, page 11) if the torque is greater than the prescribed value, fit a thicker adjustment shim. 24. Unscrew the nut and fit the oil seal (16, page 10 or 18, page 11) and the relative dust seal ring. Tighten the nut to a torque value of 294 Nm (30 kgm) while simultaneously rotating the pinion shaft to ensure that the bearings are seated correctly. 25. With torque wrench 380001633 (2) fitted on wrench 380001623 (1) check that the pinion rolling torque, with the oil seal and relative dust seal is โ ค 0.50 Nm (0.050 kgm). Finally, carefully secure the nut.
25588
48
1
2
25595
49
1
2
25596
50
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 BEVEL DRIVE ADJUSTMENTS Adjustment of the crown wheel bearings and checking the backlash between the pinion and crown wheel.
1
2
29
3
Proceed as follows. 26. Install the differential assembly complete with crown wheel (2), inner crown wheel bearing rings, adjustment shim (1) and relative circlip in the bevel drive--differential housing.
25578
51 27. Install the differential support caps and the ring nut (2), tighten the relative bolts (1) to a torque value of 59 Nm (6 kgm), then loosen and re--tighten to a torque of 20 Nm (2 kgm).
2
1
25597
28. With the bearings perfectly lubricated, rotate the crown wheel and, at the same time, tighten the ring nut using wrench 380000252 (1) to a torque value of 39 ÷ 59 Nm (4 ÷ 6 kgm) to take up the axial play between the components.
52
1
29. Measure the backlash between pinion and crown wheel, using a 1/100 dial gauge perpendicular to the outer edge of a tooth on the crown wheel (1).
25598
53 30. Repeat the measurement in a further two positions 120° apart and compare the average of the three values (Gm) with the prescribed normal backlash: 0.15 ÷ 0.20 mm average value 0.18 mm. If the measured backlash exceeds the prescribed value, fit a thinner adjustment shim (8, page 11) to be fitted. The definitive value (8, page 11) to be fitted in the bevel drive--differential housing is given by:
1
25599
54 87666787A - 11 - 2007
30
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 S = Sp -- {(Gm -- 0.18 ) x 1.35} where: Sp = thickness of test shim installed in the bevel drive--differential housing; Gm = average backlash measured between the sides of the teeth of the bevel drive. If the backlash measured is less than the prescribed value, it will be necessary to fit a thicker adjustment shim (8, page 11) the value being given by: S = Sp + {(0.18 -- Gm) x 1.35} where: Sp = thickness of test shim installed in the bevel drive--differential housing;
1
Gm = average backlash measured between the sides of the teeth of the bevel drive 31. Install a shim (8, page 11) of the calculated thickness and with a 1/100 scale dial gauge positioned perpendicular to the outside edge of one of the crown wheel teeth, check that the backlash between the pinion and the crown wheel is within the prescribed tolerance limits 0.15รท 0.20 mm
25598
55 32. Using wrench 380000252 (1) turn the adjustment ring nut and check, using torque wrench 380001633 (2), that the rolling resistance torque of the crown wheel and pinion bearings, as measured in the same conditions used to check only the pinion, is:
1
2
A2 = A1 + 1 รท 1.5 Nm (0.10 รท 0.15 kgm) where: A2 = pinion--crown wheel rolling resistance torque; A1 rolling resistance torque of pinion only as previously measured; 0.1 รท 1.5 Nm (0.10 รท 0.15 kgm) = ring gear rolling torque measured at the end of the pinion using wrench 380001623 (1) and torque wrench 380001633 (2).
87666787A - 11 - 2007
25596
56
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 33. Tighten the cap bolts (1) to a torque value of 119 รท 144 Nm (12 รท 14.7 kgm).
31
2
1
34. Fit the safety plate, screwing the adjustment ring nut in or out, to reach the nearest notch. 35. Attach the bevel drive--differential to the axle casing after having carefully cleaned and degreased the mating surfaces and apply sealing compound (approx. 2 mm) along the marked line shown in the drawing below.
25597
57 Sealing compound application diagram for assembly of bevel drive unit and epicyclic final drive unit. The types of mastic to use are listed on page 1, Sect. 00.
27157
58
87666787A - 11 - 2007
32
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
Op. 25 102 24 FRONT AXLE DIFFERENTIAL Overhaul In case of differential assembly overhaul it is necessary to adjust the backlash between the teeth of the sun and planet pinions. Proceed as follows. 1. Thoroughly clean the components of the differential to remove any traces of oil that would otherwise prevent accurate backlash measurement. 2. Fit the two sun gears without thrust washers on the differential casing. 3. Fit the planet pinions complete with thrust washers and pins and screw down the pin retaining bolts by a few turns to hold the pins in place. 4. Position a dial gauge on the differential housing. 5. Move the left hand side gear to bring it into full contact with the planet pinion and then push it up against the differential housing, reading the endfloat (Gs) on the dial gauge. 24597
59 6. Repeat the above operations to measure the endfloat on the right hand side gear (Gd). The normal backlash between the sides of the side gear and planet pinion teeth is 0.15 mm. Considering that between this value and the side gear endfloat there is an average ratio value of 1:1.7 The axial movement of the crown wheels corresponding to the normal clearance is: 0.15 x 1.7 = 0.25 mm. Therefore the rings to be inserted in the differential housing are given by: Ss = Gs -- 0.25 mm for the left--hand side gear; Sd = Gd -- 0.25 mm for the right--hand sun gear; 7. Install shims as near as possible to the calculated value and, using a dial gauge and following the previously described procedure, check that the endfloat of the left-- and right--hand sun gears is approximately 0.25 mm.
87666787A - 11 - 2007
24598
60
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 Op. 25 104 34 FRONT DIFFERENTIAL LOCK CLUTCH UNIT Overhaul
33
1
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Clamp the crown wheel--differential assembly in the vice, then proceed as follows. 25571
1. Detach the oil delivery union (1) on the differential lock.
61
2. Remove the upper (1) and lower (2) bolts of the external differential lock bell housing (3), and install two bolts (minimum length 70 mm) in their place. Gradually unscrew the remaining bell housing (3) bolts so as to allow the gradual extension of the differential lock release spring.
NOTE: It is necessary to install two bolts with a minimum length of 70 mm because the normal bell housing bolts are not long enough to allow the spring to extend to its full free length.
1
3
2
25572
62
Unscrew the 70 mm bolts last of all. 3. Disassemble the clutch bell housing (1), complete with the differential lock release spring and differential lock control piston.
1
25573
63
87666787A - 11 - 2007
34
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
4. Remove the differential lock sleeve clip (1).
1
25574
64 5. Remove the differential lock sleeve (1).
1
25575
65 6. Remove the circlip securing the differential lock piston, recover the sliding sleeve with the two thrust washers.
66 7. Gently tap the piston out of the clutch bell housing.
67 87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
35
8. Remove the differential lock piston. 9. To refit the differential lock assembly, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Refer to the instructions on page 11 for the positioning of the various parts.
--
Respect the tightening torque values prescribed on page 4.
--
Carefully check the condition of the two O--ring seals installed on the piston.
--
Install the piston, complete with O--ring seals.
--
Install the sliding sleeve and the relative thrust washers.
--
Assemble the differential lock sleeve and clip.
--
Fit the clutch bell housing complete with spring and piston, securing in position following the removal instructions on page 33 for removal.
--
Refit the oil delivery union.
68
87666787A - 11 - 2007
36
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
Op. 25 108 30 FRONT EPICYCLIC FINAL DRIVE WITH BRAKE Disassembly -- Assembly
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Front epicyclic final drive removal and installation can be carried out with the axle detached and positioned on the stand 380000251, or with the axle fitted on the tractor. If the operation is performed with the axle fitted on the tractor, a support stand must be positioned under the engine sump. Proceed as follows 1. Fit tool 380001625 (2) on the pivot pin, attach a chain (1) to the hoist, place the axle on the stand 380000251 (4) and secure in position. 2. Unscrew the retaining bolts and remove the two crosswise tie rods (3) (if any).
1
2
3 4 25558
69
3. Remove the plug (1) and drain the oil from the epicyclic final drive.
1
25559
70 4. Unscrew all of the epicyclic final drive casing retaining bolts (1).
1
25560
71
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 5. Using an extractor (1), fitted on the oil drainage plug, detach the epicyclic final drive casing (2) and remove.
1
37
2
25561
72 6. Remove the circlip (1) and extract the external brake disk (2).
73 7. Recover the hub (1) on the brake disk.
1
25563
74 8. Unscrew the retaining bolts and remove the drive fixed gear (1) using two bolts as extractors.
1
9. To refit the front epicyclic final drive, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Refer to the illustrations on pages 10 and 11 for the positioning of the various parts.
25562
75 87666787A - 11 - 2007
38
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
--
Respect the tightening torque values prescribed on page 4.
--
Refit the drive fixed gear.
--
Refit the brake disk hub.
--
Fit the outer brake disk and secure in position.
--
Before reassembling the epicyclic final drive casing, carefully clean and degrease the mating surfaces, then apply sealing compound (approx. 2 mm) along the marked line shown on page 31.
--
Assemble the epicyclic final drive casing, complete with gears.
--
Fill up the front epicyclic final drive (for recommended products and quantities see page 6, Sect. 00).
WHEEL HUB SEAL Replacement
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows: 1. Carry out operation 25 108 30: Front epicyclic final drive with brake, only removal (see page 36). 2. Remove the hub casing (1). 76 3. Remove the seal and fit the pins (1) of tool 380000286.
77
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
39
4. Carefully clean the seat and position the seal (1), ready for fitting.
NOTE: The external surface on the seal (1), indicated by the arrow, does not require lubrication.
78 5. Fit the seal (2) fully tightening the screws on tool 380000286 (1). 6. To refit the wheel hub parts, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Remove tool 380000286 from the hub.
--
Carry out operation 25 108 30 Front epicyclic final drive with brake, only installation (see page 37).
79
87666787A - 11 - 2007
40
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
Op. 25 108 30 FRONT EPICYCLIC FINAL DRIVE Removal--Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Front epicyclic final drive removal and installation can be carried out with the axle detached and positioned on the stand 380000251, or with the axle fitted on the tractor. If the operation is performed with the axle fitted on the tractor, a support stand must be positioned under the engine sump.
1
2
Proceed as follows. 1. Fit tool 380001625 (2) on the pivot pin, attach a chain (1) to the hoist, place the axle on the stand 380000251 (4) and secure in position. 2. Loosen the retaining bolts and remove the two track rods (3).
3 4 25558
80
3. Remove the plug (1) and drain the oil from the epicyclic final drive.
1
25559
81 4. Unscrew all of the epicyclic final drive casing retaining bolts (1).
1
25560
82
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 5. Using an extractor (1), fitted on the oil drainage plug, detach the epicyclic final drive casing (2) and remove.
1
41
2
25561
83 6. Remove the securing ring (1) on the wheel hub bearing lock ring (2).
1
2
25597
84 7. Remove the lock nut on the wheel hub bearings using wrench 380000302 (1).
1
25598
85 8. Remove the wheel hub (1) together with the final drive fixed gear (2). Recover all disassembled parts.
1
2
9. To refit the front epicyclic final drive, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Refer to the illustrations on pages 10 and 11 for the positioning of the various parts.
25599
86 87666787A - 11 - 2007
42
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
--
Respect the tightening torque values prescribed on page 4.
--
Assemble the wheel hub and the epicyclic final drive fixed gear.
--
Progressively tighten the ring nut, using the torque wrench and wrench 380000295 (1) to obtain a torque value of 392 Nm (40 kgm); at the same time, rotate the wheel hub to ensure that the bearings are correctly seated. Measure the rolling resistance (Rt) of the wheel hub using the relative torque wrench, or a torque meter and cord positioned on the base of the wheel disk flange. Loosen the ring nut by half a turn and measure the rolling resistance (R) as described previously. The difference between the two measurements is the rolling torque value of the wheel hub bearings (Rc): Rc = Rt -- R = 5.9 รท 14.7 Nm (0.6 รท 1.5 kgm) or if measured with a torque meter. Rc = Rt -- R = 4.8 รท 12 kg If the measurement is less than 5.9 Nm (0.6 kgm) or the torque meter 4.8 kg it is necessary to replace the parts involved and perform the above check again.
--
Progressively tighten the ring nut, using the torque wrench and wrench 380000295 (1) to obtain a torque value of 392 Nm (40 kgm); at the same time, rotate the wheel hub to ensure that the bearings are correctly seated.
--
Carefully secure the ring nut.
--
Before reassembling the epicyclic final drive casing, carefully clean and degrease the mating surfaces, then apply sealing compound (approx. 2 mm) along the marked line shown on page 31.
--
Assemble the epicyclic final drive casing, complete with gears.
--
Fill up the front epicyclic final drive (for recommended products and quantities see page 6, Sect. 00).
--
Fit the track rods.
87666787A - 11 - 2007
87
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
43
WHEEL HUB SEAL Replacement
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows 1. Carry out operation 25 108 30: Front epicyclic final drive with brake, only removal (see page 40). 2. Remove the hub casing (1) and the spacer. 88 3. Remove the worn seal, carefully clean the seat and position the new seal (1) on the seat fitting.
NOTE: The external surface on the seal (1), indicated by the arrow, does not require lubrication.
89 4. Fit tool 380000287 (2) on the hub and fit, by a few mm, the seal (3) using a striker (1).
90 5. Fully fit the seal in position using the ring nut and wrench 380000295 (1). 6. To refit the wheel hub parts, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. ---
Remove tool 380000287 from the hub. Carry out operation 25 108 30 Front epicyclic final drive with brake, only installation (see page 41). 91 87666787A - 11 - 2007
44
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
Op. 25 108 38 WHEEL HUBS AND STEERING KNUCKLE
Removal--Installation
1
2
3
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Wheel hub removal can only be carried out after having disassembled the front epicyclic final drive, as indicated on pages 41 and 42, proceeding as follows.
25564
92
1. Place the stub axle in a nylon sling (1), remove the pin and grease fittings (2) retaining bolts (3). 2. Fit tool 380000265 (1) on the pin (2) and, using the screw on the tool, detach the pin. Repeat the operation on both pins and recover the adjustment shims.
1
2
25565
93 3. Detach the wheel hub and steering knuckle (1) and separate the two units.
1
4. To refit the steering knuckle and wheel hub, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Refer to the illustrations on pages 10 and 11 for the positioning of the various parts.
--
Respect the tightening torque values prescribed on page 4.
--
Assemble the steering knuckle on the axle body and adjust the bearings as follows.
87666787A - 11 - 2007
25566
94
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 5. Apply AMBRA GR 9 grease on the outer races of the bearings and fit the upper cover, without the adjustment plate, but with tool 380000235 (1). Tighten the retaining bolts to a torque value of 64 Nm (6.5 kgm).
45
1
6. Fit the lower cover without adjustment plate, lubricate the three retaining bolts with engine oil. 7. Gradually tighten the lower cover bolts in sequence, while simultaneously rotating the casing to allow the excess grease to escape. 25715
95 8. Using a torque wrench and tool 380000235 (1), check that the torque required to rotate the casing is 3.9 รท 5.9 Nm (0.4 รท 0.6 kgm) without considering the peak starting value. If not, adjust by way of the lower cover bolts.
1
9. Measure the gap (H) created between the lower cover and the casing in correspondence with the three bolts. 10. Calculate the average of the three values measured. The total thickness of the adjustment shims (14, page 10) to be fitted under the lower cover will be the average obtained, rounded down to the next 0.05 mm.
25716
96
11. Partially unscrew the lower cover bolts, insert the shims (14, page 10) and tighten the bolts to a torque value of 64 Nm (6.5 kgm). 12. Check that the torque necessary to rotate the casing is 3.9 รท 9.8 Nm (0.4 รท 1.0 kgm), without considering the initial peak torque. 13. If the torque value measured is greater than the specified value, increase the thickness of the shims, if it is less than the specified value, reduce the thickness of the shims. 14. Remove tool 380000235 and tighten the retaining bolts to a torque value of 64 Nm (6.5 kgm).
97
15. Fit the grease nipples in the upper and lower covers and grease the assembly. 16. Refit the front epicyclic final drive (see pages 41 and 42).
87666787A - 11 - 2007
46
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
Op. 25 108 46 or 25 108 47 STEERING KNUCKLE PINS AND BEARINGS Replacement Proceed as follows. 1. Remove the grease nipples and the steering swivel pin retaining bolts. 2. Fit the bolts (1) of tool 380000265. 3. Fit the plate (2) of the tool and fix it to the three bolts with nuts (5). 4. Fit the central tie bolt (4) screwing it fully into the grease nipple bore on the pin (6). 5. Screw in the nut (3) to drive the pin out of its bore.
98 6. Using extractor tool 380000234 (1) remove the steering knuckle bearings.
1
7. Re--install the steering knuckle bearings using a suitable striker.
24599
99
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
47
Op. 44 511 80 LEADING DRIVE WHEELS TOE--IN CHECK When travelling in a straight line, the wheels on four--wheel drive models must be parallel to the longitudinal axis of the tractor. A slight toe--in of the front wheels is permissible -- up to a maximum of 6 mm, as measured at the edges of the wheel rims. To check the exact value of the toe--in setting of four--wheel drive tractors, proceed as follows. 1. Inflate the front tyres to the prescribed pressure. 2. Place the steering wheel at mid--travel, with one spoke along the tractor centre line. 3. Check if wheels are parallel to the tractor centre line. 4. Measure the distance (1) between the front inside edges of the rims. 5. Turn both front wheels through 180o then, at the height of the wheel hub centres, measure the distance (2) between the rear inside edges of the wheel rims, checking that the new measurement is equal to or greater than distance (1) by a maximum of 6 mm. The rotation of the wheels through 180o is required in order to eliminate the effect on the measurement of any eventual wear on the rims.
1 2
24666
100 6. If wheel toe--in needs to be adjusted, remove nut (2) and extract the track rod end (1) from the housing. Loosen lock nut (3) and screw the track rod end (1) in or out to decrease or increase the distance (2, fig. 100). Reposition the track rod end (1) in the housing and check the toe--in as described in points 4 and 5. On obtaining the prescribed toe--in, lock the locknut (3) to 180 Nm (18.3 kgm) and the nut (2) to 100 Nm (10.2 kgm).
1
3
2
24667
101 NOTE: Self--locking nut (2) must be replaced each time it is removed or unscrewed.
87666787A - 11 - 2007
48
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
1
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION Chapter 2 -- Front axle mechanical transmission (Mod. T4040 Deluxe and T4050 Deluxe) CONTENT Section
Description
Page
25 000
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Front axle with brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
25 100 30
Front axle. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
25 100 38
Front axle. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
25 104 34
Front axle differential lock clutch assembly. Overhaul (with unit removed) . . . . . . . . . . . . 24
25 108 46
Steering knuckle bearing pins. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
25 108 47
Steering knuckle bearing pins. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
25 102 24
Front axle differential. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
25 102 27
Front axle differential with LIM--SLIP. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
44 511 80
Leading drive wheels toe--in check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SPECIFICATIONS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
steering, stress--supporting, centrally pivoted
Bevel drive -- differential Pinion--crown gear ratio 30 km/h: . . . . . . . . . . . . . . . . . . . . . . . . . . .
8/30= 1:2.66
Pinion--crown gear ratio 40 km/h: . . . . . . . . . . . . . . . . . . . . . . . . . . .
10/30= 1:3.33
Backlash between bevel drive teeth: . . . . . . . . . . . . . . . . . . . . . . . .
mm
0.15 รท 0.20
Ratio between front wheel revs and rear wheel bevel drive revs 30 km/h: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1,378 (1) -- 1,306 (2)
Ratio between front wheel revs and rear wheel bevel drive revs 40 km/h: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1,374 (1) -- 1,303 (2)
(1) Normal four--wheel drive models. (2) Automatic four--wheel drive models. (continued)
87666787A - 11 - 2007
2
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2 SPECIFICATIONS (overleaf)
Thickness of bevel pinion position adjustment spacer (11, page 7) mm
2.5 -- 2.6 -- 2.7 -- 2.8 -- 2.9 -- 3.0 -- 3.1 -- 3.2 -- 3.3 -- 3.4 -- 3.5 -3.6 -- 3.7
Thickness of bevel pinion bearing adjustment spacer rings (12) .
mm
2.5 -- 2.55 -- 2.6 -- 2.65 -- 2.7 -2.75 -- 2.8 -- 2.85 -- 2.9 -- 2.95 -3.00 -- 3.05 -- 3.1 -- 3.15 -- 3.2 -3.25 -- 3.3 -- 3.35 -- 3.4 -- 3.45 -3.5 -- 3.55 -- 3.6 -- 3.65 -- 3.7 -3.75 -- 3.8 -- 3.85 -- 3.9 -- 3.95 -4.00 -- 4.05 -- 4.1 -- 4.15 -- 4.2 -4.25 -- 4.3 -- 4.35 -- 4.4 -- 4.45 -4.5 -- 4.55 -- 4.6 -- 4.65 -- 4.7 -4.75 -- 4.8
Thickness of crown wheel position adjustment rings (4, page 7)
mm
0.9 -- 1 -- 1.1 -- 1.2 -- 1.3 -- 1.4 -1.5 -- 1.6 -- 1.7 -- 1.8 -- 1.9 -- 2
Clearance between sides of sun and planet pinion teeth . . . . . . .
mm
0.15
Thickness of planet pinion thrust washers . . . . . . . . . . . . . . . . . . . .
mm
1.470 ÷ 1.530
Thickness of side gear thrust washers (1) . . . . . . . . . . . . . . . . . . . .
mm
1.5 -- 1.6 -- 1.7 -- 1.8 -- 1.9 -- 2.0
Diameter of cross pin (14) for planet pinions . . . . . . . . . . . . . . . . .
mm
21.939 ÷ 21.960
Side pinion cross pin bore diameter (3) . . . . . . . . . . . . . . . . . . . . . .
mm
22.040 ÷ 22.061
Assembly clearance between cross pin and bores . . . . . . . . . . . .
mm
0.080 ÷ 0.122
Spring free length (5, page 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
∼ 75
Spring length under load of: 1370 ÷ 1566N (139.7 ÷ 159.7 kg) . .
mm
∼ 41
Diameter of outer axle shafts (7, page 7) in relation to bushings (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
44.975 ÷ 45.000
Inside diameter of installed bushes (8) . . . . . . . . . . . . . . . . . . . . . .
mm
45.100 ÷ 45.175(1)
Clearance between axle shafts and bushes . . . . . . . . . . . . . . . . . .
mm
0.100 ÷ 0.200
Bushings to seats fitting interference . . . . . . . . . . . . . . . . . . . . . . . .
mm
0.064 ÷ 0.129
Thickness of steering knuckle bearing adjuster plates (10) . . . . .
mm
0.10 -- 0.15 -- 0.20 -- 0.25 -- 0.30
Differential lock
Axle--shafts and swivel assemblies
Epicyclic final drives Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thickness of driven gears thrust rings (9, page 7) . . . . . . . . . . . .
12 : (12 + 60) = 1 : 6 mm
0.77 ÷ 0.83
Axle clearance on pivot between body and support . . . . . . . . . . . .
mm
0.3 ÷ 1.1
Maximum permitted wear clearance . . . . . . . . . . . . . . . . . . . . . . . . .
mm
2
Diameter axle pivot front pin (3, page 8) . . . . . . . . . . . . . . . . . . . . .
mm
52.652 ÷ 52.671
Axle pivot
(continued)
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
3
SPECIFICATIONS (overleaf)
Installed front bush internal diameter (1) . . . . . . . . . . . . . . . . . . . . .
mm
52.720 ÷ 52.790(1)
Clearance between pin (3) and bush (1) . . . . . . . . . . . . . . . . . . . . .
mm
0.049 ÷ 0.138
Outside diameter of rear bush (6) installed in the bevel pinion support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
99.020 ÷ 99.050
Inside diameter of rear bush (5) installed in the axle pivot support
mm
99.146 ÷ 99.221(1)
Assembly clearance between the two bushes . . . . . . . . . . . . . . . .
mm
0.096 ÷ 0.201
Thickness of the front (2) and rear (4) front axle thrust washers .
mm
4.95 ÷ 5.00
(1) Measurement to be obtained without reaming
BOLT TORQUES PARTS TO BE TIGHTENED
Thread
Tightening torque Nm
kgm
Front axle Crown wheel to differential gearbox retaining bolt (C1, page 4) . .
M 12 x 1.25
119 ÷ 144
12.1 ÷ 14.7
Differential lock device retaining bolt (C2) . . . . . . . . . . . . . . . . . . . .
M 10 x 1.25
60 ÷ 70
6.1 ÷ 7.1
Differential bevel gear support to axle casing retaining bolt (C3) .
M 12 x 1.25
119 ÷ 144
12.1 ÷ 14.7
Bevel pinion shaft locknut (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 35 x 1.5
294
30
Steering knuckle pin retaining bolt (C5) . . . . . . . . . . . . . . . . . . . . . .
M 10 x 1.25
55 ÷ 67
5.6 ÷ 6.8
Wheel hub bearing locknut (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 70 x 2
392
40
Epicyclic final drive housing retaining bolt (C7) . . . . . . . . . . . . . . . .
M 10 x 1.25
55 ÷ 67
5.6 ÷ 6.8
Front axle support to engine retaining bolt (C8) . . . . . . . . . . . . . . .
M 18 x 1.5
310 ÷ 380
31.6 ÷ 38.7
Front axle pivot front and rear supports retaining bolt (C9) . . . . . .
M 18 x 1.5
370 ÷ 410
37.7 ÷ 41.8
Differential housing support cap retaining bolt (C10) . . . . . . . . . . .
M 12 x 1.25
119 ÷ 144
12.1 ÷ 14.7
Ring nut fastening the steering control hydraulic cylinder to the front axle (C11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
630 ÷ 670
64.2 ÷ 68.3
Bolt retaining steering control linkage ball joint (C12) . . .
--
242 ÷ 299
24.6 ÷ 30.5
M 18 x 1.5
170 ÷ 208
17.3 ÷ 21.2
Rim to disk retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87666787A - 11 - 2007
4
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
C5 55รท67Nm
C6 -- 392 Nm
26125
C7 55รท67Nm
1
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
5
TOOLS Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual. List of specific tools required for the various operations described in this Sect. 380000251
Front axle overhaul stand.
380000227
Front differential unit removal--installation hook.
380000255
Front axle differential overhaul support.
casing
X 380000252
Wrench for front differential case bearing threaded adjustment ring.
X 380000286
Wheel hub seal splining tool (for axle with brake).
X 380000287
Wheel hub seal splining tool (for axle without brake).
X 380000295
Wrench for front axle wheel hub bearing retaining nut (only for standard models without brake).
X 380000265
Front axle pivot pin removal tool.
X 380000234
Front axle pivot bearing outer ring removal tool.
X 380000235
Tool for measurement of rolling drag torque of front axle bearings.
380000240
Universal kit for testing oil pressure for front axle differential lock engagement (with 380000618 and 380000613).
X 380000268
Wrench for front bevel drive pinion ring nut.
X 380000248
Bevel pinion bearing adjustment tool (with 50118).
50169
X 380000257
Front bevel drive pinion retaining wrench.
Pins (M 12 x 1.25) for front axle and cover.
50165
380000249
Universal gauge for positioning of front bevel drive pinion.
Pins (M 16 x 1,25) for front axle wheels disassembly/assembly.
Tool to be made for adjustment of bevel drive pinion; to be used in conjunction with tool 380000248 (mark tool No. 50118 -- Measurements in mm). Construct in UNI C40 material.
26135
2
87666787A - 11 - 2007
6
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
27892
3 Tool to be made for front axle wheel disassembly--assembly (mark tool with No. 50165 -- Measurements in mm) Make in UNI C40 material.
27893
4 Tool to be made for front axle gear unit cover disassembly--assembly (mark tool with No. 50169 -- Measurements in mm) Make in UNI C40 material.
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
7
8
7
9
10 X
26128
15 14
MDF1669A
5 Cross--sectional views of front axle H4 = 95 mm. Nominal distance between crown wheel 8. Axle shaft bush (7). axis and greater diameter of the pinion. 9. Epicyclic reduction unit driven gear shims. 1. Thickness of sun pinion thrust washers. 10. Steering knuckle adjustment plates. 2. Sun pinions. 11. Thickness of bevel pinion position adjustment spacer. 3. Planet pinions. 12. Thickness of bevel pinion bearing adjustment spacer. 4. Bevel crown wheel bearing adjustment shims. 13. Seal. 5. Differential lock disengagement spring. 14. Cross pin for side pinions. 6. Differential lock control piston. 15. Crown wheel bearing adjustment ring nut. 7. Axle shaft.
Note -- On assembly apply a bead of sealing compound to the surfaces X as indicated on page 35.
87666787A - 11 - 2007
8
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
6 Cross--sectional views of front axle pivot 1. 2.
Axle pivot front bush. Front thrust washer.
4. 5.
Rear thrust washer. Rear bush installed on axle support.
3.
Axle pivot front pin.
6.
Rear bush installed on bevel drive--differential support.
DESCRIPTION AND OPERATION The tractors are provided with a centrally pivoting front axle with pivot and drive shaft coaxial to the tractor longitudinal axis. The drive shaft is not fitted with universal joints. The differential has two planet pinions; drive is transmitted to lateral epicyclic final drive units
87666787A - 11 - 2007
(installed on the wheel hubs) through universal joints which do not require any maintenance. For the hydraulically controlled front gear--type differential lock, see page 9.
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
9
1 Front differential lock disengaged
2 26133
1
Front differential lock engaged
Discharge oil Pressurised oil 2
26134
7
FRONT DIFFERENTIAL LOCK
In rest conditions the oil inside the annular chamber of the piston (1) is static and not pressurised as the relative solenoid valve is in the discharge position (not energised).
In these conditions, the helical spring (2) keeps the teeth of the two coupling sleeves of the differential lock apart.
87666787A - 11 - 2007
10
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
By operating the relative switch on the control panel, the solenoid valve opens to allow the oil sent from the pump to enter the annular chamber of the control
piston (1), overcome the resistance of the spring (2) and thus cause the teeth of the coupling sleeves to mesh and engage the differential lock.
HYDRAULICALLY CONTROLLED DIFFERENTIAL LOCK TROUBLESHOOTING FRONT AXLE Problems The differential lock fails to engage.
Possible Problem
Solutions
1. Transmission oil level low.
Top up oil.
2. Clogged oil filter.
Replace filter.
3. Hydraulic pump faulty.
Overhaul or replace the pump.
4. Faulty differential switch.
Replace switch.
5. Lack of power supply to the Check electrical connections and solenoid valve: connections loose replace defective parts. or damaged, contactor faulty. 6. Differential lock control solenoid Overhaul or replace solenoid valve. valve jammed in discharge position. 7. Oil leakage through the seals with Replace damaged seals. consequent pressure drop: piston seals or delivery pipe seals. Differential lock fails to disengage.
1. Differential lock solenoid valve Overhaul or replace solenoid valve. jammed in delivery position. 2. Differential lock release spring Replace spring. broken. 3. Lack of power supply to the Check electrical connections and solenoid valve: connections loose replace defective parts. or damaged, contactor faulty.
With differential lock engaged and the control switch in position 3, when the lift arms are raised with the LIFT--O--MATIC the differential lock fails to disengage.
1. Differential lock control switch Replace switch. (connected to LIFT--O--MATIC device) defective.
With differential lock engaged, the differential lock does not disengage when brake pedals are pressed.
1. Differential lock control switch Replace switch. (connected to brake pump) defective.
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
11
OP. 25 100 30 FRONT AXLE ASSEMBLY Removal--Installation
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that the load is supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted. Proceed as follows:
Note -- The front axle assembly can be removed from the tractor either with or without previously removing the drive shaft. The description below refers to removal of the front axle with the drive shaft installed on the tractor. For removal of the drive shaft refer to section 23. 1. Unscrew the bolts (1) and remove the front mudguard supports (2) (if applicable).
1
2
25575
8 2. Attach a nylon sling to the front ballast (1), extract the locking pin; lift the ballast and remove to a safe position (if applicable).
1
25577
9
87666787A - 11 - 2007
12
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
3. Unscrew the bolts (1) and remove the drive shaft guard (2).
1
2
25576
10 4. Remove the circlip (2), slide the sleeve (1) towards the rear and free the drive shaft from the front axle.
1
2
25584
11 5. Hook the front of the tractor, with a chain (1), to a hoist.
12 6. Raise the tractor and position a fixed stand under the engine sump.
25581
13 87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
13
7. Unscrew the retaining bolts and remove the front wheels (1).
14 8. Disconnect the steering cylinder control pipes (1).
15 9. Disconnect the differential lock control pipes (1).
16 10. Fasten a chain (1) to the front axle and to the hoist, then make it take up the strain.
17 87666787A - 11 - 2007
14
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
11. Unscrew the bolts (1) fastening the rear support of the front axle.
18 12. Remove the front axle front support retaining bolts (1).
19 13. Using the hoist, detach the front axle. 14. To refit the front axle on the tractor, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Fit the axle and secure it with the rear and front supports.
--
Connect the differential lock pipe and the hydrostatic steering control pipes.
--
Fit the front wheels.
--
Using the hoist, raise the front of the tractor and remove the fixed stand.
--
Connect the drive shaft and position the guard.
--
Fit the two front mudguards (if applicable).
--
Fit the ballasts and lock them (if applicable).
--
Connect the battery negative lead.
--
Respect the tightening torque values prescribed on page 3.
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
15
OP. 25 100 38 FRONT AXLE Disassembly--Assembly
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Note -- Front axle overhaul operations must be carried out on stand no. 380000251.
25587
20 1. Unscrew the plug (1) and drain the oil from the axle casing.
1 25588
21 2. Unscrew plug (1) on the left--hand epicyclic final drive casing; repeat the same operation on the right--hand casing.
1
25589
22 3. Remove the front axle rear support (1); remove the front support and washer.
1
25590
23 87666787A - 11 - 2007
16
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
4. Unscrew the left--hand final drive cover (1) retaining bolts. Tighten two pins 50169 (2) and, using an extracting tool screwed into the oil drainage plug hole, remove the cover (1).
2
1
25594
24 5. Remove the driving gear stop (2) circlip (1).
1
2
25595
25 6. Remove the driving gear stop (2) snap ring (1, fig. 25).
1
25596
26 7. Remove the securing ring (1) on the wheel hub bearing lock ring (2).
1
2
25597
27 87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
17
8. Remove the lock nut on the wheel hub bearings using wrench 380000295 (1).
1
25598
25598
28 9. Remove the wheel hub (1) together with the epicyclic crown (2). Recover all disassembled parts.
2
1
25599
29 10. Unscrew the three stub axle lower pin retaining bolts (1). Recover the lower pivot pin and the relative adjusting spacers.
1
25600
30 11. Unscrew the three mudguard support (2) retaining bolts (1).
1
2
25601
31 87666787A - 11 - 2007
18
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
12. Extract the upper pivot pin (1) and remove the stub axle (2). Retrieve the disassembled parts.
2
1
25602
32 13. Unscrew the retaining bolt (2) of the axle shaft (1).
2
1
25603
33 14. Using a crowbar, remove the axle shaft (1, fig. 33). 15. To disassemble the right--hand final drive follow the operations carried out for left--hand final drive disassembly, from operation no. 7 to operation no. 17.
25604
34 16. Unscrew the bracket (1), loosen the union (3) and remove the differential lock control rigid pipe (2).
1
2
3
25605
35 87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2 17. Unscrew the two bevel drive--differential support retaining bolts from the axle casing, screw on the two pins 50169 (1). Remove the remaining bolts and the bevel drive--differential support, attach a chain (2) and put the hoist under strain. Remove the bevel drive--differential support (3) from the axle casing.
1
2
19
3
25606
36 18. Fit tool 380000255 (1) in the vice on a work bench, lock the bevel drive--differential support in the tool and remove the chain.
1
2
19. Unscrew the screw (2) and retrieve the ring nut locking plate (3). Remove the differential lock control internal pipe.
3
25607
37 20. Remove the upper (2) and lower bolts of the external differential lock bell housing (1), and install two bolts (minimum length: 70 mm) in their place. Gradually unscrew the four remaining bell housing bolts so as to allow the gradual extension of the differential lock release spring.
1
2
Note -- It is necessary to install two bolts with a minimum length of 70 mm, because the normal bell housing bolts are not long enough to allow the differential lock spring to extend to its full free length. 25608
38 21. Unscrew the two 70 mm bolts last of all, remove the bell (1), the spring (2) and differential lock control piston.
1
2
25609
39 87666787A - 11 - 2007
20
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
22. Remove the snap ring (2) with a screwdriver and detach the differential lock sleeve.
2
1
25610
40 23. Unscrew the bevel drive--differential support cap (1) retaining bolts (2) and remove.
2
1
25612
41 24. Remove the crown wheel--differential unit (2) from the casing (1).
1
2
25613
42 25. Remove the circlip (1) from the splined shaft (2).
1
2
25614
43 87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2 26. Straighten the staking on the splined shaft lock nut (1).
21
1
25615
44 27. Unscrew the nut with wrench 380000268 (1) keeping the bevel pinion shaft locked with wrench 380000257.
1
25616
45 28. Remove the splined shaft stop ball (1).
1
25617
46 29. Acting on the rear part, extract the bevel pinion shaft (1) and recover the spacer, adjusting shims and the bearing.
1
25618
47 87666787A - 11 - 2007
22
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
30. Using a screwdriver, detach and remove the dust seal, seal (1) and rear bearing.
1
25619
48 31. To assemble the front axle, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Refer to the illustrations on pages 7 and 8 for the positioning of the various parts.
--
Respect the tightening torques prescribed on page 3.
--
Carry out the adjustments described on pages 27 รท 36.
--
Fit the rear bearing, seal, dust seal, adjusting shims, spacer and bevel pinion shaft, complete with front bearing.
--
Position the stop ball, tighten and secure the bevel drive nut, then position the circlip.
--
Assemble the crown wheel--differential unit and support caps and tighten the relative screws.
--
Assemble the differential lock sleeve and relative stop ring.
--
Assemble the differential lock control piston, spring, bell housing and tighten the relative bolts, then fit the ring nut locking plate and differential lock internal pipe.
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
23
--
Reconnect the bevel drive--differential support to the front axle casing and fit the differential lock external pipe.
--
Fit the wheel hub, final drive crown wheel and ring nut and tighten to the prescribed torque whilst rotating the hub to settle the bearings.
--
Fit the axle shaft and screw.
--
Fit the snap rings, drive gear and final drive cover.
--
Fit the stub axle, the adjustment shims, the upper and lower pivot pins, the mudguard bracket and related bolts.
--
Fit the front and rear supports and the oil drainage plugs.
87666787A - 11 - 2007
24
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
OP. 25 104 34 FRONT DIFFERENTIAL LOCK CLUTCH UNIT Overhaul with unit removed
ATTENTION Handle all parts with carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Position the bevel crown wheel--differential assembly on the support 380000255 and proceed as follows. 1. Unscrew the differential lock control internal pipe.
1
2
2. Remove the upper (2) and lower bolts of the external differential lock bell housing (1), and install two bolts (minimum length: 70 mm) in their place. Gradually unscrew the four remaining bell housing bolts so as to allow the gradual extension of the differential lock release spring. Note -- It is necessary to install two bolts with a minimum length of 70 mm, because the normal bell housing bolts are not long enough to allow the differential lock spring to extend to its full free length. 3. Unscrew the two 70 mm bolts last of all, remove the bell (1), the spring (2) and differential lock control piston.
25608
49
1
2
25609
50 4. Remove the snap ring (2) with a screwdriver and detach the differential lock sleeve.
1
2
25610
51
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
25
5. Remove the circlip securing the differential lock piston, recover the sliding sleeve with the two thrust washers.
24093
52 6. Gently tap the piston out of the clutch bell housing.
24094
53 7. Remove the differential lock piston. 8. To refit the differential lock clutch parts follow the disassembly procedure in reverse order, proceeding as follows.
24095
54
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
Carefully check the condition of the two O--ring seals installed on the piston.
--
Fit the clutch bell unit complete with spring and piston using the two 70 mm bolts used during disassembly operations.
87666787A - 11 - 2007
26
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
OP. 25 108 46 or 25 108 47 STEERING KNUCKLE PINS AND BEARINGS Replacement
ATTENTION Handle all parts with carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. If steering knuckle pivot pins present problems during disassembly operations, proceed as follows. 1. Remove the grease nipples and the steering swivel pin retaining bolts. 2. Fit the bolts (1) of tool 380000265. 3. Fit the plate (2) of the tool and fix it to the three bolts with nuts (5). 4. Fit the central tie bolt (4) screwing it fully into the grease nipple bore on the pin (6).
24596
5. Screw in the nut (3) to drive the pin out of its bore.
55 6. Using extractor tool 380000234 (1) remove the steering knuckle bearings.
1
7. Re--install the steering knuckle bearings using a suitable striker.
24599
56
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
Carry out the following adjustments.
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
27
STUB AXLE ADJUSTMENT Proceed as follows.
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
8. Smear AMBRA GR 9 grease on the outer races of the bearings and fit the upper cover, without the plates, but with tool 380000235 (2). Tighten the retaining bolts (C5, page 3) to a torque of 55 รท 67 Nm (5.6 รท 6.8 kgm).
1
2
24076
57 9. Fit the lower cover without adjustment plates, lubricate the three retaining bolts with engine oil. 10. Gradually tighten the lower cover bolts in sequence, while simultaneously rotating the casing to allow the excess grease to escape.
24077
58 11. Using a torque wrench and tool 380000235 (1), check that the torque required to rotate the casing is 2.9 Nm (0.3 kgm) (with a torque increase of 0.98 Nm -- 0.1 kgm) without considering the peak starting value. If not, adjust by way of the lower cover bolts.
1
12. Measure the gap (H) created between the lower cover and the casing in correspondence with the three bolts.
24078
59
87666787A - 11 - 2007
28
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
13. Calculate the average of the three values measured. The total thickness of the adjustment plates (10, page 7) to be fitted under the lower cover will be given by:
S3= H
24079
If necessary, round the value down to the next 0.05 mm.
14. Partially unscrew the lower cover bolts, insert the plates (10, page 7) and tighten the bolts (C5, page 3) to a torque of 55 รท 67 Nm (5.6 รท 6.8 kgm).
15. Check that the torque necessary to rotate the casing is 2.9 รท 7.8 Nm (0,3 รท 0.8 kgm) without considering the initial peak torque.
16. If the torque value measured is greater than the specified value, increase the thickness of the shims, if it is less than the specified value, reduce the thickness of the shims.
17. Fit the grease nipples in the upper and lower covers and grease the assembly.
87666787A - 11 - 2007
10 60
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
29
BEVEL DRIVE ADJUSTMENTS Adjusting the preloading on the bevel drive shaft bearings (12, page 7).
ATTENTION
Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Clamp tool 380000248 (1) in the vice, install the inner rings on the bearings (2 and 4), the spacer (3) and fully tighten the nut on the tool. Note -- Place the tool 50118 (see page 5) between the tool 380000248 (1) and the bearing (2).
24584
61 2. Using the micrometer, measure the distance (H1) between the upper surface and the pin of tool 380000248 (1). 3. Disassemble the parts mentioned above and lubricate the bearings with engine oil. Reassemble the parts, excluding the spacer (3, fig. 61), in the bevel drive--differential housing, using tool 380000255, complete with outer bearing races, held in the vice.
24585
62 4. Fully tighten the nut on the tool 380000248 (1) (see Note above) whilst turning the tool to ensure that the bearings are seated correctly. 5. Using the micrometer, measure the distance (H2) shown by the tool in this condition. 6. The thickness of the adjustment shim (12, pages 7) required is given by: S = H2 -- H1 + 0.05 mm
24586
63
87666787A - 11 - 2007
30
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
If necessary, round the adjustment shim (12) value up to the nearest 0.05 mm. Note -- On completing the adjustment, do not remove the adjustment tool from the bevel drive--differential housing: leave in place for adjustment of the bevel pinion position. Determining the thickness of the bevel pinion position adjustment shim (11, page 7). Proceed as follows. 7. Fit tool 380000249 (1) in the bevel drive--differential housing, complete with outer bearing rings, crown wheel bearings adjustment shim, circlip and differential housing caps. 8. Screw the cones (3) of tool 380000249 (1) in or out in order to position the micrometer shaft in the direction of the inner bearing ring (2) and eliminate end float between the cones and the outer rings of the bevel crown wheel bearings.
1
3
9. Adjust the micrometer so that the shaft is in contact with the inner bearing ring (2) and measure the distance (H3). 10. Determine the correct distance (H5) between the crown wheel axis and the large diameter base of the pinion: H5 = H4 Âą C where: H4 = 95 mm. Nominal distance between the crown wheel axis and the large diameter base of the pinion (see pages 7). C = correction value stamped on pinion preceded by a + or -- sign (if other than 0), to be added to or subtracted from the nominal distance (H4) according to the sign. 11. The thickness of the adjustment shim (11, page 7) will be given by: S = H3 -- H5 where: H3 = micrometer reading; H5 = corrected nominal distance between the crown wheel axis and the large diameter base of the pinion. 87666787A - 11 - 2007
24588
64
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
31
Example --
Distance measured using micrometer H5 = 98 mm.
--
Nominal distance between crown wheel axis and large diameter base of H4 = 95 mm.
--
Correction value C = + 0.2 mm.
--
Corrected nominal distance H5 = 95 + 0.2 = 95.2 mm
--
Thickness of adjustment shim S = 98 -- 95.2 = 2.8 mm.
--
Correction value C = -- 0.2 mm.
--
Corrected nominal distance H5 = 95 -- 0.2 = 94.8 mm.
--
Thickness of adjustment shim S = 98 -- 94.8 = 3.2 mm.
--
Correction value C = 0 mm.
--
Corrected nominal distance H5 = H4 = 95 mm.
--
Thickness of adjustment shim S = 98 -- 95 = 3 mm.
12. Remove tools 380000248 and 380000249 from the bevel drive housing.
1
13. Install the drive pinion complete with: inner bearing rings, spacer and adjustment shims (11 and 12) of the previously determined thickness. 14. Fit the O--ring (1) on the bevel pinion shaft. 15. Insert the spacer on the pinion and, after having carefully greased the outer surface, fit the anti--rotation ball. 24589
65 87666787A - 11 - 2007
32
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
16. Fit pinion retaining tool 380000257 (2).
17. Insert wrench 380000268 on the adjuster ring nut.
1 18. Using the torque wrench on the pinion retaining wrench (2), hold the bevel pinion in position and, using a torque wrench (positioned as in the figure) on the ring nut wrench (1), tighten the ring nut (C3, page 3) to a torque of 294 Nm (30 kgm), while simultaneously rotating the pinion shaft to ensure that the bearings are seated correctly.
2
24590
66
19. With torque wrench 380001633 (1) fitted on the pinion retaining wrench 380000257 (2), check that the pinion rolling torque, without oil seal (13, page 7) and relative dust seal, is 0.5 รท 1 Nm (0.050 รท 0.100 kgm). If the rolling torque is less than the prescribed value, fit a thinner adjustment shim (12, page 7); whereas, if the torque is greater than the prescribed value, fit a thicker adjustment shim.
20. Unscrew the ring nut and fit the seal (13, pages 7) and the relative dust seal ring. Tighten the nut to a torque value of 294 Nm (30 kgm) while simultaneously rotating the pinion shaft to ensure that the bearings are seated correctly.
21. With torque wrench 380001633 (1) fitted on pinion retaining wrench 380000257 (2) check that the pinion rolling torque, with the oil seal and relative dust seal, is โ ค 0.50 Nm (0.050 kgm). Finally, secure the ring nut and fit the snap ring on the bevel pinion shaft
24587
67
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
33
Adjusting the bevel crown wheel bearings and checking the clearance between the sides of the bevel drive teeth. Proceed as follows. 24112
22. Install the differential assembly complete with crown wheel and inner bearing rings on the differential bevel drive support.
24112
68 23. Insert the outer rings on the bevel drive--differential support, install the differential support caps, tighten the relative bolts to a torque value of 59 Nm (6 kgm), then loosen and re--tighten to a torque of 20 Nm (2 kgm).
24. Fit the adjuster shim (4, pages 7), that was previously removed during the axle overhaul operation, and the relative circlip.
24591
69 25. With the bearings perfectly lubricated, rotate the crown wheel and, at the same time, tighten the ring nut using wrench 380000252 (1) to a torque value of 39 ÷ 59 Nm (4 ÷ 6 kgm) to take up the axial play between the components.
26. Measure the backlash between pinion and crown wheel, using a 1/100 dial gauge perpendicular to the outer edge of a tooth on the crown wheel (1, fig. 71).
1
24592
70 27. Repeat the measurement in a further two positions 120° apart and compare the average of the three values (Gm) with the prescribed normal backlash: 0.18 ÷ 0.23 mm average value 0.20 mm. If the measured backlash exceeds the prescribed value, fit a thinner adjustment shim (4, page 7).
1
24593
71 87666787A - 11 - 2007
34
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
Note -- On standard models (fitting without differential lock) if the clearance value is not within the prescribed field of tolerance, unscrew one of the ring nuts, whilst tightening the other to an equal amount, so as to reset the prescribed clearance. The definitive shim value (4, page 7) to fit on the bevel drive--differential support will be given by: S = Sp -- {(Gm -- 0.20 ) x 1.35} where: Sp = thickness of test shim installed in the bevel drive--differential housing; Gm = average backlash measured between the sides of the teeth of the bevel drive. If the backlash measured is less than the prescribed value, it will be necessary to fit a thicker adjustment shim (4, page 7), the value being given by: S = Sp + {(0.20 -- Gm ) x 1.35} where: Sp = thickness of test shim installed in the bevel drive--differential housing; Gm = average backlash measured between the sides of the teeth of the bevel drive. 28. Fit a shim (4, pages 7) of the calculated thickness and with a 1/100 scale dial gauge positioned perpendicular to the outside edge of one of the crown wheel teeth, check that the backlash between the pinion and the crown wheel is within the prescribed tolerance limits 0.18 รท 0.23 mm. 29. Using wrench 380000252 (1) turn the adjustment ring nut and:
1 24592
72 check using torque wrench 380001633 (1), that the rolling resistance torque of the crown wheel and pinion bearings, as measured in the same conditions used to check only the pinion, is: A2 = A1 + 1 รท 1.5 Nm (0.10 รท 0.15 kgm) where: A2 = pinion--crown wheel rolling resistance torque; A1 rolling resistance torque of pinion only as previously measured;
1
24594
73
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
35
1 รท 1.5 Nm (0.10 รท 0.15 kgm) = rolling resistance torque of crown wheel only measured at the end of the pinion, using wrench 380000257 and torque wrench 380001633.
30. Tighten the cap bolts (C10, page 3) to a torque value of 119 รท 144 Nm (12.1 รท 14.7 kgm). 31. Fit the safety plate, screwing the adjustment ring nut in or out, to reach the nearest notch.
32. Attach the bevel drive--differential to the axle casing after having carefully cleaned and degreased the mating surfaces and apply sealing compound (approx. 2 mm) along the marked line shown in the drawing below.
24591
74
Sealing compound application diagram for assembly of bevel drive unit and epicyclic final drive unit. The types of mastic to use are listed on page 1, Sect. 00.
24595
75
87666787A - 11 - 2007
36
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
OP. 25 102 24 FRONT AXLE DIFFERENTIAL Overhaul In case of differential assembly overhaul it is necessary to adjust the backlash between the teeth of the sun and planet pinions.
Proceed as follows. 1. Thoroughly clean the components of the differential to remove any traces of oil that would otherwise prevent accurate backlash measurement.
2. Fit the two sun gears without thrust washers on the differential casing.
3. Fit the planet pinions complete with thrust washers and pins and screw down the pin retaining bolts by a few turns to hold the pins in place. 4. Position a dial gauge on the differential housing. 24597
5. Move the left hand side gear to bring it into full contact with the planet pinion and then push it up against the differential housing, reading the endfloat (Gs) on the dial gauge.
76
6. Repeat the above operations to measure the endfloat on the right hand side gear (Gd). The side gear endfloat will be 0.25 mm. Therefore the rings to be inserted in the differential housing are given by: Ss = Gs -- 0.25 mm for the left--hand side gear; Sd = Gd -- 0.25 mm for the right--hand sun gear. 7. Install shims as near as possible to the calculated value and, using a dial gauge and following the previously described procedure, check that the endfloat of the left-- and right--hand sun gears is approximately 0.25 mm.
87666787A - 11 - 2007
24598
77
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
37
LIM--SLIP SELF--LOCKING DIFFERENTIAL LOCK Operating The differential with limited slip locking (LIM -- SLIP) is of the two planet gear--type, provided with two multi--disk clutch assemblies fitted between the side gears and the differential casing. This differential lock device is totally automatic, requires no manual operation and notably reduces (without completely eliminating) wheel slipping that may result from tractor grip loss. The difference in revolutions, between the sun gears and the differential casing when a wheel begins to slip as a result of grip loss, is impeded by clutch assemblies that are compressed by axial thrusts from the bevel drive torque transmitted to the sun gears by means of the teeth on the two planet gears. These torque values may be different, according to the nature of the ground and the route followed by the tractor, and may vary in intensity thereby proportionally determining the axial stress on the clutches, allowing the sun gears to mesh with the differential casing which, in turn, permits the axle to overcome the unevenness of the ground.
27966
78 LIM--SLIP self--locking differential
OP. 25 102 27 FRONT AXLE DIFFERENTIAL WITH LIM--SLIP UNIT Overhaul
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 1. Remove the bevel drive--differential casing assembly from the front axle, attach to support 380000255 (4), lock in a vice and proceed with disassembly operations as follows. 2. Remove the bolts (2) and the right--hand (Gd) and left--hand ring nut lock plates (3). 3. Check that the right-- and left--hand caps (1) are marked so as not to interchange them during assembly. 4. Remove the right and left--hand bearing adjustment ring nuts (Gd) from the bevel crown wheel. 5. Remove the bolts (C9) and caps (1) and separate the crown wheel from the bevel pinion support. 6. If necessary, unscrew the retaining bolts (C1, page 4) and remove the crown wheel.
79
87666787A - 11 - 2007
38
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
Disassemble the LlM--SLlP self--locking differential lock as follows. 7. Remove the retaining bolts (1) from the differential half--casing. 8. Open the differential casing (6). 9. Remove the half--casing (7) the differential pin (4), complete with the planet gears (3), the thrust washers (2) and the retaining pin (9). 10. Remove the side gear (5), the friction disk (11), the metal disks (10) and the friction disks (12). 11. Remove the side gear (5), the friction disk (11), the metal disks (10) and the friction disks (12) from the half--casing (8). 12. Check the wear on the metal disks (10) and the friction disks (11 and 12, see table below), replacing parts that are near their wear limit. 13. Proceed with self--locking differential assembly operations, carrying out the previously described operations in reverse order, apply LOCTITE 270 to the threads on the screws (1) and tighten to a torque value of 50 Nm (5.1 kgm).
27966
80
LIM--SLIP self--locking differential
14. Refit the crown wheel (if previously disassembled) on the half--casing (8), tightening the bolts (C1, page 4) to a torque value of 113 Nm (11.5 kgm). 15. Check the rolling torque of the bevel pinion, as indicated on page 32. 16. Assemble the crown wheel, complete with LIM--SLIP self--locking differential lock, on the bevel drive support, remembering to fit the previously marked crown wheel bearing support caps in the correct order and assemble and adjust the crown wheel bearings as indicated on page 34.
z 27967
81 Friction parts detail
LIM--SLIP self--locking differential friction disks Item no.
Meaning
Amount
Thickness mm
Maximum wear per disk mm
10
Metal disk
10
1.5
--
11
Friction disk
2
2.8
0.10
12
Friction disk
8
1.6
0.15
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
39
Op. 44 511 80 LEADING DRIVE WHEELS TOE--IN CHECK When travelling in a straight line, the wheels on four--wheel drive models must be parallel to the longitudinal axis of the tractor. A slight toe--in of the front wheels is permissible -- up to a maximum of 6 mm, as measured at the edges of the wheel rims. To check the exact value of the toe--in setting of four--wheel drive tractors, proceed as follows. 1. Inflate the front tyres to the prescribed pressure. 2. Place the steering wheel at mid--travel, with one spoke along the tractor centre line. 3. Check if wheels are parallel to the tractor centre line. 4. Check that the distance (L) between the ball joint (1) and the end of the cylinder (2) is the same on both sides of the steering control cylinder (2). 82 5. Measure the distance (1) between the front inside edges of the rims.
1
6. Turn both front wheels through 180o then, at the height of the wheel hub centres, measure the distance (2) between the rear inside edges of the wheel rims, checking that the new measurement is equal to or greater than distance (1) by a maximum of 6 mm. The rotation of the wheels through 180o is required in order to eliminate the effect on the measurement of any eventual wear on the rims.
2
24666
83 7. If wheel toe--in needs to be adjusted, unscrew the lock nut (1) and screw the ball joint (2) in or out to obtain the prescribed toe--in. During this operation, it is necessary to check that the distance (L, fig. 82) stays the same on both sides of the steering control cylinder (2, fig. 82). After having adjusted the toe--in to within the prescribed limits, tighten lock nut (1).
84
87666787A - 11 - 2007
40
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
Op. 25 108 30 FRONT EPICYCLIC FINAL DRIVE Removal--Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Front epicyclic final drive removal and installation can be carried out with the axle detached and positioned on the stand 380000251, or with the axle fitted on the tractor. If the operation is performed with the axle fitted on the tractor, a support stand must be positioned under the engine sump.
25587
1
1
Proceed as follows. 1. Unscrew the plug (1) and drain the oil from the epicyclic final drive casing.
25589
2 2. Unscrew the left--hand final drive cover (1) retaining bolts. Tighten two pins 50169 (2) and, using an extracting tool screwed into the oil drainage plug hole, remove the cover (1).
2
1
25594
3 3. Remove the securing ring (1) on the wheel hub bearing lock ring (2).
1
2
25597
4 87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
41
4. Remove the lock nut on the wheel hub bearings using wrench 380000295 (1).
1 25598
25598
5 5. Remove the wheel hub (1) together with the epicyclic crown (2). Recover all disassembled parts.
1
2
6. To refit the front epicyclic final drive, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Refer to the instructions on page 7 for the positioning of the various parts.
--
Respect the tightening torque values prescribed on page 3.
--
Assemble the wheel hub and the epicyclic final drive fixed gear.
--
Progressively tighten the ring nut, using the torque wrench and wrench 380000295 (1) to obtain a torque value of 392 Nm (40 kgm); at the same time, rotate the wheel hub to ensure that the bearings are correctly seated.
--
Carefully secure the ring nut.
--
Before reassembling the epicyclic final drive casing, carefully clean and degrease the mating surfaces, then apply sealing compound (approx. 2 mm) along the marked line shown on page 35.
--
Assemble the epicyclic final drive casing, complete with gears.
--
Fill up the front epicyclic final drive (for recommended products and quantities see page 6, Sect. 00).
25599
6
87666787A - 11 - 2007
42
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
Op. 25 108 30 FRONT EPICYCLIC FINAL DRIVE WITH BRAKE Disassembly -- Assembly
1
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Front epicyclic final drive removal and installation can be carried out with the axle detached and positioned on the stand 380000251, or with the axle fitted on the tractor. If the operation is performed with the axle fitted on the tractor, a support stand must be positioned under the engine sump. If the operation is performed with the axle fitted on the tractor, a support stand must be positioned under the engine sump.
25560
7
1
Proceed as follows. 1. Unscrew the plug (1) and drain the oil from the epicyclic final drive casing.
25589
8 2. Unscrew the left--hand final drive cover (1) retaining bolts. Tighten two pins 50169 (2) and, using an extracting tool screwed into the oil drainage plug hole, remove the cover (1).
1
2
25594
9
87666787A - 11 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
43
3. Remove the circlip (1) and extract the external brake disk (2).
10 4. Recover the hub (1) on the brake disk.
1
25563
11 5. Unscrew the retaining bolts and remove the drive fixed gear (1) using two bolts as extractors.
1
6. To refit the front epicyclic final drive, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Refer to the instructions on page 13, Chapter 1 for the positioning of the various parts.
--
Respect the tightening torque values prescribed on page 4, Chapter 1.
--
Refit the drive fixed gear.
--
Refit the brake disk hub.
--
Fit the outer brake disk and secure in position.
--
Before reassembling the epicyclic final drive casing, carefully clean and degrease the mating surfaces, then apply sealing compound (approx. 2 mm) along the marked line shown on page 35.
25562
12
87666787A - 11 - 2007
44
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 2
--
Assemble the epicyclic final drive casing, complete with gears.
--
Fill up the front epicyclic final drive (for recommended products and quantities see page 6, Sect. 00).
87666787A - 11 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
1
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION Chapter 1 -- Rear axle mechanical transmission CONTENT Section
Description
Page
27 000
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
27 100
Removal--Installation--Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BEVEL DRIVE AND DIFFERENTIAL DATA 9/40 = 1:4.4(1) 11/39 = 1:3.54(2)
Bevel drive gear ratio: Clearance between sides of bevel gear pair teeth . . . . . . . . . .
mm
0.18 ÷ 0.23
Type of differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with two side pinions
Mechanically controlled differential lock . . . . . . . . . . . . . . . . . . .
pedal operated
Electrohydraulically controlled differential lock . . . . . . . . . . . . .
controlled by switch located on control panel
Side pinion internal seat diameter (5, fig. 8) . . . . . . . . . . . . . . .
mm
24.040 ÷ 24.061
Side pinion pin diameter(19, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . .
mm
23.939 ÷ 23.960
Clearance between planet pinions and pin . . . . . . . . . . . . . . . .
mm
0.080 ÷ 0.122
Diameter of crown wheel pinion hub seats on differential housing (3, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
44.080 ÷ 44.119
Diameter of crown wheel pinion hubs (17, fig. 8) . . . . . . . . . . .
mm
43.961 ÷ 44.000
Clearance between crown wheel pinion hubs and seats . . . . .
mm
0.080 ÷ 0.158
Bevel gear bearing adjustment and bevel pinion clearance . . Thickness of bearing adjuster rings and bevel gear clearance (21, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1)
30 km/h model -- (2) 40 km/h model.
see pages 21 ÷ 24 mm
0,15 -- 0,20 -- 0,50 (continued)
87666787A - 11 - 2007
2
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 BEVEL DRIVE AND DIFFERENTIAL DATA (overleaf)
Clearance between sides of sun and planet pinion teeth . . . .
mm
0.15
Thickness of differential crown wheel shim adjustment rings (16, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm 1.4 -- 1.5 -- 1.6 -- 1.7 -- 1.8 -- 1.9 -- 2.0
Thickness of differential side pinion shim adjustment rings (4, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
1.470 รท 1.530
Adjustment of clearance between the sun and planet pinion teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
see pages 24 and 25
Adjustment of differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . .
see page 20
Thickness of differential lock control fork adjuster . . . . . . . . . .
mm
0.5
Differential lock control fork spring (Mechanical control): --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
220
--
length of springs under load 177 รท 195 N (18.1 รท 19.9 kg)
mm
157.5
mm
237
Differential lock control fork spring (Electrohydraulic control): --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
spring length under a load of 304 รท 335 N (31.0 รท 34.2 kg) mm
159.5
FINAL DRIVE DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
epicyclic with three side pinions with straight toothing
Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13:(13+65)= 1:6
Thickness of side pinion shim rings (8, fig. 8) . . . . . . . . . . . . . . Adjusting end float of side pinion casing . . . . . . . . . . . . . . . . . . Thickness of axial clearance adjuster rings for side pinion casing (10, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87666787A - 11 - 2007
mm
1 see page 31
mm 4.5 -- 4.6 -- 4.7 -- 4.8 -- 4.9 -- 5.0 -- 5.1 -- 5.2 -- 5.3 -- 5.4 -- 5.5 -- 5.6 -- 5.7 -5.8
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
3
BOLT TORQUES Tightening torque PARTS TO BE TIGHTENED
Thread Nm
kgm
Transmission gearbox -- clutch retaining bolts (C1, fig. 1) . . . . . . .
--
117 ÷ 129
11.9 ÷ 13
Transmission -- PTO casing cover retaining bolt (C2) . . . . . . . . . .
--
20 ÷ 25
2 ÷ 2.5
PTO driven shaft ring nut (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
256 ÷ 309
26 ÷ 31.5
Transmission gearbox lower cover retaining bolts (C4) . . . . . . . . .
--
43 ÷ 51
4.4 ÷ 5.2
Bevel pinion shaft ring nut (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
280 ÷ 309
28.5 ÷ 31.5
Gear driven shaft bearings retaining bolts (C6) . . . . . . . . . . . . . . .
--
84 ÷ 93
8.6 ÷ 9.5
Bevel crown wheel retaining bolt (C7) . . . . . . . . . . . . . . . . . . . . . . .
--
131 ÷ 144
13.3 ÷ 14.7
Reduction shaft bearings support retaining bolts (C8) . . . . . . . . . .
--
47 ÷ 51
4.8 ÷ 5.2
Reduction gearbox -- transmission gearbox retaining bolts (C9) .
--
135 ÷ 149
13.8 ÷ 15.2
Drive wheel axle retaining bolts (C10) . . . . . . . . . . . . . . . . . . . . . . . .
--
285 ÷ 345
29 ÷ 35.2
Plate disk -- drive wheel hub retaining bolt (C11) . . . . . . . . . . . . . .
--
310
31,6
Plate disk -- drive wheel rim ring nut (C12) . . . . . . . . . . . . . . . . . . . .
--
217 ÷ 262
22 ÷ 26.7
87666787A - 11 - 2007
4
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 BOLT TORQUES
C2 -- 20 B 25 Nm C1 -- 117 ÷129 Nm
Z=43
C6 -- 84 ÷93 Nm
C5 -- 280 ÷ 309 Nm
C7 -- 131 ÷144 Nm
C4 -- 43 ÷51 Nm
C8 -- 47 ÷51 Nm
C3 -- 256 ÷ 309 Nm
C9 -- 135 ÷149 Nm C10 -- 285 ÷345 Nm
C11 -- 264 ÷319 Nm C12 -- 217 ÷ 262 Nm
25999
1
87666787A - 11 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 SPECIAL TOOLS Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual.
5
List of specific tools required for the various operations described in this Sect. 380000227
Clutch casing lift hook.
380000301
Turning stand for overhaul.
380001626
Grooved wrench for bevel gear.
24663
2 Tool to be made for removal--installation of the final drives, to be used with 50114. (Mark the tool with no. 50091 -- Measurements in mm) Make in Aq 42 D material. 1. Make no. 2 tie--rods in C 40 bon material.
87666787A - 11 - 2007
6
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
26258
3 Tool to be made for removal--installation of the final drives, to be used with a part of 50091. (Mark the tool with no. 50114 -- Measurements in mm) Make in Fe 42 C material -- (*) Measurement according to hoist seat.
26260
4 Tool to be constructed for adjusting differential lock sleeve travel. (Mark the tool with no. 50041 -- Measurements in mm) Make using C40 material.
87666787A - 11 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
7
26000
5 Tool to be constructed for securing the transmission gearbox to the rotating stand. (Mark part with No. 50156 -- Measurements in mm) Construct in Aq 42 material -- (1) Rotating stand axle
87666787A - 11 - 2007
8
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
6 Series of guide pins (no. 2) to be constructed for differential support removing--refitting. (Mark the pins with no. 50164 -- Measurements in mm) Make using C40 material
87666787A - 11 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
1
2
3
11
10
9
4
9
8
7
6
5
26001
7 Longitudinal section of gearbox--transmission 1. 2. 3. 4. 5. 6.
Gearbox driving shaft. PTO control shaft. Gearbox driving gear. Crown wheel. Bevel Pinion Shaft. Gearbox low -- mid -- upper range gear engagement sleeve.
7. 8. 9. 10. 11.
Low -- mid driven gear shaft. Low -- mid -- upper range gear engagement. Gearbox driven shaft. 1st and 2nd gear engagement synchroniser. 3rd and 4th gear engagement synchroniser.
87666787A - 11 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
10
1
2
3
4
5
6
7
8
9
10
11
12
A B
16 21
20
19
18
15
14
13
17
26002
8 Sectional view of transmission A. 8.1 รท 8.2 mm. Differential lock engage sleeve travel. B. 0.2 รท 0.4 mm. Final drive planet pinion support end float. 1. Bevel crown wheel bearing support. 2. Differential lock control fork. 3. Differential cage. 4. Shim ring. 5. Planet gear. 6. Differential lock spring. 7. Bevel crown wheel bearing support. 8. Shim rings. 9. Differential output half shaft. 10. Planet gear casing support (13) end float adjuster shim.
87666787A - 11 - 2007
11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Wheel half--axle. Seal. Final drive planet gear support. Final drive planet gear. Bearing. Sun gear clearance adjuster ring. Side gear. Crown wheel. Side pinion pin (5). Differential lock engagement sleeve. Adjuster rings for bearings and coupling clearance between ring bevel gear and pinion.
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
1
2
3
4
11
5
26269
Rear differential lock disengaged
1
2
3
4
5
26270
Rear differential lock engaged Pressurised oil Discharge oil
9
HYDRAULICALLY CONTROLLED REAR DIFFERENTIAL LOCK When the differential lock is not needed, it is kept disengaged by spring (4), which exerts a force on fork (3). The relevant switch on the control panel activates the solenoid valve that directs the oil from the pump to the compartment (1). Inside the compartment the oil acts on the piston (2) and, overcoming the resistance of spring (4), moves
rod (5), fork (3) and the sleeve, thereby engaging the differential lock. When the switch is pressed to disengage the differential lock, spring (4) exerts a force on fork (3), rod (5) and piston (2), which discharges the oil through the corresponding solenoid valve.
87666787A - 11 - 2007
12
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 DESCRIPTION AND OPERATION
The rear transmission transmits drive from the gearbox to the lateral final drives by means of the bevel gear pair. The bevel gear pair is of the helical tooth type and is supported by taper--roller bearings. The differential has two side pinions and is fitted with a mechanically or hydraulically operated differential lock.
The lateral final drives are of the epicyclical type and are operated by the bevel gear pair output half shafts, the same shafts that control the service brakes.
BEVEL DRIVE AND DIFFERENTIAL TROUBLESHOOTING Problems
Possible Problem
Solutions
Transmission is noisy while the 1. Incorrect adjustment or wear Remove the rear transmission tractor is moving, even when the of sun and side pinions. gearbox and replace the worn parts, gears are in neutral (not due to then correctly adjust the differential final drives). gears (page 24). 2. Excessive clearance between Remove the rear transmission casing half--shaft keyed groove and and replace the damaged parts. sun gears. Transmission is noisy when 1. Internal part faulty. tractor is under or released from load.
Remove the rear transmission gearbox and replace the worn parts, then correctly adjust the differential gear clearance (page 24).
Transmission noisy and assembly 1. Insufficient coupling Remove the rear transmission overheats. clearance between the teeth gearbox and correctly adjust the ring of the pinion and of the bevel bevel gear bearings (page 21). crown wheel.
FINAL DRIVE FAULT DIAGNOSIS Problems
Possible Problem
Final drives are noisy while the 1. Internal part faulty. tractor is moving, even when the gears are in i neutral. t l 2. Excessive clearance between wheel axle shaft spline and epicyclic final drives.
87666787A - 11 - 2007
Solutions Remove the final drive housing and replace the damaged parts. Remove the final drive housing and replace the damaged parts.
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
13
HYDRAULICALLY CONTROLLED DIFFERENTIAL LOCK TROUBLESHOOTING Problems The differential lock engage engage.
Possible Problem fails
to 1. Transmission oil level low.
Solutions Top up oil.
2. Clogged oil filter.
Replace filter.
3. Hydraulic pump faulty.
Overhaul or replace the pump.
4. Faulty differential switch.
Replace switch.
5. Lack of power supply to the Check electrical connections and solenoid valve: connections replace defective parts. loose or damaged, contactor faulty. 6. Differential lock control Overhaul or replace solenoid valve. solenoid valve jammed in discharge position. 7. Oil leakage through the seals Replace damaged seals. with consequent pressure drop: cylinder piston or feed pipe seals. Differential lock fails to disengage. 1. Faulty differential lock--unlock Replace switch. switch. 2. Differential lock solenoid valve Overhaul or replace solenoid valve. jammed in delivery position. 3. Disengage spring faulty. With the differential lock engaged 1. Differential lock control and the control switch in the switch (connected to automatic position, the differential LIFT--O--MATIC device) lock does not disengage when the defective. lift arms are raised with the LIFT--O--MATIC device.
Remove the hydraulic lift and replace the spring. Replace switch.
With the differential lock engaged, 1. Differential lock control switch Replace switch. it cannot be disengaged by (connected to brake pump) operating the brake pedals. defective.
87666787A - 11 - 2007
14
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
Op. 27 106 16 REAR TRANSMISSION GEARBOX Disassembly--Assembly
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. To remove the gearbox, proceed as follows. 1. Carry out operation 90 150 10: Cab with platform unit, only removal (see Section 90, Chapter 1). 2. Carry out operation 21 118 10 or 21 118 12: Rear transmission--gearbox, only removal (see Section 21, Chapter 1). 3. Carry out operation 21 118 85: Gearbox transmission casing, only removal of gearbox from casing (see Section 21, Chapter 1). 4. Carry out operation 31 112 20: Mechanically engaged PTO, only removal (see Section 31, Chapter 1).
26003
5. Remove the pin (1) from the differential lock fork (2).
10
6. Unscrew the retaining bolts (1) differential lock rod (2) stop plate.
26004
11 7. Extract the differential lock rod (1) removing the fork (2) and the return spring (3) from inside the transmission gearbox.
26005
12
87666787A - 11 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
15
8. Remove the control piston (1) of the differential lock rod.
26006
13 9. Unscrew the retaining bolts (1) that support the ring bevel gear (2), removing the supports and adjuster shims.
26007
14 10. Remove the ring bevel gear (1) from inside the transmission gearbox.
26008
15 11. Extract the two stop pins (1) of the final drive control.
26009
16 87666787A - 11 - 2007
16
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
12. Unscrew the rod support retaining bolts (1).
26010
17 13. Extract the retaining pins (1) of the fork and final drive control nib.
26011
18 14. Remove the two rods (1), the forks and the final drive control nib (2) with the relative poppet balls and return spring from the front section of the transmission gearbox.
26012
19 15. Remove the retaining circlip (1) from the pinion shaft rear gear (2).
26013
20 87666787A - 11 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
17
16. Remove the pinion shaft rear gear (1).
26014
21 17. Remove the pinion ring nut safety tab pressure washer (1).
26015
22 18. Rotate the transmission gearbox (3) through 180°. Fit tool 380001626 (1) on the rear of the pinion shaft, position the 55 mm wrench (2) on the internal ring nut; using tool 380001626 unscrew the ring nut and take out the pinion shaft from the rear of the transmission gearbox.
26016
23 19. Remove the gears (1) transmission gearbox.
from
inside the
20. To refit the various parts in the rear transmission gearbox, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
26017
24 87666787A - 11 - 2007
18
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
--
With the transmission gearbox facing upwards, place the gears and the pinion shaft in the housing, via the opening on the PTO housing.
--
Position the ring bevel gear inside the transmission gearbox, fit the LH ring bevel gear support with the 0.5 mm test shim.
--
Insert the 55 mm wrench on the internal ring nut; using a dynamometric wrench and tool 380001626, move the end of the pinion so as to tighten the ring nut to a torque of 280 รท 309 Nm (28.5 รท 31.5 kgm) and squeeze the safety washer.
--
Adjust the ring bevel gear bearings and the clearance between the sides of the ring bevel gear teeth, as described on pages 21 รท 24.
--
Fit the differential lock rod with the fork control piston and return spring.
--
Insert the remaining gears on the pinion shaft.
--
--
Fit the two rods, forks and final drive nib.
Adjust the position of the differential lock engagement sleeve as described on page 20.
--
Check the rolling torque of the pinion, as described on page 21.
--
Carry out operation 31 112 20 Mechanically engaged PTO, only installation (see Sect. 31, Chapter 1).
--
Fit the rods, the pinion shaft sleeve forks and the drive shaft sleeve with relative poppet balls and return spring and the rod limit switch pins.
--
Carry out operation 21 118 85: Transmission gearbox, only installation of gearbox in housing (see Section 21, Chapter 1).
--
Before fitting the ring bevel gear, check and (if necessary) adjust the clearance between the side pinion teeth and the crown wheels, as described on page 24.
--
Carry out operation 21 118 10 or 21 118 12 Rear transmission housing--gearbox, only installation (see Section 21, Chapter 1).
--
Carry out operation 90 150 10: Cab with platform unit, only installation (see Section 90, Chapter 1).
87666787A - 11 - 2007
Sealing compound application diagram for rear transmission--gearbox casing The types of sealing compound are indicated on page 1, Section 00
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 19
27153
27153
87666787A - 11 - 2007
20
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
Op. 27 110 10 Adjusting the position of differential lock engagement sleeve
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Fit the differential lock control device (mechanically operated model) or the plate (hydraulically operated model) without the adjuster shim. 2. Insert gauge 50041 (2, see page 6) with the 8.1 รท 8.2 mm shim between the sleeve and the differential housing, so that it makes contact with the sliding surfaces of the sleeve on the housing. 3. Using a crowbar, bring the sleeve into contact with gauge 50041 and the differential casing, adjusting the fork (1) to the position of the gauge. 26018
25 4. Using a feeler gauge(1), measure the clearance between the control pin (2) and the seat on the rod (3) (mechanically operated model.
26019
26 5. Using a feeler gauge (1), measure the clearance between the plate (2) and the seat on the rod(3)(hydraulically operated model. 6. Position the required shim under the differential lock control device (mechanically operated model) or under the plate (2) (hydraulically operated model) and secure in position using the bolts.
26020
27
87666787A - 11 - 2007
SECTION 27 - REAR AXLE MECHANICAL TRANSMISSION - CHAPTER 1
21
ADJUSTING THE BEVEL GEAR PAIR Adjusting the bevel crown wheel bearings and checking the clearance between the sides of the bevel drive teeth
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
Proceed as follows. 1. Fit the bevel pinion, together with the relevant parts, and tighten the ring nut to a torque of 280 รท 309 Nm (28.5 รท 31.5 kgm). 2. Check that the pinion rolling drag torque is 0.040 รท 0.450 kgm, corresponding to a dynamometric force on the mid-upper driven gear range of 5.9 รท 62.8 N (0.6 รท 6.4 kg). 3. With the bevel pinion fitted, insert the differential assembly complete with the bevel crown wheel. Screw the left-hand ring nut (1) onto the gearbox-transmission casing. 26021
28
87666787A1 - 03 - 2008
22
SECTION 27 - REAR AXLE MECHANICAL TRANSMISSION - CHAPTER 1
4. Set the right-hand ring nut on the gearbox-transmission casing and screw it on. 5. Tighten the ring nut gradually, turning the crown wheel at the same time to allow the bearings to settle, until you reach a tightening torque of 39 Nm (4 kgm). Under these conditions you should be at the position of the minimum rolling value of the bevel crown wheel bearings that is the result of the rolling torque measured for just the pinion added to the values given in the table. 26023
CROWN WHEEL ROLLING 9/40
9/38
0.045 ÷ 0.100 kgm 0.44 ÷ 0.98 Nm
11/39
11/36
0.060 ÷ 0.140 kgm 0.59 ÷ 1.37 Nm
11/32 0.070 ÷ 0.160 kgm 0.68 ÷ 1.57 Nm
This torque can be measured with a dynamometer (1) and cord wrapped around the mid-upper gear drive and corresponds to a force on the dynamometer for the single pinion, added to the values shown on the table. CROWN WHEEL ROLLING 9/40
9/38
0.6 ÷ 1.4 kg 5.9 ÷ 13.7 N
11/39
11/36
0.8 ÷ 2.0 kg 7.8 ÷ 19.6 N
11/32 1.0 ÷ 2.3 kg 9.8 ÷ 22.8 N
Tighten the ring nut further to bring the safety screw onto one of the three holes, then tighten the safety screw.
87666787A1 - 03 - 2008
29
SECTION 27 - REAR AXLE MECHANICAL TRANSMISSION - CHAPTER 1 6. Using a dial gauge (1), check the clearance between the sides of the teeth of the bevel gear pair (four measurements at 90° and the arithmetic mean of the four readings) and compare the mean of the four values with the normal prescribed clearance: 0.15 ÷ 0.50 mm.
23
1
NOTE: The difference between the four readings must be 3 0.06 mm.
26026
30
87666787A1 - 03 - 2008
24
SECTION 27 - REAR AXLE MECHANICAL TRANSMISSION - CHAPTER 1
Adjustment of the clearance between the sun and planet pinion teeth
1
2
3
4
5 6
With the differential disassembled on the bench, proceed as follows. 7. Fit the two crown wheels (2 and 5) without rings (1 and 6) on the differential casing. Insert the side pinions (3 and 8) complete with fifth wheel ring adjustment and pin (7); turn the retaining bolt (4) a few times to prevent the pin from sliding out.
7 8 25920
31 8. Manipulate the LH crown wheel, so that it comes into contact with the side pinion and, using a depth micrometer, measure the distance (H1), taking two diametrically opposed measurements, taking the arithmetic means of the two values measured.
H1 25921
32
87666787A1 - 03 - 2008
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
25
14. Push the crown wheel so that it touches the differential and measure the distance (H2). 15. Repeat the same operations for the RH side gear.
H2
25922
38 16. The axial movement of the crown wheels (2 and 5) without adjustment rings is given by:
1
Gs or Gd = H1 -- H2
2
3
4
5 6
where: Gs = axial movement of LH crown wheel; Gd = axial movement of RH crown wheel;
7
H1 and H2 = are the LH or RH sun gear measurements.
8
The normal clearance envisaged between the sides of the side pinion teeth is 0.15 mm.
25920
39
Therefore, the normal clearance and the equivalent axial movement of the sun gears has an average ratio of 1:1.7. The axial movement of the side gears corresponding to the normal clearance is: 0.15x1.7 = 0.25 mm. Therefore the adjustment rings (1 and 6) to insert on the differential housing will be given by: Ss = Gs -- 0.25 mm ( for LH crown wheel). Sd = Gd -- 0.25 mm (for RH crown wheel). Insert the adjustment rings obtaining a distance which is as close as the value thus obtained (the available values are listed on page 2).
87666787A - 11 - 2007
26
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
Op. 27 120 10 -- 27 120 20 RH OR LH FINAL DRIVE CASING ASSEMBLY Removal--Installation
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted. Proceed as follows. 1. Lock the front wheels using chocks. 2. Using a hoist and cable (1) raise the rear part of the tractor, positioning a fixed stand under the towing hook, then remove the right--hand wheel (2).
27837
40 3. Unscrew the plug and drain the oil from the rear transmission casing (the prescribed quantity is 42 litres).
25628
41 4. Position a wooden block (1) between the cab (2) and the lift body (3)
27838
42
87666787A - 11 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
27
5. Unscrew the cab (2) retaining bolts (1) and the pin, then remove together with the securing bracket.
27839
43 6. Unscrew the stabiliser strut bracket retaining bolts (1).
27840
44 7. Attach tool 50091 (1) and adapter 50114 (2) to the final drive body.
27841
45 8. Position a hydraulic jack (2) under the gear unit, unscrew the retaining bolts and, using the jack (2), remove the right--hand gear unit (1) and the spacer.
27842
46 87666787A - 11 - 2007
28
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
9. Extract the axle shaft (1) from the brake disk and differential. 10. To refit the final drive casing, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Before refitting the housings, supports and covers clean and de--grease the mating surfaces and apply sealing compound (approx. 2 mm in diameter) as shown in figure 48.
--
Insert the axle--shaft in the brake disk and differential.
--
Using tools 50091, 50114 and a hydraulic jack, refit the lateral final drive unit to the rear transmission gearbox.
--
Fit the lateral stabiliser strut bracket.
--
Fit the pin to the lateral final drive housing.
--
Fit the cab to the pin.
--
Mount the rear RH wheel.
--
Remove the wooden block, remove the fixed stand from under the towing hook and unhook the hoist.
--
Screw the plug on the rear transmission casing and fill up with oil (see page 6, Sect. 00 for prescribed products and quantities).
87666787A - 11 - 2007
27843
47
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
29
27154
48 Diagram of seal compound application for brake assembly and final drives on the transmission casing. The types of sealing compound are listed on page 1, Sect. 00.
Op. 27 120 34 DRIVE WHEEL SHAFT Disassembly--Assembly
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. With the final drive casing removed from the rear transmission, proceed as follows. 1. Remove the drive wheel shaft lock bolt safety plate (1).
26030
49
87666787A - 11 - 2007
30
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
2. Unscrew the bolts securing the driven gear support (1) on the drive wheel shaft and remove the safety plate.
26031
50 3. Extract the support (1) from the driven gears and remove the end float adjuster shim from the support.
26032
51 4. Connect the lateral final drive (1) to a hoist (2) and raise, checking that the wheel axle leaves the housing (tap on the end of the driving gear axle with a rubber mallet to ease it out).
26033
52 5. Remove the seal (1). 6. To refit the final drive casing, proceed as follows.
ATTENTION
1
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
For the positioning of the various parts refer to figures 7 and 8. 24614
53 87666787A - 11 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 --
Respect the tightening torques prescribed on page 3.
--
Fit the seal using a suitable drift.
--
Assemble the drive wheel shaft.
--
Fit the driven gear support and the relative adjuster shim.
--
Insert the safety plate and tighten the bolt to the prescribed torque.
--
Adjust the end float of the gear support as follows.
7. Using a dial gauge (1), check that the axial clearance of the support (2) is 0.2 รท 0.4 mm; if not, adjust the shim (10, fig. 8).
31
26034
54 NOTE: The adjustment shims are listed on page 2.
Op. 27 120 32 EPICYCLIC FINAL DRIVE Removal--Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. With the assembly detached from the housing, proceed as follows. 1. Remove circlip (1). 2. Extract the pins and remove the gears, complete with the roller bearings. 3. Fit all the parts of the epicyclic final drive, reversing operations 1 and 2.
24620
55
87666787A - 11 - 2007
32
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
87666787A - 11 - 2007
SECTION 31 -- MECHANICAL POWER TAKE--OFF -- CHAPTER 1
1
SECTION 31 -- MECHANICAL POWER TAKE--OFF Chapter 1 -- Mechanical power take--off CONTENT Section
Description
Page
31 000
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Bolt Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
31 112 20
Mechanical power take--off. Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPECIFICATIONS 540 rev/min power take--off Type (two functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) independent in relation to tractor speed or: 2) synchronized to gearbox
Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mechanical, by means of hand lever located under the steering wheel (RH side) (see page 9 and 10)
Direction of rotation (from tractor rear) . . . . . . . . . . . . . . . . . .
clockwise
Engine speed with PTO at 540 rpm . . . . . . . . . . . . . . . . . . . .
rpm
1957
PTO revolution speed with engine at max. power of 2300 rpm: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- PTO 540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rpm
634
540 rpm, gearbox synchronized, PTO revolution speed (30 km/h model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
revs/ wheel rev
16.69
540 rpm, gearbox synchronized, PTO revolution speed (4WD 40 km/h model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
revs/ wheel rev
12.94
Diameter of driven shaft at grooved terminal . . . . . . . . . . . .
13/8â&#x20AC;? (6 grooves) (continued)
87666787A - 11 - 2007
2
SECTION 31 -- MECHANICAL POWER TAKE--OFF -- CHAPTER 1 SPECIFICATIONS (overleaf)
540/540E rpm power take--off Type (two functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) independent in relation to tractor speed or: 2) synchronized to gearbox
Engagement and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mechanical, by means of hand lever located under the steering wheel, on RH and LH side of driver’s position (see page 9 and 10)
Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of hand lever located on the rear LH side of the transmission or (on request) with lever to the operator’s left
Direction of rotation (from tractor rear) . . . . . . . . . . . . . . . . . .
clockwise
Engine speed with PTO at 540 rpm . . . . . . . . . . . . . . . . . . . .
rpm
1957
Engine speed with PTO at 540E rpm (750 rpm) . . . . . . . . . .
rpm
1535 (2132)
PTO revolution speed with engine at max. power of 2300 rpm: -- PTO 540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- PTO 540E rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rpm rpm
634 809
540 rpm, gearbox synchronized, PTO revolution speed (30 km/h model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
revs/ wheel rev
16.69
540 rpm, gearbox synchronized, PTO revolution speed (4WD 40 km/h model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
revs/ wheel rev
12.94
PTO revolution speed (540E rpm) synchronized with gearbox (30 km/h model) . . . . . . . . . . . . . . . . . . . . . . . . . .
revs/ wheel rev
21.29
PTO revolution speed (540E rpm) synchronized with gearbox (40 km/h model) . . . . . . . . . . . . . . . . . . . . . . . . . .
revs/ wheel rev
16.50
mm
49.938 ÷ 50.000
Diameter of driven shaft at bearings . . . . . . . . . . . . . . . . . . . Diameter of driven shaft at grooved terminal . . . . . . . . . . . .
13/8” (6 grooves) (continued)
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SECTION 31 -- MECHANICAL POWER TAKE--OFF -- CHAPTER 1
3
SPECIFICATIONS (overleaf)
PTO 540/540E/1000 rpm (optional for all models) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
same as PTO 540/540E rpm
Engagement and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
same as PTO 540/540E rpm
Direction of rotation (from tractor rear) . . . . . . . . . . . . . . .
same as PTO 540/540E rpm
Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of hand lever located on the rear LH side of the transmission or (on request) with lever to the operator’s left
Engine speed with PTO at 540 rpm . . . . . . . . . . . . . . . . . . . .
rpm
1957
Engine speed with PTO at 540E rpm (750 rpm) . . . . . . . . . .
rpm
1535 (2132)
Engine speed with PTO at 1000 rpm . . . . . . . . . . . . . . . . . . .
rpm
2125
rpm rpm rpm
634 809 1082 see power take off 540/540E rpm
PTO revolution speed with engine at max. power of 2300: -- PTO 540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- PTO 540E rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- PTO 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For PTO revolution speed (540/540E rpm) synchronized with gearbox (30 and 40 km/h models) . . . . . . . . . . . . . .
revs/ wheel rev
PTO revolution speed (1000 rpm) synchronized with gearbox (30 km/h model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
revs/ wheel rev
28.47
PTO revolution speed (1000 rpm) synchronized with gearbox (4 WD 40 km/h model) . . . . . . . . . . . . . . . . . . . . . . .
revs/ wheel rev
22.07
Diameter of driven shaft at grooved terminal: -- 540 rev/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 540E rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- speed of 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External diameter of driven gear support bushings . . . . . . .
rpm rpm rpm mm
13/8” (6 grooves) 13/8” (6 grooves) 13/8” (21 grooves) 45.925 ÷ 45.950
Internal diameter of driven gears . . . . . . . . . . . . . . . . . . . . . .
mm
46.050 ÷ 46.075
Clearance between driven gears . . . . . . . . . . . . . . . . . . . . . .
mm
0.100 ÷ 0.150
Diameter of driven shaft at front and central bushings . . . .
mm
37.966 ÷ 37.991
Diameter of driven shaft at rear bushing . . . . . . . . . . . . . . . .
mm
34.966 ÷ 34.991
Internal diameter of front and central bushings . . . . . . . . . .
mm
38.000 ÷ 38.039
Internal diameter of rear bushing . . . . . . . . . . . . . . . . . . . . . .
mm
34.000 ÷ 34.039
Clearance between shaft and front and centre bushings . .
mm
0.009 ÷ 0.073
Clearance between shaft and rear bushing . . . . . . . . . . . . . .
mm
0.009 ÷ 0.073
87666787A - 11 - 2007
4
SECTION 31 -- MECHANICAL POWER TAKE--OFF -- CHAPTER 1
SPECIAL TOOLS
Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual. X 380001609
Drift for PTO driving shaft roller bearings.
X 380001610
Hand grip (with 380001609).
X 380001611
Grooved guide for synchronized PTO shaft hub installation.
1
Tool to be made to remove--install the PTO shaft (Mark tool with no. 50159 -- Measurements in mm) Construct in C40--(1) material CH 36 hexagonal.
26636
1
87666787A - 11 - 2007
SECTION 31 -- MECHANICAL POWER TAKE--OFF -- CHAPTER 1
5
BOLT TORQUES
C2 --25 Nm
C--21Nm 1 C --294Nm 27853
C4 -- 294 Nm
C1 -- 21 Nm
26038
540 rev/min power take--off
2
540/540E rpm power take--off
BOLT TORQUES
PARTS TO BE TIGHTENED
Thread
Bearing support retaining bolts (PTO 540/540E and 540/1000 rpm) . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torque Nm
kgm
M 12 x 1.25
98
10
PTO cover retaining bolts (C1, pages 5 and 6) . . . . . . . . . . . . . . . .
--
21
2
PTO guard retaining bolts (C2, pages 5 and 6) . . . . . . . . . . . . . . .
M 8 x 1.25
25
2,6
Self locking nuts for securing grooved terminal C3, page 6 for 540/540E/1000 rpm PTO) . . . . . . . . . . . . . . . . . . . .
M 12 x 1.25
162
16,5
Nut locking driven gear shaft: (C4) for 540 rpm and 540/540E rpm PTO . . . . . . . . . . . . . . . . . . . . (C4, page 6) for 540/540E/1000 rpm PTO . . . . . . . . . . . . . . . . . . . .
M 32 x 1.5 M 28 x 1.5
294 294
30 30
87666787A - 11 - 2007
SECTION 31 -- MECHANICAL POWER TAKE--OFF -- CHAPTER 1
6
C2 -- 25 Nm
C3 -- 162 Nm
26639
C4 -- 294 Nm
C1 -- 21 Nm
3 540/540E/1000 rpm power take--off
87666787A - 11 - 2007
SECTION 31 -- MECHANICAL POWER TAKE--OFF -- CHAPTER 1
7
2 3 4
1
5
21 21
6
17 20 19 18
13 16
11 27854
14
7 8
A
26041
10
9
B
4 Longitudinal sectional diagram of 540 rpm and 540/540E rpm PTO A. B. 1. 2. 3. 4. 5. 6. 7. 8. 9.
Sectional diagram of 540 rpm PTO. Sectional diagram of 540/540E rpm PTO. 540 rpm PTO cover. 540/540E rpm PTO cover. Drive shaft bearings. Driven shaft bearings. Sealing Washer. Grooved terminal 540/540E rpm. PTO cover retaining bolt. Rear transmission casing. Driven gears support bushings.
10. 11. 13. 14. 16. 17. 18. 19. 20. 21.
Rear bearing support. 540 rpm driven gear. PTO cover retaining bolts. Nut locking driven gear shaft. Fixed gear. Grooved terminal. Coupling sleeve. 540 rpm driven gear. 540E rpm driven gear. Driving gear.
87666787A - 11 - 2007
SECTION 31 -- MECHANICAL POWER TAKE--OFF -- CHAPTER 1
8
1
2 35X80X21
3
26042
4
5
6
12 11 7
10
26043
9
8 5
Sectional view of 540 -- 540E -- 1000 rpm PTO 1. 2. 3. 4. 5. 6.
Input Shaft. Guard. Thrust washer. Driven gears. Thrust washer. Seal.
87666787A - 11 - 2007
7. 8. 9. 10. 11. 12.
Driven gear bushings. Coupling sleeve PTO 540/540E rpm. 1000 rpm PTO coupling sleeve. Driven shaft lock nut. Driven shaft. Grooved terminal.
SECTION 31 -- MECHANICAL POWER TAKE--OFF -- CHAPTER 1
9
DESCRIPTION AND OPERATION OF MECHANICAL PTO The PTO (1) installed on the tractor transfers motion to the transported or towed implements. Control is either directly from the engine clutch or from the gearbox clutch. Mechanically engaged/disengaged PTO devices are available in three versions: --
(standard) one speed, 540 rpm.
--
(optional) two synchronized.
--
speeds,
540/540E
r.p.m. 6
(optional) three speeds, 540/540E/1000 r.p.m. synchronized.
PTO controlled directly from the engine clutch Proceed as follows: --
engage the clutch by moving the control lever (1) to position (A).
When engaged, the PTO grooved terminal rotates.
7 In these conditions PTO operation is completely independent from the tractor travel, therefore: --
stop the tractor without stopping the power take--off;
--
stop the power take--off without stopping the tractor (by disengaging the power take--off clutch).
--
B
To disengage the power take--off, move the control lever (1) into position (B). 8
87666787A - 11 - 2007
10
SECTION 31 -- MECHANICAL POWER TAKE--OFF -- CHAPTER 1
PTO synchronized with gearbox (mechanically controlled models) Proceed as follows: --
disengage the clutch control lever (1, fig. 7);
--
with the tractor stationary, fully press the engine gear clutch pedal;
A
--
wait briefly, then move the lever (1) to position (B) and release the engine gear clutch pedal.
B 26502
9 PTO synchronized with gearbox Power--Shuttle/Dual Command (2 Speed Power Shift) models. Proceed as follows: --
disengage the clutch control lever (1, fig. 7);
--
with the tractor stationary, move the mode selection lever (1, fig. 9) to position (B).
In these conditions the PTO coupling sleeve (3) is directly driven by the toothed coupling of the gearbox gear (1).
1
When the tractor is stationary, the synchronized PTO does not rotate; reverse the direction of rotation of the output shaft by moving from forward gear to reverse.
2
3
ATTENTION Do not engage the synchronized PTO when the tractor is moving. Select 1000 rpm PTO for engine axle trailers.
NOTE: For models with mechanical gearboxes, when the PTO is not in use, keep the clutch lever (1, fig. 8) in position (B) and the control lever (1, fig. 9) in position (A).
87666787A - 11 - 2007
26044
10
SECTION 31 -- MECHANICAL POWER TAKE--OFF -- CHAPTER 1
11
Selecting the speed with the lever To select the PTO speed, move the lever (1) to the required position (2) and secure the lever (1) in the groove. This activates the internal cam device that, by means of coupling sleeves (8 and 9, fig. 5), selects the speed of the power take--off.
540 540E
1000
26325
11 With the lever (1) in the central position (A), the grooved PTO terminal will not rotate (two speed PTO).
A 540
540E
26083
12 Power take--off two or three speed selection from the driving seat (on request) To select the power take--off speed, proceed as follows: --
pull the stop ring (1) upwards;
--
position lever (2) on the required speed.
NOTE: For the two--speed version, the neutral power take--off position is on 540E/540 (central).
540
540
1000
540E
540E
540 540E 13
MECHANICAL PTO TROUBLESHOOTING Problems
Possible Problem
Solutions
Slipping with speed loss on PTO Wear of clutch disk or of engine Check the data on the appropriate pagrooved terminal. flywheel pressure plate. ges in Sect. 18, replace the worn Incorrect adjustment of PTO parts and adjust the clutch lever. clutch lever. Difficulty in selecting PTO speed External control stiff or incorrectly Lubricate the control cable sheath. by means of lever 1, fig. 11. adjusted. Adjust the control.
87666787A - 11 - 2007
12
SECTION 31 -- MECHANICAL POWER TAKE--OFF -- CHAPTER 1
Op. 31 112 20 MECHANICAL PTO Removal--Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 1. Carry out operation 90 150 10: Cab with platform unit, only removal (see Section 90, Chapter 1). 2. Carry out operation 21 118 10 or 21 118 12: Rear transmission--gearbox, only removal (see Section 21, Chapter 1). 3. Remove the securing ring and extract the PTO drive shaft rear cover (1). 26046
14 4. Remove the front and rear rings (1) securing the external PTO gearbox and remove the end of the drive shaft.
26047
15 5. Remove the external PTO gear (1), through the cover opening, together with the gear control rod and final drive.
26048
16
87666787A - 11 - 2007
SECTION 31 -- MECHANICAL POWER TAKE--OFF -- CHAPTER 1
13
6. From the same opening, also remove the synchronized PTO gear (1).
26049
17 7. Remove the ring and extract the front PTO shaft (1) recovering the synchronized PTO driven gear.
1
26050
18 8. Remove the retaining pins (1) securing the control lever (2).
26051
19 9. Remove the PTO driven shaft lock nut, using the grooved wrench 50159 (1) and remove the driven shaft.
26052
20 87666787A - 11 - 2007
14
SECTION 31 -- MECHANICAL POWER TAKE--OFF -- CHAPTER 1
10. Unscrew the retaining bolts (1) from the PTO cover (2) and remove the cover by means of the internal revs selection rod.
26053
21 11. Remove the external pin (2) and extract the PTO revs selection rod (1).
26054
22 12. Remove the speed selection control cam, gears and levers from the PTO housing. 13. To re--fit the PTO, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Fit the control levers and PTO gears in their seats. 26055
23 --
Fit the PTO revs selection rod and insert the rod securing pin.
--
Fit the internal revs selection rod and the PTO cover, securing in position with the bolts.
--
Fit the driven shaft in the PTO housing, tightening the driven shaft lock nut with grooved wrench 50159.
--
Fit the control lever securing pin.
87666787A - 11 - 2007
SECTION 31 -- MECHANICAL POWER TAKE--OFF -- CHAPTER 1 --
Insert the front PTO shaft, using the grooved guide for fitting the synchronized PTO gear shaft hub N° 380001611 (1). When the gear is in its seat, remove the grooved guide. Fit the retaining ring on the shaft.
--
Insert the driven gear and the PTO external gear from the cover hole, with gearbox command rods and final drive.
--
Insert the terminal part of the drive shaft and install the front and rear external PTO gear securing rings.
--
Install the rear drive shaft cover and the respective fastening ring.
--
Carry out operation 21 118 10 or 21 118 12 Rear transmission housing--gearbox, only installation (see Section 21, Chapter 1).
--
Carry out operation 90 150 10 : Cab with platform unit, only installation (see Section 90, Chapter 1).
15
26056
24
87666787A - 11 - 2007
16
SECTION 31 -- MECHANICAL POWER TAKE--OFF -- CHAPTER 1
87666787A - 11 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
1
SECTION 33 -- BRAKING SYSTEM Chapter 1 -- Braking system CONTENT Section
Description
Page
33 000
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
33 202 60
Right or left--hand brake. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
33 202 46
Braking system hydraulic pump. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
33 110 40
Parking brake. Brake disks Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
33 110 08
Handbrake control. Travel adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIFICATIONS Type: --
service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with oil bath disk, acting on differential drive shafts
--
parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with oil bath disks, engaging a gear on the bevel pinion shaft
Driving: --
service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
hydrostatic, with independent pedals (connected by means of a pin)
--
parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mechanical, by means of a hand lever
Service brake disk material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
sintered
Parking brake disk material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
steel
Parking brake mobile sectors material . . . . . . . . . . . . . . . . . . . . . . .
sintered or organic agglomerate
Disk thickness: --
service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
10
--
wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
8,6
--
parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
3.95 รท 4.05 (continued)
87666787A - 11 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
2
SPECIFICATIONS (overleaf)
Parking brake friction disk thickness (mobile sectors): --
lateral sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
3.1 รท 3.4
--
intermediate sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
4.2 รท 4.5
Hydrostatic control Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with 2 master cylinders independently operated by brake pedals 17.6 (18 kg/cm2)
bar
Control pedal adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
see page 14
Bleeding air from brake circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
see page 15
BOLT TORQUES PARTS TO BE TIGHTENED
Thread
Nut securing final drive to transmission casing (C1) . . . . . . . . . . . Guide bolts for parking brake mobile sector (C2) (:) .
.......
Tightening torque Nm
kgm
--
135 รท 149
13.8 รท 15.2
--
24
2,5
(:) Apply 2 drops of LOCTITE 243 thread lock.
C1 --135:149 Nm
C 2--24 Nm 26057
26058
1
87666787A - 11 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
8
9
1
3
2
60x95x23
26059
X
3
7
6
26060
5
4 2 Service brake and parking brake sectional drawings
1. 2. 3. 4. 5.
Service brake disc. Final drive casing spacer. Parking brake discs. Braking sectors. Parking brake internal control lever.
6. 7. 8. 9.
Parking brake support. Seals. Brake piston. Guide grub screw.
NOTE: When fitting apply sealing compound to surfaces X as shown on page 10. 87666787A - 11 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
4
1
2
3 4 5
26062
3 Front axle brake diagram 1. 2. 3.
Brake piston. Brake wear disk. Guide Pin.
87666787A - 11 - 2007
4. 5.
Brake disc. Seals.
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
5
24664
4 Service brake sectional drawing 1. 2. 3.
Spring. Pump body. Control piston.
SPECIAL TOOLS Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended
4. 5. 6.
Rear seal. Central seal. Front seals.
specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual. List of specific tools required for the various operations described in this Sect.
24663
5 Tool to be made for removal--installation of the final drives, to be used with 50114. (Mark the tool with no. 50091 -- Measurements in mm) Make in Aq 42 D material. -- 1. Make no. 2 tie--rods in C 40 bon material.
87666787A - 11 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
6
26258
6 Tool to make for removal--refitting of final drives, use with a part of 50091. (Mark part with No. 50114 -- Measurements in mm) Construct in Fe 42 C material -- (*) Define measurement according to the hydraulic jack seat.
DESCRIPTION AND OPERATION SERVICE BRAKES The service brakes are hydraulically operated with oil bath disks. The two control pumps (one for each pedal) are located in the front part of the cab and are connected to their respective pedals by means of two tie--rods. These pumps can be operated individually or together. If operated together, the pedals are connected by a pin. A connecting pipe between the two pumps ensures balanced braking, even when the brake disks are not equally worn. The two control pumps are fed from a single reservoir positioned above the pumps. The brake disks (one for each rear wheel) are located between the rear transmission casing and the final drive casing. The disks are splined on the differential drive shafts.
87666787A - 11 - 2007
PARK BRAKE The parking brake is mechanically operated, by means of an intermediate gear on the rear bevel pinion shaft, and is controlled by a lever located on the left--hand side of the operator. When the parking brake control lever is applied, the tie--rod acts on the external support lever and moves the braking sectors up against the three brake disks splined to the intermediate gear, thereby stopping the tractor.
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
7
BRAKE TROUBLESHOOTING Problems Brake pedals hard to operate.
Possible Problem 1. Corresponding cylinder seized.
Solutions master Replace the brake control pump.
2. Brake control pipes Clean or replace the control pipes. obstructed or pinched. The brakes stick when the pedals 1. Brake control pump pistons Release the piston and, if necessary, locked. replace the brake control pumps. are released. 2. Master cylinders seized.
Replace the brake control pumps.
Noisy brakes.
1. Friction material on brake Replace the brake disks. disks worn (1, page 3).
Pedal stroke too long.
1. Air in the brake circuit.
Bleed air from the brake circuit.
2. Brake control pumps worn.
Replace the brake control pumps.
3. Leakage from control pipes.
Eliminate the cause of the leakage.
1. Wrong tyre pressure.
Inflate tyres to correct pressure.
2. Brake control pumps worn.
Replace the brake control pumps.
Unbalanced braking.
3. Pump connection pipes Clean or replace the pipes. obstructed or pinched. 4. Brake control pipes Clean or replace the control pipes. obstructed or pinched. 5. Pump control piston seals Replace the brake control pumps. worn or damaged. 6. Friction material on brake disk Replace disk. worn (1, page 3). (continued)
87666787A - 11 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
8
BRAKE TROUBLESHOOTING (overleaf)
Problems Inefficient braking.
Possible Problem
Solutions
1. Friction material on brake Replace the brake disks. disks worn (1, page 3). 2. Brake control pumps worn.
Replace the brake control pumps.
3. Air in the brake circuit.
Bleed air from the brake circuit.
4. Leakage from control pipes.
Eliminate the cause of the leakage.
5. Pump control piston seals Replace the brake control pumps. worn or damaged. Parking brake does not lock.
1. Brake control adjusted.
incorrectly Adjust correctly.
2. Braking sectors worn (4, page Replace the braking sectors. 3). return The tractor remains braked when 1. Control obstructed. the parking brake is disengaged.
stroke Remove obstructions.
2. Braking sectors (4, page 3) Release and replace the damaged seized on brake disks. parts.
87666787A - 11 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
9
Op. 33 202 60 RIGHT OR LEFT HAND BRAKE Removal -- Installation
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted. 26063
Proceed as follows.
7
1. Carry out operation 27 120 10 or 27 120 20: Right or left--hand final drive casing, only removal (see Section 27, Chapter 1). 2. Remove the brake disk (1) from the seat in the transmission casing (2) and recover the control piston. 3. To refit the right or left--hand brake, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Check the control piston seals and replace, if necessary.
--
Fit the control piston (1) in the seat in the rear transmission casing (2), using a rubber mallet.
--
Fit the brake disk (1, fig. 7).
--
Carry out operation 27 120 10 or 27 120 20: Right or left--hand final drive casing, only installation (see Section 27, Chapter 1).
26064
8
87666787A - 11 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
10
26254
9 Diagram of seal compound application for brake assembly and final drives on the transmission casing The types of sealing compound are listed on page 1, Sect. 00.
87666787A - 11 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
11
Op. 33 202 46 BRAKE HYDRAULIC PUMP Removal--Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. To remove the hydraulic pump, proceed as follows. 1. Block the wheels using chocks. 2. Carry out operation 90 100 22 Bonnet, only removal (see section 90). 3. Carry out operation 90 110 14 Instrument panel lower guard, only removal (see Sect. 90).
25758
10
4. Delicately remove the cover bearing the NEW HOLLAND symbol from the steering wheel, unscrew the retaining nut and remove the steering wheel (1). 5. Carry out operation 55 418 10 Multiple indication panel, only removal (see Section 90). 6. Remove the retaining bolts on the dashboard, detach the electrical connections (1), the light control switch (2) from their seats, complete with the dust guard (3).
25761
11 7. Remove the electrical connections (1) connected to the dashboard and remove the dashboard (2).
25762
12
87666787A - 11 - 2007
12
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
8. Remove the fuel filter (1).
27845
13 9. Disconnect the two power steering reservoir oil delivery pipes (1) on the brake pump (2).
14 10. Disconnect the two oil delivery pipes(1) from the unions on the front part of the cab.
26067
15 11. Disconnect the two oil delivery pipes(1) from the unions on the brake pump (2).
26068
16 87666787A - 11 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
13
12. Disconnect the PTO clutch control tie--rod (1).
26069
17 13. Unscrew the two retaining bolts (1) that secure the electrohydraulic 4WD disengagement control unit (2). Move the unit to the left in order to facilitate operations.
26070
18 14. Unscrew the retaining bolts that secure the relay to the brake pedals support bracket (2), loosen the brake levers/cab front brake pump retaining bolts and remove the bracket (1) that supports the electrohydraulic 4WD engagement control unit by unscrewing the bolts (3).
26071
19 15. Unscrew the three retaining bolts (1) located under the electrohydraulic 4WD engagement control unit and remove the pump support bracket (2), complete with pump and brake pedals.
26072
20 87666787A - 11 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
14
16. Disconnect the levers on the brake pedals (1), using the springs to remove the pins. Remove the bolts (2) securing the pump to the bracket (3) and remove the brake pump. 17. To refit the brake control hydraulic pump unit, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 26073
--
Adjust the brake pedals stroke following the instructions on page 15.
--
Fit and secure the pumps, and connect to the control pedals.
--
Fit the brake support bracket electrohydraulic control unit.
--
Fit the brake levers/cab front brake pump retaining bolts and the relay to the brake pedals support bracket.
--
Fit the electrohydraulic control unit.
--
Connect the tie--rod to the PTO clutch.
--
Connect the oil delivery pipes to the brake pump unions on the front part of the cab and the oil delivery pipes from the power steering reservoir on the pump.
--
Position the fuel filter.
--
Carry out operation 55 418 10: Multiple indication panel, only installation (see Section 90).
--
Fit and secure the steering wheel and cover with the NEW HOLLAND symbol.
--
Carry out operation 90 110 14: Instrument panel lower guard, only installation (see Sect. 90).
--
Carry out operation 90 100 22: Bonnet, only installation (see section 90).
--
Bleed the air from the brake circuit, following the instructions on page 16.
--
Remove the chocks on the wheels.
87666787A - 11 - 2007
and
the
21
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
15
Service brakes control pedals stroke adjustment (tractors with cabs).
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 18. Attach the brake pump unit (1), complete with bracket, to tool 380001632 (2) and lock in a vice.
27846
22 19. Press the left--hand pedal (2) fully down and insert the pin (1) of tool 380001632.
NOTE: The pin (1) must slot into the hole on the pedal (2) without forcing. If not, proceed as follows.
27847
23 20. Detach the spring (3), remove the safety springs (1) and extract the pin (2); repeat the operation on the other pump.
27848
24 21. Loosen the locknut (2) and screw or unscrew the fork (1) until the pin (1, fig. 23) slots freely into the hole (2, fig. 23), then tighten the locknut. 22. Repeat the operation on the right--hand pedal.
27849
25 87666787A - 11 - 2007
16
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
23. Check that the pin (1) slots into the holes on the pedal (2) without forcing.
27850
26 24. Detach the brake pump unit from the tool 380001632 (1, fig. 23) and fit in position in the cab, following the instructions on page 14. 25. When the right--hand pedal (1) is fully pressed down, check that the clearance (A) between the pedal and the cab window is at least 10 mm. 26. Repeat the operation on the other pedal.
27851
27
Op. 33 202 04 BRAKE HYDRAULIC SYSTEM Air bleeding Air must be bled out whenever carrying out work on the brake hydraulic system. Proceed as follows. 1. Remove the cap and thoroughly clean the external parts of the assemblies near the bleeding screws and the hydraulic oil reservoir cover. 2. Check that the right--hand (2) and the left--hand (1) brake reservoirs are full, both before and during bleeding. 3. Push the left--hand brake pedal down, slowly and fully, so that the oil is put in pressure.
87666787A - 11 - 2007
28
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
17
4. Keep the pedal pressed down, unscrew the bleeding screw (1) by half a turn, allowing the oil/air bubble mixture to flow out. 5. Tighten the screw (1) and repeat the aforementioned operation until oil without air bubbles flows out. 6. Push the brake pedal down again so that the oil is put in pressure i.e.: when the brake pedal stroke returns to normal. 7. Repeat the aforementioned operation on the right--hand part of the brake circuit. 29
8. On completion of the operation, top up the oil level in the reservoir. 9. After having bled the rear brake circuit, thoroughly clean the external parts of the assemblies near the hydraulic oil reservoir cover (2). 10. Check that the right--hand brake reservoir (1) is full, both before and during bleeding.
30 11. Thoroughly clean the external parts of the assemblies near the bleeding screws (1) and (2). 12. Push the left--hand brake pedal down, slowly and fully, so that the oil is put in pressure. 13. Keep the pedal pressed down, unscrew the bleeding screw (1) by half a turn, allowing the oil/air bubble mixture to flow out. 14. Tighten the screw (1) and repeat the aforementioned operation until oil without air bubbles flows out. 15. Push the brake pedal down again so that the oil is put in pressure i.e: when the brake pedal stroke returns to normal.
26605
31
16. Repeat the aforementioned operation on the brake circuit screw (2). 17. On completion of the operation, top up the oil level in the reservoir.
87666787A - 11 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
18
18. Remove the cap (1). 19. Connect the brake pedals by means of the pin and push both brake pedals down, slowly and fully, so that the oil is put in pressure.
26457
32 20. Keep the pedal pressed down, unscrew the bleeding screw (1), located inside the front final drive, by half a turn, allowing the oil/air bubble mixture to flow out. 21. Tighten the screw (1) and repeat the aforementioned operation until oil without air bubbles flows out. 22. Push the brake pedal down again so that the oil is put in pressure i.e: when the brake pedal stroke returns to normal. 23. Repeat the aforementioned operation on the right--hand part of the brake circuit.
26583
33
24. On completion of the operation, top up the oil level in the reservoir and tighten the caps (1).
NOTE: To align the front brake (1) fig. 33 bleeding screws with the front final drive (1) fig. 32, position the final drive vertically.
Trailer brake valve
ATTENTION On tractors with a hydraulic trailer brake valve, after having bled the air from both the rear and front brakes, bleed the trailer brake valve by means of the screw (1).
27633
34
87666787A - 11 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
19
Op. 33 110 40 -- 33 110 44 PARKING BRAKE Removal--Installation parking brake disks
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. To remove the parking brake disks, proceed as follows. 1. Unscrew the cap and drain the oil from the rear transmission casing (the prescribed quantity is 42 litres).
25628
35
2. If fitted, carry out operation 33 220 40 Trailer brake valve, only removal (see Sect. 35, Chapter 3). 3. Unscrew the four retaining bolts (1) and remove the parking brake disks access guard (2).
1
26078
36 4. Remove the safety ring (1) from the parking brake disks (2).
26080
37
87666787A - 11 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
20
5. Recover the safety ring (1), the brake disks (2) and the friction disks (3). 6. To refit the parking brake disks, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Study the illustrations in fig. 2 for the positioning of the various parts.
--
Insert the brake disks and friction disks in their respective seats.
--
Fit the safety ring.
--
Fit the access guard on the transmission casing and secure with the four bolts.
--
If fitted, Carry out operation 33 220 40: Trailer brake valve, only installation (see Section 35, Chapter 3).
--
Tighten the cap on the rear transmission casing and fill up with oil (for products and quantities see Section 00, page 6).
87666787A - 11 - 2007
26081
38
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
21
Op. 33 110 08 HANDBRAKE CONTROL Stroke adjustment The parking brake lever must be adjusted whenever service operations are carried out on the assembly and if the lever travel becomes excessive. Proceed as follows. 1. Press the button (1) and move the parking brake lever (2) fully down (brake disengaged). 2. Apply some force on the lever (7) to overcome the resistance of the spring (9) and move the lever upwards, checking it does not stick on the link rod (3). 3. Move the sleeve (5) into contact with its seat (4), insert the gauge (A, fig. 40) and keep it in contact with the above--mentioned sleeve (5). 4. Keeping the gauge (A, fig. 40) in contact with the sleeve (5) screw on the nut (6) to bring it into contact with the gauge. 5. Check that the gauge can slide freely, but with no play, between the nut (6) and the sleeve (5), and extract it. 6. Operate the parking brake lever (2) with a force of 20 รท 30 kg, move the lever (2) fully back down. 39
7. Insert the gauge back between the nut (6) and sleeve (5), check there is no play and, if there is, screw down the nut (6) to cancel it. 8. Repeat operations 6 and 7 and extract the gauge. Adjusting the parking brake ON switch. Proceed as follows. 1. Place the switch (8, fig. 39) in its seat, screw down the retaining bolts (10, fig. 39) without locking the switch. 2. Move the switch (8, fig. 39) towards the bracket (11, fig. 39) until they come into contact with each other. 3. Move the switch (8, fig. 39) further towards the bracket (11, fig. 39) until the switch trips over. 4. Tighten the retaining bolts (10, fig. 39) to lock the switch (8, fig. 39). 5. Check that on applying the parking brake the switch (8, fig. 39) trips and lights up the indicator on the control panel.
40 Gauge (A) to be made in Fe 510 material Measurements in mm.
87666787A - 11 - 2007
22
87666787A - 11 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
1
SECTION 35 -- HYDRAULIC SYSTEMS Chapter 1 -- Rear mechanical hydraulic lift CONTENT Operation
Description
Page
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 35 110 30
Rear hydraulic lift R.I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 19 Chap. 4
35 110 40
Lift internal controls Disassembly--Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Lift adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
35 110 08
Linkage adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Various adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
35 110 42
Arm shaft and lifting cylinder D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
35 114 14
Lift control valve D.A. (with control valve removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
35 114 30
Lift pressure relief valve R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
35 114 32
Lift pressure relief valve (Setting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REAR HYDRAULIC LIFT DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with position/draft control and mixed control
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of two independent levers
Setting speed of lift reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
automatic, by means of hydraulic device integral to control valve
LIFT--O--MATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
provides fast lifting/lowering operations using pushbuttons, without using the position or draft control levers
Single--acting cylinder: --
rated diameter and stroke: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
95 x 128
capacity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cm3
907
Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
bar
190 ÷ 195 (194 ÷ 199 kg/cm2)
Cylinder safety valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
bar
210 ÷ 215 (214 ÷ 219 kg/cm2)
Lift piston diameter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
94.980 ÷ 95.000
Internal diameter of cylinder liner: . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
95.036 ÷ 95.071
Clearance between piston and liner . . . . . . . . . . . . . . . . . . . . . . . . .
mm
0.036 ÷ 0.091
--
(continued)
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
2
REAR HYDRAULIC LIFT DATA (overleaf)
Diameter of arm lifting shaft (5, fig. 4) at bushings: --
right--hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
54.970 ÷ 55.000
--
left--hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
47.975 ÷ 48.000
Internal diameter of bushings fitted on lift body: --
right--hand side (4, fig. 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
55.100 ÷ 55.184 (1)
--
left--hand side (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
48.100 ÷ 48.184 (1)
mm
0.100 ÷ 0.214
mm
0.100 ÷ 0.209
mm
0.065 ÷ 0.161
Axial clearance of shaft complete with lift arms . . . . . . . . . . . . . . .
mm
0.2 ÷1.4
External diameter of draft control idler shaft . . . . . . . . . . . . . . . . . .
mm
21.967 ÷ 22.000
Internal diameter of seats in support . . . . . . . . . . . . . . . . . . . . . . . .
mm
22.020 ÷ 22.072
Clearance between idler shaft and its seat . . . . . . . . . . . . . . . . . . .
mm
0.020 ÷ 0.105
Diameter of position control transmission shaft . . . . . . . . . . . . . . .
mm
13.973 ÷14.000
Internal diameter of position control idler shaft . . . . . . . . . . . . . . . .
mm
14.016 ÷14.059
mm
0.016 ÷ 0.086
mm
0.008 ÷ 0.012 (2)
mm
0.008 ÷ 0.014 (2)
Clearance between lifting arm shaft and relative right--hand side bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearance between lifting arm shaft and relative left--hand side bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interference between bushings and their seats . . . . . . . . . . . . . . .
Clearance between draft control idler shaft and position control idler shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearance between control valve block pin (8, fig. 9) and the relative seat on the control valve block body . . . . . . . . . . . . . . . . . Clearance between lift control valve (9) and the relative seat on the control valve block body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check valve return spring (3, fig. 9): --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
25.5
--
spring length under load of 52 ÷ 56 N (5.28 ÷ 5.72 kg) . . . . .
mm
17.5
Control valve block pin return spring (5, fig. 9): --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
50.5
--
spring length under load of 31.7 ÷ 35 N (3.23 ÷ 3.57 kg)
mm
34
Control valve return spring (10, fig. 9) --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
44
--
spring length under load of 103 ÷ 114.7 N (10.5 ÷ 11.7 kg)
mm
29
Arm descent speed control valve spring (13, fig. 9) --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
34
--
spring length under load of 67 ÷ 73 N (6.86 ÷ 7.46 kg)
mm
27
Intervention speed control valve spring (11, fig. 9): --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
14.5
--
spring length under load of 65 ÷ 71 N (1.61 ÷ 1.79 kg) . . . . .
mm
11
(1) Value to be obtained after obtaining interference fit without grinding operations. (2) During assembly the control valve block pins and control valves are carefully selected so as to obtain the required clearance.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
3
IMPLEMENT HITCHING DEVICE DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
three--point linkage 1st and 2nd
Category: Draft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of lower arms with flex bar
Maximum lifting load from horizontal arm link ends with three--point linkage connected to upper hole on top link and full length of lifting stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum lifting load with centre of gravity 610 mm from the lower arm link ends for the full length of lifting stroke (with top link connected to upper hole on support): . . . . . . . . . . . . Flex bar diameter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End float of flex bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
kg
2670
kg mm mm
2385 24.867 รท 24.900 1.5 รท 5.42
BOLT TORQUES Tightening torque Nm kgm
PARTS TO BE TIGHTENED
Thread
Lift Lift intervention speed adjustment valve cap (C1, fig 1) . . . . . . . . . . .
--
54
5.5
Control valve block pin spring cap (C2) . . . . . . . . . . . . . . . . . . . . . . . . .
--
54
5.5
Bolts securing control valve block to lift (C3) . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
26
2.7
Bolts securing union to control valve block (C4) . . . . . . . . . . . . . . . . . .
--
44
4.5
Check valve return (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 24 x 1.5
83
8.5
Cylinder safety valve (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 20 x 1.5
83
8.5
Control valve cap (C7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 20 x 1.5
54
5.5
Lift cylinder retaining bolts: -- front (C8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- top (C10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 14 x 1.5 M 16 X 1.5
157 260
16 26.5
Bolts securing lift to rear transmission housing (C9) . . . . . . . . . . . . . . M 12 x 1.25
98
10
Control lever quadrant cover stud bolts (C11) . . . . . . . . . . . . . . . . . . . .
--
49
5
Nuts for lever quadrant cover stud bolts (C12) . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
25
2.6
LIFT--O--MATIC control lever quadrant retaining nut (C13) . . . . . . . . .
--
54
5.5
Lifting arm plate retaining bolts (C14) . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 14 x 1.5
142
14.5
Eccentric pin retaining nuts (C15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
49
5
Eccentric pin seat cap (C16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
83
8.5
LIFT--O--MATIC control lever retaining bolts (C17) . . . . . . . . . . . . . . . .
--
54
5.5
Quadrant with arms control pivot cam retaining bolts (C18) . . . . . . . .
--
49
5
Internal lever mechanisms support pin (C19) . . . . . . . . . . . . . . . . . . . .
--
54
5.5
Flex bar seal support retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
64
6.5
Limiter stabiliser strut support retaining bolts . . . . . . . . . . . . . . . . . . . .
M16 X 1.5
221
22.5
Towing hook support retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M16 X 1.5
221
22.5
Three point hitch assembly
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
4
C1
C2
BOLT TORQUES
C3
C4
C5 25427
C3
25428
C6
1 87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 HYDRAULIC LIFT TOOLS
X 380000260
Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual.
X 380000230
380000224 380000301 X 380001627 X 380001628 X 380000261
X 380000260 X 380000260
Hydraulic lift lifting hook. Turning stand for overhaul. Ring for fitting piston with lift seals. Punch for fitting lift arm shaft seal. Punch for fitting needle bearings on control valve block control lever bushing. Punch for fitting needle bearings on lower draft control lever. Punch for fitting needle bearings on upper draft control lever.
X 380000231 X 380001629 380000240 380000215 X 380000218 X 380000217 X 380000274 X 380000275 X 380001630 X 380001631
5
Punch for fitting needle bearings on draft control link rod. Wrench for cylinder safety valve setting ring nut. Wrench for lift pressure relief valve setting ring nut. Guard for fitting seal on arm descent speed control pin. Universal pressure control kit. Hand pump for valve calibration. Union for cylinder safety valve calibration. Union for lift pressure relief valve calibration. Union for checking control valve seal. Guard for pilot valve seal. Draft control setting tool. Position and draft control setting tool.
(*)
26626
2 Bracket to be made for hook 380000224 or for overhauling lift to rotating stand (mark tool No. 50155 -- measurements in mm). Make in Aq 42 material -- (*) Area for fixing bore to rotating stand.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
6
*
27860
3 Adapter to use with hook 380000224 (mark tool No. 50163 -- Measurements in mm). Make in Fe 42 C material
Note* (See tool No. 50155)
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
7
4 1. 2. 3. 4. 5. 6. 7.
Cross--sectional view of lift arms drive shaft Right--hand arm. 8. Left--hand arm thrust washer. Right--hand arm thrust washer. 9. Left--hand arm. Right--hand seal. 10. Internal arm. Right--hand bush shaft support (5). 11. Position control cam. Lift arm control shaft. 12. LIFT--O--MATIC control pin. Left--hand bush shaft support (5). 13. LIFT--O--MATIC control external lever. Left--hand seal.
5 1. 2.
Longitudinal cross--sectional view of lift Cylinder liner. 3. Lifting piston. Control valve block/cylinder connecting pipes.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
8
6 1. 2. 3. 4.
Longitudinal and cross--sectional views of lift Anti--extrusion seal and ring. 5. Position control transmission shaft. Control valve block arm lever pin. 6. Lift adjustment rod in position control operation. 7. Lever mechanism unit in position control operation. Control valve block arm lever. Draft control transmission shaft.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
9
254 38
7 1. 2. 3.
Longitudinal and cross--sectional views of lift Control valve block pin. 4. LIFT--O--MATIC device spring. Control valve block lever pin. 5. LIFT--O--MATIC lever control pin. Contact ball joint between control valve block pin (1) 6. LIFT--O--MATIC external control lever. and control lever (2).
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
10
8 C1. G= 1. 2. 3.
Draft control device cross--sectional views Spacer ring and lower lift arm retaining bolt. 4. Flexion bar. 5. Spacer. 1.5รท5.42 mm. End float of flex bar. 6. Seal. Lever mechanism unit in draft control operation. 7. Ball bushing. Lift adjustment rod in draft control operation. 8. Draft transmission lever. Draft transmission rod.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
11
1 14
2 13
3 4 25443
12
5
6 11
25444
10
7 9
8 9
1. 2. 3. 4. 5. 6. 7.
Hydraulic lift control valve block cross--sectional views Oil infeed union. 8. Control valve block pin. Check valve ball. 9. Control valve. Check valve return spring. 10. Control valve return spring. Cylinder safety valve. 11. Intervention speed adjustment valve spring. Control valve block pin return spring. 12. Intervention speed adjustment valve. Seal and ring. 13. Arm descent speed adjustment valve spring. Control valve block pin seat. 14. Seal and ring.
NOTE: When fitting seals 6 and 14, heat the corresponding support disks in oil at a temperature of approximately 50°C. When fitting seal (14) and its support disk, use protection device 380001629. When fitting seal (6) and its support disk, use guard 380000275.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
12
DESCRIPTION AND OPERATION The mechanical lift can operate with controlled position and draft, and with mixed control. The lift is controlled by two special levers located on the operatorâ&#x20AC;&#x2122;s right--hand side. It also features the Lift--O--Matic device which raises and lowers the implement without having to use the position and draft control levers.
Draft control is performed by the flex bar, positioned in the seat mounted in the rear transmission housing. The lower lift arms and corresponding control rods are connected to the flex bar.
4 1
2
3 5
6 27898
Oil at static rest
Discharge oil
Intake oil
Brake circuit oil at rest
Pressure oil
10 1. 2. 3.
Hydraulic Pump. Pressure relief valve. Trailer brake valve.
87666787A - 11 - 2007
HYDRAULIC LIFT CIRCUIT 4. Rear auxiliary control valves. 5. Lift hydraulic control valve. 6. Filter.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
13
1
7
2 3 6
4 5 26625
Discharge oil Pressurised oil 25445
A 11
A. 1. 2. 3.
Detail of control position operation. Intervention speed adjustment valve. Arm descent speed control valve. Cylinder safety valve.
ARM LIFT PHASE 4. Non--return valve. 5. Draft transmission rod. 6. Control valve block pin. 7. Control valve.
When the operator uses the position control lever (located on the right--hand side) to raise the arms, the movement shown by the arrows (detail a) is transmitted by the internal lever mechanisms to the control valve block pin (6). This pin interrupts the oil flow to the control valve (7), which is pulled by its spring. The pressurised oil opens the check valve (4) and pushes on the arm lifting piston.
With controlled draft operation, the lift command is sent to the flex bar, which in turn transmits the movement (shown by the arrows) to the control valve block pin (6) via the transmission rod (5).
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
14
1
7
2 3 6
4
5 26624
Oil at static rest Discharge oil Pressure oil
26678
12 1. 2. 3. 4.
Intervention speed adjustment valve. Arm descent speed control valve. Cylinder safety valve. Non--return valve.
NEUTRAL PHASE 5. Draft transmission rod. 6. Control valve block pin. 7. Control valve.
When the lift arms have reached the predetermined height, the internal lever mechanisms are stationary. The position of the control valve block pin (6) directs the oil to the control valve piston (7). The oil pressure
87666787A - 11 - 2007
on the control valve piston overcomes the resistance of the spring and moves the valve. This creates a discharge opening and allows the oil to flow to the transmission casing instead of the lift cylinder.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
15
Discharge oil Pressure oil
1
7 2 3 6 4
5 A
26623 26676
13 A. 1. 2. 3.
Control position operation. Intervention speed adjustment valve. Arm descent speed control valve. Non--return valve.
ARM LOWER PHASE 4. Draft transmission rod. 5. Control valve block pin. 6. Control valve. 7. Cylinder safety valve.
When the operator lowers the position control lever on the right--hand side, the arms are lowered. The internal lever mechanisms transmit movement (shown by the arrows, detail a) to the control valve block pin (6). The control valve block pin (6), is pulled downward by its spring, allowing the cylinder of oil, under the thrust of the piston, to discharge through the arm descent speed control valve (2) and the outlet created by the control valve block pin. The discharge oil passes through the valve (2) and pushes on the control valve piston (7). This overcomes the resistance of the spring and moves the valve, thereby creating an outlet and allowing the oil to flow to the transmission housing instead of the lift cylinder.
With draft control operation, the lowering command is sent to the flex bar, which in turn transmits the movement (shown by the arrows) to the control valve block pin (6) via the transmission rod (5). NOTE: The lowering speed of the implement connected to the lift arms is controlled by the position of the arm descent speed control valve (2). Slackening the valve (2) control screw reduces the size of the outlet between the valve and the control valve block body. This means that the implement takes longer to lower. Fully tightening the screw increases the size of the discharge opening and the implement lowers more quickly.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
16
HYDRAULIC LIFT TROUBLESHOOTING
Problems
The lift does not rise.
Possible Problem
Solutions
1. Clogged oil filter.
Replace filter.
2. Control valve jammed discharge position.
The lift moves in jerks.
The lift rises too slowly.
in Release control valve.
3. Hydraulic pump faulty.
Overhaul or replace the pump.
1. Clogged oil filter.
Replace filter.
2. Air in the pump suction line.
Check that the unions are airtight and the seals are efficient.
1. Clogged oil filter.
Replace filter.
2. Oil leakage through the seals Replace damaged seals. with consequent pressure drop: piston seals or seals on discharge fitting to cylinder.
3. Hydraulic pump faulty.
Overhaul or replace the pump.
The lift lowers too slowly.
1. Arm descent incorrectly.
speed
set Adjust correctly.
The lift lowers too quickly.
1. Arm descent incorrectly.
speed
set Adjust correctly. (continued)
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
17
HYDRAULIC LIFT TROUBLESHOOTING (overleaf)
Problems
Possible Problem
Solutions
Dismantle, check and replace the The lift is unable to keep the load 1. Faulty seal on check valve. parts concerned, if necessary. raised(with the engine running, the load moves up and down rhythmically; with the engine turned off, the load lowers). 2. Oil leaking past the seals on Replace seals. the control valve block pin seat.
3. Control valve block pin seal Dismantle and clean the seal; faulty. replace the control valve block pin and seat if defective.
4. Oil leaking past lift piston seal Replace seals. or seals on discharge fitting to cylinder.
5. Defective seal or cylinder safety Renew it. valve set to very low value.
The pressure relief valve cuts in when the lift arms reach the completely raised position.
1. Lift arm travel set incorrectly.
Adjust correctly.
Poor lifting capacity.
1. Pressure relief incorrectly.
valve
set Renew it.
2. Cylinder safety incorrectly.
valve
set Renew it.
3. Poor pump efficiency Overhaul or replace the pump. (generally combined with a considerable increase in lift time).
87666787A - 11 - 2007
18
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
OP. 35 110 40 LIFT INTERNAL CONTROLS DISASSEMBLY--ASSEMBLY (With the lift removed)
DANGER Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
1
Proceed as follows.
2
1. Position the lift on a rotating stand 380000301 using the bracket 50155 to be made in the workshop (see fig. 2). 2. Disconnect the connecting pipe (2) between the auxiliary control valve block (1) and the lift control valve block, unscrew the retaining bolts and remove the auxiliary control valve block (1), recovering the O--Ring seal.
25453
14 3. Unscrew the retaining bolts and remove the lift hydraulic control valve block (1). 4. Rotate the lift holding the relative arms.
1
25454
15 5. Using a magnetic flexible tool (1), recover the control valve block pin contact ball (2).
1
2
25455
16
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 6. Remove the front bolts, the rear union and recover the oil delivery pipe (1) to the lift cylinder.
19
1
25456
17 7. Unscrew the retaining bolts and remove the Lift--O--Matic device spring (1).
1
25457
18 8. Unscrew the retaining bolts (1), loosen and remove the pin (2) and bush, then recover the control valve block lever mechanisms (3). 9. Unscrew the cylinder retaining bolts and remove.
1
3
2 25458
19 10. Unscrew the retaining nuts and recover the support cap (1) and spring.
1
NOTE: Apply pressure on the support (1) to prevent the spring from pressing it against the retaining nut.
25461
20 87666787A - 11 - 2007
20
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
11. Unscrew and remove the draft control internal lever pivot eccentric pin (1).
1
25462
21 12. Remove the circlip (4) and recover the washer, the external lever (3), the relative clutch disks, the Woodruff key and extract the draft and position control internal levers (1 and 2) and shafts from the inside.
1
2 3
4 25463
22 13. Using the drift 380000260 (1), replace the draft control internal lever (2) bearings.
1
2
14. Using the drift 380000261, replace the control valve lever bearings.
26298
23
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
21
Assembly Procedure
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
15. To re--fit the hydraulic lift internal controls, proceed as follows. --
Study the illustrations in figs. 4, 5, 6, 7, and 8 for the positioning of the various parts.
--
Apply the torque settings listed on page 3.
--
Fit the position and draft control internal levers, complete with: shafts, woodruff keys, clutch disks, external levers, washers and circlip.
--
Tighten the draft control internal lever pivot eccentric pin.
--
Fit the spring and cover on the position and draft control axis and secure the cover with the lock nuts.
--
Fit the control valve block control lever unit.
--
Fit the cylinder.
--
Fit the Lift--O--Matic device spring.
--
Fit the oil delivery pipe to the lift control cylinder.
--
Fit the control valve pin contact ball.
--
Carefully clean and degrease the mating surfaces, then apply sealing compound (approx. 2 mm) along the marked line shown in the drawing. The types of sealing compound are listed on page 1, Sect. 00. Fit the hydraulic lift on the lift box and secure in position with the relative retaining bolts.
--
Fit the auxiliary control valve block, the O--Ring seals and the connecting pipe to the lift hydraulic control valve block. Carry out the adjustments described below.
NOTE: The adjustments must be carried out in the order specified.
27156
24
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
22
LIFT ADJUSTMENTS The following adjustments refer to a lift without hydraulic control valve block and mounted on a rotating stand.
1
NOTE: These adjustments must be carried out in the order specified. 16. Detach the spring (1) in order to exclude the Lift--O--Matic device. 25470
25 Adjusting position control Proceed as follows. 17. Move the external position control lever (2) completely forward against the spacer for the stud bolt securing the spring retaining bracket, and the external draft control lever (1) completely back against the spacer. 18. Turn the arm control shaft so that the internal arm comes into contact with the lift body.
1
2 25471
26 19. Position the contact ball (3, fig. 7) in its seat and attach tool 380001631 (1) to the lift body so that it makes contact with the ball.
1
Rotate the lift through 180° holding the arms.
25472
27 20. Loosen the locknut and totally unscrew the adjustment bolt (2), to the end of the lever (1).
1
NOTE: To facilitate this operation, lower the lift arms. Once the operation has been completed, return the lift arms to their original position.
2
25473
28 87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 21. Unscrew the locknut (1) and tighten or slacken the rod (2) so that
23
1
2
25474
29 the end of the cap (2) of tool 380001631 (1) is at exactly the same external stop face as the tool. Tighten the locknut (1, fig. 29).
1 2 25475
30 22. Move the external position control (1) and draft control (2) levers completely backwards against the spacer.
1
2
25476
31 23. With the lift arms fully lowered, check that the cap (2) of tool 380001631 (1) is either aligned with or further inside than the internal reference surface on the tool (1).
1
2 25477
32 87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
24
Upper stroke limit adjustment Proceed as follows. 24. Move the external position control lever (2) completely forward against the spacer for the stud bolt securing the spring retaining bracket, and the external draft control lever (1) completely back against the spacer. 25. Turn the arm control shaft so that the internal arm comes into contact with the lift body.
1
2 25471
33 26. Position the contact ball (3, fig. 7) in its seat and attach tool 380001631 (1) to the lift body so that it makes contact with the ball.
1
Rotate the lift through 180°.
25472
34 27. Tighten the adjustment bolt (2) on the lever (1) until the cap (2, fig. 36) of tool 380001631 (1, fig. 36) is aligned with the internal reference surface of the tool.
1
NOTE: To facilitate this adjustment bolt (2) tightening operation, lower the lift arms, then return the lift arms to their original position to check the position of the cap (2, fig. 36) on the tool.
2
Lock in position using the locknut. 25473
35
1
2 25477
36 87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
25
Adjusting draft control Proceed as follows.
1 28. Move the external position control (1) and draft control (2) levers completely backwards against the spacer.
2
25476
37 29. Make sure that the milling on the eccentric pin (1) is in the vertical position.
1
25478
38 30. Place the tool 380001630 (2), complete with the end section (3) and the draft transmission rod, on a reference plane. Adjust the end section (3) until the rod on tool (1) is aligned with the tool, providing a micrometer (1) reading of 0.
1
2 3 25479
39 31. Place the tool (2) on the lift body, secure in position with the two bolts and fully tighten the screw (1).
1
2
3 25480
40 87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
26
32. Adjust the draft control rod (3, fig. 40) until the end of the cap (2, fig. 41) on the tool 380001631 (1) is exactly aligned with, or as near as is possible, to the external reference surface as the tool. 33. Remove tools 380001631 and 380001630 from the lift body, fit the hydraulic control valve block and attach the Lift--O--Matic device spring (1, fig. 25). Fit the lift on the tractor as follows.
1 2 25475
41 WARNING -- First position tool 380001630 (2) on a reference surface and use a micrometer depth gauge (1) to measure the distance (L5) between the point where the tool rests on the reference surface and the point where the micrometer gauge rests on the tool. Mark the measured distance (L5) on the tool.
1 2
L5
25481
42 34. Fit the complete draft measuring device (3), but without the flex bar, on the rear transmission housing. 35. Rest the transmission lever (3) on the transmission casing and fit tool 380001630 (1) on this housing. 36. Use a micrometer depth gauge (2) to measure the distance (L8) between the top end of the rod (3) and the micrometer gauge resting surface on the tool 380001630 (1).
1
2
L8 L6 3 25482
43 NOTE: The distance (L6) the top end of the rod (3) protrudes from the transmission casing (with flex bar removed) is given by: L6=L5 - L8 where: L5 and L6 = distance measured with tool 380001630 fitted on contact surface (L5, fig. 42) or on the transmission casing (L8).
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 37. Fit the flex bar in the seat on the rear transmission casing and, using the micrometer depth gauge (2), measure the distance (L9) between the top end of the rod (3) and the micrometer gauge resting surface on the tool 380001630 (1).
27
1 2 L7
NOTE: The distance (L7) the top end of the rod (3) protrudes from the transmission casing (with flex bar fitted) is given by:
L9
3
4 25483
L7 = L5 - L9
44
where: L5 and L9 = distance measured with tool 380001630 fitted on contact surface (L5, fig. 42) or on the transmission casing (L9) 38. Check that the distance (L7) is at least 5 mm greater than the distance (L6).
39. Slacken the locknut (4) and adjust the length of the draft control rod until it protrudes by a new distance (L7 = 23.4 รท 23.6 mm).
40. This distance (L7) can be calculated by subtraction using tool 380001630 L10 = L5
-- L7
where: L7 = 23.4 รท 23.6 mm. Distance the end of the rod (3) protrudes with respect to the transmission casing. L5 = distance measured with tool 380001630 fitted on the reference surface. L10 = distance to be measured with the micrometer gauge on the tool 380001630.
41. Tighten the locknut (4) and fit the lift on the tractor.
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
28
OP. 35 110 08 ROD MECHANISM ADJUSTMENTS Position control rod adjustments Proceed as follows. 1. Move the position control lever (1) forward completely on the quadrant and check that the distance (L) is 5 ÷ 10 mm.
45 2. Move the external position control lever (1) completely back against the spacer.
1
2
3. Connect the control rod and adjust the length, if necessary. 4. Secure the rod in position using the locknuts.
25496
46 Draft control rod adjustments Test Conditions: --
engine running at medium speed;
--
bring the oil in the system to a temperature of 30 ÷ 40 °C. Then proceed as follows: 5. Move the position control lever (1) forward completely on the quadrant and the draft control lever (2) to a distance (L1) of 5 ÷ 10 mm from the beginning of the slot. 47 6. Move the external draft control lever (2) completely back against the spacer.
1
2
7. Connect the control rod and adjust the length, if necessary.
25496
48 87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
29
8. Move the draft control lever (2) to a distance (L2) of 103 รท 108 mm from the start of the slot and check that in this position the arms begin rising. 9. If the arms do not rise, adjust the eccentric pin (1, fig. 38) to reset this distance. 10. Lock the pin in position using the locknut.
49 LIFT--O--MATIC device adjustments Proceed as follows. 11. Move the position control lever (1) and the draft control lever (2) completely forward on the quadrant.
50 12. Raise the lift arms by means of the lever (1).
1
2
25499
51 13. Tighten the nut (1) until the arms lower. 14. With the lever (1, fig. 51) still in the same position, unscrew the nut (1) until the arms begin to rise.
1
15. Unscrew the nut (1) by another 1.5 turns. 16. Using the levers (1 and 2, fig. 51) lower and raise the arms a few times to ensure that the device is operating correctly.
25500
52 87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
30
LIFT ARM DESCENT SPEED ADJUSTMENTS
1
2
Test Conditions: ---
apply a load of 100 kg to the link ends of the lower implement attachment arms; allow the oil in the system to reach a temperature of 50 ÷ 60° C.
Proceed as follows. 1. Fully raise the arms. 2. Loosen locknut (1).
25501
53 3. Lower the arms and, by means of the screw (2), adjust the lowering speed to a time of 2 ÷ 2.5 seconds (by tightening the screw the time decreases, by unscrewing the screw the time increases). 4. Tighten the locknut (1), making sure that the screw remains stationary (2).
UPPER STROKE LIMIT ADJUSTMENT CHECK
Test condition. -- apply a load of 100 kg to the link ends of the lower implement attachment arms; -- allow the oil in the system to reach a temperature of 50 ÷ 60° C.
54
Proceed as follows.
1
1. Move the position and draft control levers (1 and 2, fig. 54) completely forwards on the quadrant.
2
2. Raise the arms (1) until the internal arm comes into contact with the lift body, stamp two corresponding reference marks (2) on the lift body and the arm.
25503
55 3. Start the engine and, using the position control lever (1, fig. 54), raise the arms (1) and check that there is a distance (A) of 2÷ 4 mm between the reference marks (2).
1 2
A 25504
56 87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
31
OPERATIONS TO BE PERFORMED TO ADJUST THE UPPER STROKE LIMIT OF THE LIFT--O--MATIC DEVICE
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows: 1. Apply a load to the link ends of the lower implement attachment arms. 2. Start the engine and keep it running at medium speed. 3. Hold down the pushbutton (1) until the arms are in the attachment position (completely lowered).
1
25505
57
4. Move the levers (1 and 2) completely forward on the quadrant (completely lowered). 5. Using the position control lever (1) raise the arms to the desired height. 6. Shut off the engine. 7. Press the LIFT--O--MATIC arm lift button.
58 8. Slacken the lever (1) and turn the mobile sector (2) clockwise until it touches the needle (3) on the LIFT--O--MATIC control lever (4). 9. Start the engine and use the LIFT--O--MATIC control buttons to raise and lower the arms a few times to ensure correct operation.
1 2
NOTE: The arm upward stroke limit only applies to the LIFT -- O -- MATIC device and does not affect the other functions of the lift. This means that the arms can be raised completely using the control levers (1 and 2, fig. 58).
3 4 25506
59
87666787A - 11 - 2007
32
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
OP. 35 110 42
ARM SHAFT AND LIFT CYLINDER DISASSEMBLY--ASSEMBLY (With the lift removed) Disassembly
DANGER Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows.
1
1. Remove the front bolts, the rear union and recover the oil delivery pipe (1) to the lift cylinder. 2. Remove the three lift cylinder retaining bolts.
25456
60 3. Remove the lift control cylinder (1).
1
25460
61 4. Loosen the nut (4) and recover the locking lever (3) on the lifting stroke limit cam (1), unscrew the nut (2) and remove the cam (1).
1 2 3 4 25464
62
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
33
5. Unscrew the retaining bolt (3) and recover the thrust washer (2) and the lifting arm (1).
Carry out this operation on both sides.
1 3
25465
2 63
6. Straighten the securing ring and unscrew the retaining bolt that secures the ring--cam to the internal arm (1).
1
25466
64 7. Using a brass drift, strike the end of the shaft (2), extract the shaft and the internal arm (1), the ring--cam and the seal (3).
1
3
2 25467
65 8. Use compressed air to remove the piston (2) from its cylinder (1).
1
2
26297
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
34
Assembly Procedure
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. To refit the arm shaft and lifting cylinder, proceed as follows. -- Study the illustrations in figs. 4, 5 and 6 for the positioning of the various parts. -- Apply the torque settings listed on page 3. 9. Using tool 380001627 (2), insert the piston (1) in the relative cylinder (3).
1
2
3
25634
67 10. Fit the lift arm shaft (2), the ring--cam and the internal arm (1) inside the lift box, matching up the reference marks. Tighten the bolt that secures the ring--cam to the internal arm and stake the retaining bolt washer.
1
2 25468
68 11. To avoid damaging the internal seal lips (2), use a flexible brass sheet (1) dimensions: 200 x 90 mm and 0.05 รท 0.1 mm. Roll up the sheet and insert the seal inside. Position the unit on the spline and push the seal manually into its seat, then remove the sheet.
1
26300
2 69
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 12. Using the drift 380001628 (1), complete the fitting of the seal into the relative seat on the arm shaft.
35
1
26326
70 13. Fit the lift arms (1) on the shaft, matching up the reference marks. Secure in position with the bolts and washers.
1
25469
71 14. Fit the lifting stroke limit cam (1), nut (2) and the relative locking lever (3) and the lock nut (4).
1 2 3 4 25464
72 15. Fit the control cylinder, securing in position with the three retaining bolts.
1
16. Fit the oil delivery pipe (1) to the control cylinder.
25456
73 87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
36
OP. 35 114 14 LIFT CONTROL VALVE DISASSEMBLY -ASSEMBLY (with control valve removed) Disassembly
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Before disassembly, thoroughly clean the surfaces of the control valve block. Lock the control valve block in a vice, loosen the screws and remove the union (1). 2. Unscrew the locknut (2) and recover the spacer (3).
1
2
3
25484
74 3. Remove the cap (1), complete with speed intervention adjustment valve, seat (3), piston (2) and control valve shutter (4).
1
2
3
4
25485
75 4. Unscrew the cap (2) and remove the control valve spring (1).
1
2
25486
76
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 5. Remove the cylinder safety valve (4) and recover the arm lowering speed adjustment valve (3), the spring (2) and the pin (1).
1
2
37
3
4
25709
77 6. Unscrew the cap (1) and remove the spring (2), the control valve block pin (3) and seat (4).
1
2
3
4
25487
78 7. Remove the check valve, comprising: ball (1), spring (2) and union (3).
1 2 3
25488
79 8. Check the wear of the seals on the control valve block--pin seat. If damaged, replace the seals using protection device 380000275 (1) and following the instructions on page 11.
1
To check the efficiency of the control valve block pin, proceed as follows.
25714
80 87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
38
9. Fit the control valve block pin (2) complete with seat (3) on tool 380000274 (1).
1
2
3
25715
81 10. Fit the control valve block pin spring (1) and the cap (2) of tool 380000274. Tighten the cap as far as it will go and check that the control valve block--pin slides in its seat.
1
2
25716
82 11. Fit tool 380000274 (2) on the hand pump 380000215 (3), filled with HYDROSYSTEM 68 oil. Connect a dial gauge (1), securing in position with the screw.
1 2 3
25717
83 12. Operate the hand pump, whilst tightening the tool screw (1), until the oil stops flowing out through the control valve block pin seat outlet.
Zero--set the dial gauge.
1 Tighten the screw (1) on the tool further to move the control valve block pin by 1.8 รท 2 mm, using the dial gauge to read this distance. 25718
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
39
13. Operate the hand pump until the oil in the system is at an initial pressure of 245 bar -- 250 kg/cm@. Using the pressure gauge, check that it takes more than six seconds for the pressure to fall 196 bar -- 200 kg/cm@ to 98 bar -- 100 kg/cm@. If it takes less than this time, replace the control valve block pin. Bear in mind that this part is supplied together with the relevant seat.
25719
85 14. Fit the cylinder safety valve (1) on the valve union 380000218 (2) and connect to the hand pump 380000217 (3).
1
2
3
15. Operate the hand pump (3) and check that the cylinder safety valve opens at a pressure of 210 รท 215 bar (214 รท 219 kg/cm@ ). If the valve setting is not to specification, the best thing to do is to replace the valve. If necessary it can be adjusted by turning the threaded cap, using wrench 380000230. Tighten to increase the valve setting value or loosen to reduce the value.
Assembly Procedure
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 16. To refit the hydraulic control valve block, proceed as follows. --
Refer to the instructions on page 11 for the positioning of the various parts;
--
Respect the tightening torques prescribed on page 3.
--
Fit the control valve block pin.
--
Fit the check valve.
--
Fit the cylinder safety valve.
--
Fit the control valve.
--
Fit the intervention speed adjustment valve.
--
Fit the oil infeed union.
25720
86
87666787A - 11 - 2007
40
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
OP. 35 114 30 LIFT PRESSURE RELIEF VALVE REMOVAL -- INSTALLATION Proceed as follows. 1. Remove the relief valve (1) and, if faulty, replace.
87
OP. 35 114 32 LIFT PRESSURE RELIEF VALVE (SETTING)
1
Proceed as follows. 1. Run the engine until the oil in the system reaches a temperature of approximately 50° C. 2. Insert the union 380000554 (1) in a quick--fit female half--coupling and connect it to the 0 ÷ 250 kg/cm@ scale pressure gauge, supplied with kit 380000240. 3. Activate the half--coupling control valve block lever until the pressure relief valve cuts in. 4. With the engine running at medium speed the pressure gauge must show a pressure of about 186 ÷ 191 bar (190 ÷ 195 kg/cm@). If the valve setting is not to specification, the best thing to do is to replace the valve. If necessary it can be adjusted by turning the threaded cap, using wrench 380000231, tighten to increase the valve setting value or loosen to reduce the value.
87666787A - 11 - 2007
25508
88
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
1
SECTION 35 -- HYDRAULIC SYSTEMS Chapter 2 -- Open centre system auxiliary control valves CONTENT Operation
Description
Page
Main data -- Tools -- Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Lift -- Chap. 1 35 130 30
Lift electronic control center (Replacement). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
35 204 46
Auxiliary control valves D.A. (With unit removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
87666787A - 11 - 2007
2
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 SPECIFICATIONS
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary control valves Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
full--flow, with replaceable paper cartridge, (common to the hydraulic lift circuit) gear pump (common to the hydraulic lift circuit, see Chap. 5) valve stack up to a maximum of 4 valves attached to the lift housing by hand lever 190 ÷ 195 (194 ÷ 199 kg/cm2)
Pressure relief valve calibration . . . . . . . . . . . . . bar Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
convertible for operation of single or double--acting actuators, convertible for operation of single or double--acting actuators and with automatic detent release, convertible for operation of double--acting actuators with float control and automatic detent release, convertible for operation of double--acting actuators with float control.
SPECIAL TOOLS Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual.
List of specific tools required for the various operations described in this Sect.
380000240
Universal pressure testing kit.
380000241
Seal guard for Kontak control valve check valve.
BOLT TORQUES Parts to tighten
Thread
Torque Specifications
Control valve elements locknut
3/8” -- 24 UNF
Nm 20.4
kgm 2.1
Front and rear cover retaining bolts
1/4” -- 20 UNC
Nm 11
kgm 1
Auxiliary control valve retaining bolts
M 10 x 1.25
Nm 59
kgm 6
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
3
A
1
2
3
4
B
5
6
7
8
9
10
11
27 28 29 30 31 26
C
25723
A. B. C.
D.
E.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
25 24
23
22
21
20
19
18
17
Auxiliary control valve cross--sectional views (fig. 1-- 2-- 3) Auxiliary control valve configured for operation of 11. Control valve rod. a double--acting cylinder. 12. Seal. Auxiliary control valve configured for operation of 13. End Cap. a single--acting cylinder. 14. Control valve rod return spring. Auxiliary control valve configured for operation 15. Cover. of a single/double--acting cylinder with float 16. Spacer. control and automatic detent release. 17. Tapered needle. Auxiliary control valve configured for operation 18. Spring. of a single/double--acting cylinder with 19. Seal. automatic detent release. 20. Coupling balls. Auxiliary control valve configured for operation 21. Seal. of a single/double--acting cylinder with 22. Seal. switching float control 23. Internal plunger. Single/double--acting operation switching valve. 24. Spring. Seal. 25. Cover. Valve retaining plug. 26. Detent release pressure adjuster screw. Seal. 27. Control valve rod return spring. Seal. 28. End Cap. Non--return valve seat. 29. Seal. Non--return valve. 30. Detent notch body. Seal. 31. Ball support. Seal. 32. Seal. Control support. 33. Seal.
1
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
4
1
2
3
4
5
6
7
8
9
10
11
28 29 30 31 27 26
D
25 24
23 22
21
20
19
18
17
25724
2
1
30
32
2
3
4
5
6
7
8
9
10
11
33
28
E 25 24
20
18
17
25725
3
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
5
DESCRIPTION AND OPERATION
The auxiliary control valves serve for control of hydraulic loads external to the tractor.
Each control lever has three or four positions, depending on the type of control valve it operates.
1. Lifting -- Pull the lever towards the operator to extend the connected cylinder and lift the implement. Up to a maximum of 3 auxiliary control valves can be fitted, on the upper part of the lift housing.
2. Neutral -- Push the lever away from the operator, leaving the lifting position, in order to select the neutral position and deactivate the connected cylinder. The rear auxiliary control valves are operated by the levers to the right of the operator.
3. Lowering -- Push the lever further away from the operator, beyond the neutral position, to return the cylinder and lower the implement.
The levers and respective control valves are identified by colour as described below: 4. Float (only available on control valve II) -- Push the lever away from the operator, beyond the ”lowering” position to select the ”float” position. This will allow the cylinder to extend or return freely, permitting implements (such as blades) to follow the profile of the ground surface. Lever colour Green Blue Brown
Control valve position/No. RH external RH internal RH rear
--I --II --III
The operation of the hydraulic control valves is described on pages 6, 7 and 8.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
6
OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR OPERATION OF A DOUBLE--ACTING CYLINDER (FIGS. 4 and 5) AND SINGLE--ACTING CYLINDER (FIGS. 6 and 7) 1. LIFTING -- On pulling back the control lever (located in the cab) the control valve stem (2, fig. 4) shifts to connect: delivery line (E) with the lower chamber of the cylinder, by way of the check valve (3) and the line (G), and also exhaust line (L) by way of line (H), intercepting the supply of oil to the lift control valve. Keeping the lever pulled completes lifting until reaching the limit stop of the governed cylinder; on releasing the lever it will automatically return to the neutral position under the action of the return spring, and the entire flow from the pump will be conveyed to the lift control valve by way of lines (M). 2. LOWERING -- To lower the implement, push the control lever (located in the cab). The control valve stem (2) will shift to the position indicated in fig. 5 thus allowing the oil in the lower cylinder chamber to flow to the exhaust (L) through the line (G), while the upper chamber is connected to the delivery line (E) through line (H) and check valve (3). 3. LIFTING -- On pulling back the control lever (located in the cab) the control valve stem (2, fig. 6) shifts to connect the cylinder with the delivery line (E) by way of the check valve (3) and line (G). Line (H), for the control of double--acting cylinders, is not used at this stage as it is permanently connected to the exhaust (L) by the open position of the switching valve (1). 4. LOWERING -- On pushing back the control lever (located in the cab) the stem (2) will shift to the position indicated in fig. 7. The oil contained in the cylinder, pressurised by the weight of the lifted implement, will flow to the exhaust (L) by way of line (G), while the entire flow from the pump is also conveyed to the exhaust (L) through the check valve (3) and line (H).
1
L
H
3
E
G
L
2
22123
M 4
L
H
3
E
G
L
2
22124
5
1
L
H
3
E
G
L
2
22125
6
L
H
3
E
G
L
Pressurised oil Oil in suction, delivery or return
2
Oil at static rest NOTE: For operation of a double--acting cylinder, tighten the screw (1). For operation of a single--acting cylinder, loosen the screw. 22126
7
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
7
OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR THE OPERATION OF A SINGLE/DOUBLE--ACTING CYLINDER WITH AUTOMATIC DETENT RELEASE AND FLOAT Pressurised oil Oil in suction, delivery or return
H
L
E
3
G
L
Oil at static rest
6
24
28
26
T
23 2
Y
22127
M 8
LIFTING On pulling back the control lever (located in the cab), the control valve stem (2) shifts and the detent balls (26) engage the left hand groove, where they are held in place by the support (28) and spring (24). The movement of the spool (2) connects: delivery line (E) with the lower chamber of the cylinder, by way of the check valve (3) and the line (G), and also the upper cylinder chamber with the exhaust line (L) by way of line (H), intercepting the supply of oil to the hydraulic lift control valve. On completion of the lifting movement, the oil pressure increases to 170 รท
L
H
175 bar (173 รท 178 kg/cm2), acting through the port (V), it overcomes the resistance of the spring of the needle valve (23). Inside chamber (T) the oil pressure increases and, acting on the support (28), it overcomes the resistance of the spring, thus moving the support (28). In this condition the two detent balls (26) drop onto the support (28), releasing the stem (2) which, under the action of the spring (6), returns to the neutral position, and consequently the entire flow from the pump is conveyed to the lift control valve through lines (M).
E
3
G
L
2
22128
LOWERING To lower the implement, push forward the control lever (in the cab). The control valve stem(2) shifts and the detent balls (26) engage in the central groove where they are held in position by the support (28) and the spring (24). In this condition the oil contained in the lower chamber of the cylinder can flow to the
9
exhaust (L) by way of line (G), while the upper chamber is connected with the delivery (E) by way of line (H) and check valve (3). On completion of the lowering operation, the detent will be automatically released in the manner described previously.
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
8
OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR THE OPERATION OF A SINGLE/DOUBLE--ACTING CYLINDER WITH AUTOMATIC DETENT RELEASE AND FLOAT
Oil in suction, delivery or return
L
Oil at static rest
28
22129
H
G
L
26
2
24
M 10
FLOAT OPERATION For float operation push forward the control lever (in the cab). The stem (2) shifts and the balls (26) enter the right--hand groove, held in place by the support and spring (24). In this position the stem (2) connects: the two lines (M) providing the lift control valve with the entire pump flow and the two exhaust lines (L), by way of lines (H, G) respectively with the
upper and lower chambers of the cylinder. In this condition the only force exerted on the implement will be that created by its own weight, thus allowing the implement to follow the profile of the terrain and permitting the hydraulic lift to be used. Automatic detent release does not occur during float control as there is no pressure inside the auxiliary control valve.
Single/double--acting switching valve (of control valve fig. 8 -- 9 -- 10) 1. Single/double--acting switching valve. 2. Seal. 3. Valve retaining plug. 4. Seal.
1
2
3
4
NOTE: For operation of a double--acting cylinder, tighten the screw (1). For operation of a single--acting cylinder, loosen the screw. 25726
11
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
9
OP. 35 130 30 LIFT ELECTRONIC CONTROL CENTRE (Replacement) Removal
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. To remove the control unit, proceed as follows: 1. Carry out operation 55 404 14 Direction indicator switch, only removal. 2. Disconnect the dashboard electrical connections (1) and the dashboard (2).
25762
12 3. Remove the retaining bolts that secure the electronic lift control centre (1) to the support and disconnect the electrical connections.
Installation
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 27161
13 Proceed as follows.
4. Connect the electrical connections to the control centre (1, fig. 13) and secure the control centre by means of the bolts. 5. Connect the dashboard electrical connections (1, fig. 12) and the dashboard (2). 6. Carry out operation 55 404 14 Direction indicator switch, only installation.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
10
OP. 35 204 46 AUXILIARY CONTROL VALVES Disassembly -- Assembly (with the unit removed)
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Convertible single/double acting auxiliary control valve Disassemble the auxiliary control valve into its component parts, referring to the cross--sectional views in fig. 1 and the following instructions: 1. Remove the cover (5), recover the spring (4) and the relative spring cup. 2. Extract the control valve stem (3). 3. Remove the control lever support (1) and recover the seal (2). 4. Remove the plug (6) and recover the single/double action switching valve (7). 5. Remove the valve housing (8) and recover the check valve and relative spring. 6. Check the condition of the seals before assembly.
3 1
4
5
2
8
7
6
24452
14
Single/double--acting auxiliary control valve float and automatic detent release
1
2
3
4
Disassemble the auxiliary control valve into its component parts, referring to the cross--sectional views in fig. 1 and the following instructions: 1. Unscrew the retaining bolts, remove the cover (4) and the spacer (3). 2. Unscrew the retaining screws, recover the control lever support (1) and relative seal (2). 24453
15
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 3. Extract the control valve stem (1). 4. Remove the cap (6, see fig. 14) and recover the single/double acting switching valve (7). 5. Remove the valve housing and recover the check valve and relative spring. 6. Check the condition of the seals before assembly. Diagram showing the installation of the tools and equipment required for the stem sticking test for control valves configured for double--acting operation (fig. 17) and control valves configured for single--acting operation (fig. 18).
11
1
24454
16
Control valve stem sticking test (figs. 17 and 18) NOTE: With the test equipment filled with HYDROSYSTEM 66 oil, the following tests must be performed at a temperature of approx. 60°C and with a flow rate of 12.5 litres/min, which can be obtained by running the electric motor at the fastest speed (1450 rpm). Install the auxiliary control valve assembly and the test equipment as indicated in the diagrams (figs. 17 and 18) and referring to the following instructions:
17
--
on control valves configured for double--acting operation (fig. 17), the two cylinder delivery ports must be connected to the ball connector (3) by way of the pipes (2) and adjustable unions (1); -- on control valves configured for single--acting operation (fig. 18), the return line (2) must be connected, by way of the union (1), to the delivery port on the control valve (port located opposite to the switching valve). After having made the connections as indicated in the diagram, carry out the test as follows:
18 --
--
--
start the hydraulic pump and operate the hand lever to move the stem (in both directions for double--acting control valves); gradually increase the pressure by turning the handwheel on the test equipment, checking on the pressure gauge that the pressure reaches 172 bar (175 kg/cm2). In this condition the control valve spool should slide normally and return to the neutral position the moment the hand lever is released; repeat the test on the other control valves after making the appropriate connections.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
12
Diagram showing the installation of the tools and equipment required for the control valve stem leakage test Valve leakage test Install the auxiliary control valve stack and the test equipment as indicated in the diagram (fig. 19) bearing in mind that the three--way union (1) must be secured on the single-- and double--acting control valves with suitable reducers. 19 After having made the connections indicated in the diagram, carry out the test as follows: --
start the hydraulic pump and gradually increase the pressure by turning the handwheel on the test equipment until a pressure of 147 bar (150 kg/cm2) is shown on the pressure gauge;
--
collect the leaked oil flowing from the union (2), in the burette provided (3) for a period of exactly one minute. Check that the quantity of oil collected does not exceed 25 cm3/ minute in the case of a new control valve, or 60 cm3/ minute for a used valve.
Repeat the test on each control valve, checking alternately the two supply lines to the related user cylinder.
ADJUSTMENT OF THE AUTOMATIC DETENT RELEASE PRESSURE Connect the control valve to the test equipment. Start the hydraulic pump and tighten the release pressure adjuster screw (26, fig. 1) until a pressure of 170 รท 175 bar (173 รท 178 kg/cm2) is obtained in front of the tapered needle (17). Lock the screw (26) in position by tightening the locknut.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
1
SECTION 35 -- HYDRAULIC SYSTEMS Chapter 3 -- Trailer brake auxiliary control valve CONTENT
Operation
Description
Page
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 33 220 40
Trailer brake valve. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DESCRIPTION AND OPERATION The trailer brake valve, which has priority over both the auxiliary control valves and the hydraulic lift, is mounted on a support and secured on the front right--hand side of the engine, is controlled by the lift control pump. The hydraulic operation is described on pages 2 and 3.
The trailer brakes installed on ITALIA versions have the advantage that they brake the trailer even when the tractor engine is not running, and also when the pump is faulty or produces an inadequate oil flow. The operation is described on pages 4, 5, 6, and 7.
Cross--sectional view of auxiliary control valve for trailer brakes. (Open--centre circuit). 1. 2. 3. 4. 5. 6.
Non--return valve Pilot valve body. Flow control valve Pilot valve piston. Pressure limiter. Slide piston.
1
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
2
TRAILER BRAKES OFF -- With the trailer brakes off, the oil from the hydrostatic circuit connected to the control valve by union (Y) is not pressurised and therefore the piston (5) of the pilot valve (6) and the spool (7) are in the rest positions indicated in fig. 2.
1
The oil from the hydraulic pump arrives at the union (P1), passing through the diaphragm (1) and the pressure in the restriction (3) drops, thereby causing the flow control element (2) to shift to the right.
2
3 4
P1
5
6
N
The majority of the oil flows through the union (N) to the auxiliary control valves, while the rest of the oil is discharged to the hydraulic lift through the line (4), the stem (7) and the union (R).
B 7
R
25259
Y
Pressurised oil Oil in suction, delivery or return 2
Oil at static rest Tractor brake circuit oil at rest
Trailer brakes off. N. To the auxiliary control valves. P1. From the hydraulic pump to the lift circuit.
Pressurised tractor brake circuit oil
R. To the lift return line. Y.
START OF BRAKING -- On operating the tractor brake pedals, the oil of the hydrostatic circuit in port (Y) is pressurized and thus shifts the piston (7) to the left, the pressure limiter (6) and the stem (8) which closes the passage between the oil return port (R), trailer brake port (B) and the line (5).
From the tractor brakes.
1
The oil inside the flow control valve (4) is maintained at a uniform pressure, allowing the valve element, under the action of the spring, shifts to the left to assume the position indicated in fig. 3.
P1
The oil from the hydraulic pump in the union (P1) partly flows to the auxiliary control valves through the union (N) while the remainder flows to the trailer braking device via the diaphragm (2), line (3), check valve (1) and union (B).
B
As the pressure of the oil in the trailer brake port (B) increases, it acts on the active surface (9) of the spool (8), opposing the pressure applied on piston (7) by the oil in the hydrostatic tractor brake circuit.
2
3
4 5
7
N
25261
9
R
8
Y 3
Start of braking. B. To the trailer brake. N. To the auxiliary control valves. P1. From the hydraulic pump to the lift circuit. R. To the return line in the lift. Y.
87666787A - 11 - 2007
6
From the tractor brakes.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 BRAKING -- If the driver continues to operate the tractor brake pedals, the pressure of the oil in the trailer brake union (B) increases and acts on the active surface (10) of the slide piston (9), and overcomes the resistance of the pressure limiter (8) springs (7) to shift the slide piston (9) to the right.
When the pressure in the trailer brake circuit balances the pressure exerted by the springs (7), the spool (9) stabilises in the position indicated in fig. 4 opening the passage connecting the oil from the pump with the hydraulic lift return line through port (P1), the diaphragm (2), restriction (5), line (6) and the port (R).
1
2
3
4
3
5 6
P1
7
8
B 10
R
Y
9
25260
4 The diaphragm (2) and the constriction (5) cause a drop in the pressure of the oil circulating in the flow control valve (4), thus shifting the valve element to the right to close passage (3) and consequently the check valve (1).
Braking. B. To the trailer brake. P1. From the hydraulic pump to the lift circuit. R. To the return line in the lift. Y.
Further pressure on the tractor brake pedals shifts the piston (7, fig. 3), the pressure limiter (8) and the spool (2) to the left, thus causing an increase in the trailer brake circuit pressure, repeating the stages described under the heading START OF BRAKING.
From the tractor brakes.
Pressurised oil Oil in suction, delivery or return Oil at static rest
If the pressure in the trailer brake circuit increases as a result of external causes, the spool (9) shifts rapidly to open the passage connecting the trailer brake port (B) and the lift return port (R), thus maintaining a perfect balance between the oil pressure in the braking circuit and the force exerted by the springs (7) of the pressure limiter.
Pressurised tractor brake circuit oil
On releasing the tractor brake pedals, the pressure in port (Y) drops and the conditions illustrated in fig. 2 are restored.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
4
2
1
4 21
20
5a 3
18
19
5b
16 22 15
17
6
14 12 Oil in suction or delivery
13
7
11
Discharge oil Tractor brake circuit oil at rest
26430
Oil at trailer brake release pressure
8 9 10
5 ELECTRO--HYDRAULIC OPERATION OF TRAILER BRAKE VALVE (ITALIAN VERSION) Engine running -- no action on brake pedals 1. Parking brake control lever -- 2. Parking brake indicator circuit relay -- 3. Trailer brake circuit relay -- 4. Trailer braking control solenoid valves -- 5a. Delivery solenoid valve (normally open) -- 5b. Discharge solenoid valve (normally closed) -- 6. Trailer brake release pressure control valve -- 7. Trailer braking valve (see pages 2 and 3) -- 8. Trailer brake circuit safety switch -9. Hydraulic pump -- 10. Filter -- 11. Main brake control piping -- 12. Auxiliary control valve and hydraulic lift supply piping -13. Main brakes pump -- 14. Tractor--trailer coupling -- 15. Trailer brake control piping -- 16. Trailer brake on indicator switch -- 17 and 19. Springs -- 18. Trailer brake control pin -- 20. Battery -- 21. Parking brake switch -- 22. Trailer brake indicator lamp. Oil from the hydraulic pump (9) arrives at the trailer brake valve (7), from where the majority is sent through line (12), to the auxiliary control valves and the hydraulic lift. A small amount of oil reaches valve (6), where it is discharged in order to maintain the pressure at a level of 11 รท 12 bar (11.2 รท 12.2 kg/cm2). Oil at a pressure of 11 รท 12 bar (11.2 รท 12.2 kg/cm2) flows from the trailer brake valve through solenoid valve (5a), line (15) and coupling (14) to arrive at the trailer brake. This pressure level is required to overcome the resistance of the spring (19) and move the relative spring cap. At the same time, spring (17) shifts the piston (18) to prevent any braking action on the trailer.
Warning -- On starting the engine, in order to reduce the length of time required to bring the circuit up to the pressure required to release the trailer brake, with the parking brake lever lowered, operate the brake pedals (make sure that they are linked together). Once the trailer brake is released the warning light (22) will be switched off.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
5
2
1
4 21
20
5a 3
18
19 5b
16 22 15
17
6
14 12
13
A
7
11
8
Oil in suction or delivery
9
25262
Discharge oil
10
Pressurised tractor brake circuit oil Oil at tractor brake release pressure 6
ELECTRO--HYDRAULIC OPERATION OF TRAILER BRAKE VALVE (ITALIAN VERSION) Engine running -- brake pedals pressed A. Line connecting brake pump (13) to trailer brake valve (7) -- 1. Parking brake control lever -- 2. Parking brake indicator circuit relay -- 3. Trailer brake circuit relay -- 4. Trailer braking control solenoid valves -- 5a. Delivery solenoid valve (normally open) -- 5b. Discharge solenoid valve (normally closed) -- 6. Trailer brake release pressure control valve -- 7. Trailer braking valve (see pages 2 and 3) -- 8. Trailer brake circuit safety switch -- 9. Hydraulic pump -- 10. Filter -- 11. Main brake control piping -- 12. Auxiliary control valve and hydraulic lift supply piping -- 13. Main brakes pump -- 14. Tractor--trailer coupling -- 15. Trailer brake control piping -- 16. Trailer brake on indicator switch -- 17 and 19. Springs -- 18. Trailer brake control pin -- 20. Battery -- 21. Parking brake switch -- 22. Trailer brake indicator lamp. On operating the brake pedals, the pressure generated in line (A), closes the valve (6) return union (R) and consequently the pressure in the delivery line from the hydraulic pump (9) increases. The pressurised oil (12 รท 150 bar -- 12.2 รท 153 kg/cm2) flows out of the trailer brake valve (7) through line (B) to solenoid valve (5a), which is open, and through line (15) to the trailer brake, where it overcomes the resistance of the springs (17 and 19) to shift the piston (18) and thus brake the trailer.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
6
2
1
4 21
20
5a 3
18
19 16
5b
22 15
17
6
14 12
13
7
11 25263
Oil in suction or delivery
8 9 10
Discharge oil Tractor brake circuit oil at rest 7
ELECTRO--HYDRAULIC OPERATION OF TRAILER BRAKE VALVE (ITALIAN VERSION) Engine either stopped or running but with insufficient flow from hydraulic pump 1. Parking brake control lever -- 2. Parking brake indicator circuit relay -- 3. Trailer brake circuit relay -- 4. Trailer braking control solenoid valves -- 5a. Delivery solenoid valve (normally open) -- 5b. Discharge solenoid valve (normally closed) -- 6. Trailer brake release pressure control valve -- 7. Trailer braking valve (see pages 2 and 3) -- 8. Trailer brake circuit safety switch -9. Hydraulic pump -- 10. Filter -- 11. Main brake control piping -- 12. Auxiliary control valve and hydraulic lift supply piping -13. Main brakes pump -- 14. Tractor--trailer coupling -- 15. Trailer brake control piping -- 16. Trailer brake on indicator switch -- 17 and 19. Springs -- 18. Trailer brake control pin -- 20. Battery -- 21. Parking brake switch -- 22. Trailer brake indicator lamp. When the engine is stopped, or running but with insufficient flow from the hydraulic pump (9), the oil pressure at the trailer brake valve (7) is either too low or non--existent, and this condition causes the safety switch to close (8). The closure of switch (8) allows electrical current to energise relay (3), which closes the circuit to the solenoid valves (5a and 5b), thereby closing the former and opening the latter. In this condition, the oil in the trailer brake and line (15), under the action of spring (19), is discharged through solenoid valve (5b), and the braking action is obtained mechanically by the pressure of spring (19) on pin (18). The pressure drop caused by the oil discharging allows switch (16) to close and thereby allow current to reach and illuminate warning light (22) on the control panel.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
7
2
1
4 21
20
5a 3
18
19 16
5b
22 15
17
6
14 12
13
7
11
Oil in suction or delivery
8 9
25264
10
Discharge oil Tractor brake circuit oil at rest 8
ELECTRO--HYDRAULIC OPERATION OF TRAILER BRAKE VALVE (ITALIAN VERSION) Engine running -- with parking brake on 1. Parking brake control lever -- 2. Parking brake indicator circuit relay -- 3. Trailer brake circuit relay -- 4. Trailer braking control solenoid valves -- 5a. Delivery solenoid valve (normally open) -- 5b. Discharge solenoid valve (normally closed) -- 6. Trailer brake release pressure control valve -- 7. Trailer braking valve (see pages 2 and 3) -- 8. Trailer brake circuit safety switch -9. Hydraulic pump -- 10. Filter -- 11. Main brake control piping -- 12. Auxiliary control valve and hydraulic lift supply piping -13. Main brakes pump -- 14. Tractor--trailer coupling -- 15. Trailer brake control piping -- 16. Trailer brake on indicator switch -- 17 and 19. Springs -- 18. Trailer brake control pin -- 20. Battery -- 21. Parking brake switch -- 22. Trailer brake indicator lamp. On applying the parking brake (1), switch (21) is turned on. This allows electrical current to energize relay (2), which closes the circuit to the solenoid valves (5a and 5b), thereby closing the former and opening the latter. In this condition, the oil in the trailer brake and line (15), under the action of spring (19), is discharged through solenoid valve (5b), and the braking action is obtained mechanically by the pressure of spring (19) on pin (18). The pressure drop caused by the oil discharging allows switch (16) to close and thereby allow current to reach and illuminate warning light (22) on the control panel.
Warning -- After applying the parking brake, wait approximately 10 seconds before shutting off the engine, in order to allow all the oil to be discharged from the trailer brake cylinder and thus obtaining optimum braking.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
8
FUNCTIONAL TESTING AND TROUBLESHOOTING OF TRAILER BRAKE VALVE -ITALIA VERSION 40o
50oC.
÷ Oil temperature Engine speed: 1000 rpm.
Test conditions Electrical system powered. Parking brake disengaged. Trailer brake release pressure test
Proceed as follows: 1. Insert union 380000550 (1) in the trailer brake coupling, connect to the pressure gauge with 0 ÷ 40 kg/cm2 from kit 380000240. 2. With the engine and oil at the aforementioned conditions, the pressure should be 11 ÷ 12 bar (11.2 ÷ 12.2 kg/cm2). 3. Check that the warning light (22, fig. 8) is not illuminated. 4. Apply the parking brake and disconnect the pressure gauge and union 380000550 (1).
25751
9
FAULT FINDING Problems Possible Problem Trailer brake release pressure p = 0 1. Parking brake (1, fig. 8) on. b (warning bar ( i light li h 22, 22 fig. fi 8 ON). ON) 2. Trailer brake release pressure control valve (6) incorrectly adjusted. 3. Trailer brake circuit safety switch (8) faulty. 4. Hydraulic pump (9) faulty.
Solutions Disengage parking brake. Renew it.
Replace switch.
Overhaul or replace the hydraulic pump. 5. Delivery line solenoid valve (5a) Free or replace the solenoid valve. locked in closed position. 6. Discharge line solenoid valve Free or replace the solenoid valve. (5b) locked in open position.
Trailer brake pressure release 0 ÷ 1. Trailer brake release pressure Renew it. 11 bar (0 ÷ 11.2 kg/cm2). control valve (6) incorrectly adjusted. Trailer brake release pressure correct, but warning light (22) illuminated.
1. Trailer brake warning light Replace switch. switch (16) faulty.
Trailer brake release pressure p i incorrect, but b warning i light li h (22) not illuminated.
1. Warning light (22) bulb faulty.
Change the lamp bulb.
2. Trailer brake warning light Replace switch. switch (16) faulty. NOTE: The switch (8) can be identified by the red paint mark between the two terminals.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
9
Testing the setting of the trailer brake system pressure control valve incorporated in the trailer brake control valve Proceed as follows: 1. Insert union 380000550 (1) in the trailer brake coupling, connect to the pressure gauge with 0 ÷ 250 kg/cm2 from kit 380000240. 2. With the engine and the oil in the test conditions described at the beginning of the chapter, apply a force of 30 ÷ 35 daN (29.4 ÷ 34.3 kg/cm2) to the service brake pedals; the pressure reading on the gauge should be 135 ÷ 145 bar (138 ÷ 148 kg/cm2). 3. Apply the parking brake and disconnect the pressure gauge and union 380000550 (1).
25751
10
FAULT FINDING Problems Pressure above or below prescribed range.
Possible Problem
Solutions
1. Pressure control valve (6, Replace trailer brake auxiliary fig. 8) of trailer brake system control valve. faulty. 2. Hydraulic pump (9) faulty.
Replace pump.
Testing the hydraulic system for leakage Proceed as follows: 1. Insert union 380000550 (1) in the trailer brake coupling, connect to the pressure gauge with 0 ÷ 250 kg/cm2 from kit 380000240. 2. With the engine and the oil in the test conditions described at the beginning of the chapter, apply a force of 30 ÷ 35 daN (29.4 ÷ 34.3 kg/cm2) to the service brake pedals; the pressure reading on the gauge should be 135 ÷ 145 bar (138 ÷ 148 kg/cm2). 3. Apply the parking brake and disconnect the pressure gauge and union 380000550 (1).
25751
11
FAULT FINDING Problems
Possible Problem
On applying the prescribed force 1. Oil leaks in the hydraulic p , on the service brake pedals, system. there h are an excessive i number b off 2. Excessive leakage from the pressure peaks over a 10--second solenoid valve (5b, fig. 8). period period. 3. Excessive leakage from trailer brake control valve (7).
Solutions Find and eliminate the leaks. Replace solenoid valve. Replace trailer brake auxiliary control valve.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
10
Checking that trailer brake release pressure is nullified when the parking brake is applied Proceed as follows: 1. Insert union 380000550 (1) in the trailer brake coupling, connect to the pressure gauge with 2 ÷ 40 kg/cm2 from kit 380000240. 2. With the engine and the oil in the test conditions described at the beginning of the chapter, pull the parking brake lever (1, fig. 8) fully upwards. 3. Check that the pressure is 0 bar and that warning light (22, fig. 8) is illuminated. 4. With the parking brake applied, disconnect the pressure gauge and union 380000550 (1). 25751
12
FAULT FINDING Problems When the parking brake is pp applied the trailer brake release pressure is not nullified.
Possible Problem Solutions 1. Parking brake switch (21, fig. 8) Replace switch. faulty. 2. Parking brake indicator relay Replace the relay. (2) faulty. 3. Discharge line solenoid valve Free or replace the solenoid valve. (5b) locked in closed position or faulty.
Controlling the switches (8 and 16, fig. 8) Proceed as follows: 1. Insert union 380000550 (1) in the trailer brake coupling and connect to the pressure gauge with scale 0 ÷ 40 kg/cm2 from kit 380000240. 2. Without applying the service and parking brakes, operate the control lever of an auxiliary control (until the corresponding pressure relief valve is activated), hold this position for a few seconds then suddenly release the control lever. 3. Check that the parking brake release pressure remains at the prescribed level of: 11 ÷ 12 bar (11.2 ÷ 12.2 kg/cm2). 25751 4. Apply the parking brake and disconnect the pressure gauge and union 380000550 (1).
13
FAULT FINDING Problems
Possible Problem
On carrying out the operation 1. Trailer brake circuit safety described above, the trailer brake switch (8, fig. 8) setting higher release pressure is nullified than the nominal pressure (3 ± permanently. 0.5 bar). 2. Switches (8 and 16) installed in incorrect positions, or electrical leads connected incorrectly.
Solutions Replace switch.
Install the two switches in their correct positions or swap over the electrical power leads.
NOTE: The switch (8) can be identified by the red paint mark between the two terminals.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
11
OP. 33 220 40 TRAILER BRAKE VALVE Removal--Installation Removal
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
1. Position a container (3) to collect the oil discharged from the system pipes.
2. Disconnect the pipes (1) connected to the trailer brake valve.
3. Remove the two trailer brake valve retaining bolts (2).
27890
14 4. Disconnect the trailer brake valve (1).
Installation
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
27891
15
Proceed as follows.
5. Fit the trailer brake valve (1, fig. 15) and lock it with the two retaining bolts (3, fig. 14), refit the pipes (2) connected to the valve and remove the container (1).
87666787A - 11 - 2007
12
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
1
SECTION 35 -- HYDRAULIC SYSTEMS Chapter 4 -- Electronically controlled hydraulic lift CONTENT Section 35 000
Description
Page
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cross--sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
35 110 30
Electronically controlled hydraulic lift. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . 19
35 110 53
Draft sensor support. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
35 130 30
Lift electronic control unit. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
35 130 36
Lift arms potentiometer. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
35 130 56
Draft sensor. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
35 134 42
Electronically controlled hydraulic lift. Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . 32
35 138 20
Hydraulic control valve. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
35 138 24
Hydraulic control valve. Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
ATTENTION Observe the following precautions when carrying out arc welding on a tractor fitted with an electronic lift. •
•
•
Position the welder ground clamp as near as possible to the area where welding is taking place.
•
Remove the electronic control units located on the tractor if welding is to be carried out near these control units.
•
The welding leads must not be positioned on, near or come into contact with any other electric leads or electronic components whilst welding is taking place.
Where possible, remove the part or tool that requires arc welding from the tractor. Disconnect both battery leads. Isolate the ends of the leads to prevent then from making contact with each other, or with the tractor.
87666787A -- 11 -- 2007
2
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 ELECTRONICALLY CONTROLLED HYDRAULIC LIFT DATA
Type . . . . . . . . . . . . . . . . . . . . .
with controlled position/draft and float setting
Controls . . . . . . . . . . . . . . . . . .
by means of the electronic control unit, located on the left--hand part of the dashboard, with the controls to the right of the driving position and on the external mudguards. 1 working depth and draft control knob 2 arm up/down Lift--O--Matic button; 3 lift disabled inside control signal lamp; 4 system error alarm signal lamp 5 lift arms raise limit adjustment knob; 6 drop rate control knob; 7 lower limit for lowered arms adjustment knob; 8 position/draft sensitivity control knob; 9 external up/down pushbuttons
Ground position control . . . . .
by means of two push--buttons fitted on the rear mudguards
5
8
7
6
9
1
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
3
ELECTRONICALLY CONTROLLED HYDRAULIC LIFT DATA Diameter of arm lifting shaft (5, fig. 5) in relation to bushings: --
right--hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
54.970 ÷ 55.000
--
left--hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
47.975 ÷ 48.000
Internal diameter of bushings fitted on lift body: --
right--hand side (4, fig. 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
55.100 ÷ 55.184 (1)
--
left--hand side (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
48.100 ÷ 48.184 (1)
Clearance between lifting arm shaft and relative right--hand side bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
0.100 ÷ 0.214
Clearance between lifting arm shaft and relative left--hand side bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
0.100 ÷ 0.209
Interference between bushings and their seats . . . . . . . . . . . . . . . .
mm
0.065 ÷ 0.161
Axial clearance of shaft complete with lift arms . . . . . . . . . . . . . . . .
mm
0.2 ÷1.4
(1) Value to be obtained after obtaining interference fit without grinding operations.
IMPLEMENT HITCHING DEVICE DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
three--point linkage 1st and 2nd
Category: Draft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of lower arms with flex bar and draft sensor
Maximum liftable load from horizontal arm link ends with three--point linkage connected to upper hole on top link and full length of lifting stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
kgs
2670
Maximum lifting load with centre of gravity 610 mm from the lower arm link ends for the full length of lifting stroke (with top link connected to upper hole on support): . . . . . . . . . . . . . . . . . . . . . . . .
kgs
2385
Flex bar diameter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
24.867 ÷ 24.900
End float of flex bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
1.5 ÷ 5.42
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
4
BOLT TORQUES
PARTS TO BE TIGHTENED
Thread
Bolts securing control valve cover to lift . . . . . . . . . . . . . . . . . . . . . . . . Cylinder safety valve (C6), page 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torque Nm
kgm
M 8 x 1.25
26
2.7
M20 x 1.5
83
8.5
Lift
Lift cylinder retaining bolts: --
front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 14 x 1.5
157
16
--
upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 16 X 1.5
260
26.5
Draft sensor retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M24 X 1.5
20
2.0
Flex bar seal support retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
64
6.5
Limiter stabiliser strut support retaining bolts . . . . . . . . . . . . . . . . . . . .
M16 X 1.5
221
22.5
Towing hook support retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M16 X 1.5
221
22.5
Three point hitch assembly
SPECIAL TOOLS Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual. 380000224
Hydraulic lift lifting hook.
380000301
Turning stand for overhaul. (With 50155).
X 380001627
Ring for fitting piston with lift seals.
X 380001628
Punch for fitting lift arm shaft seal.
X 380000260
Punch for fitting needle bearings on draft control lower lever.
87666787A -- 11 -- 2007
X 380000230
Wrench for cylinder safety valve setting ring nut.
X 380000231
Wrench for lift pressure relief valve setting ring nut.
380000240
Universal pressure control kit.
X 380000215
Hand pump for valve calibration.
X 380000218
Union for cylinder safety valve calibration.
X 380000217
Union for lift pressure relief valve calibration.
X 380000282
Instrument for system diagnostics.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
5
(*)
26626
2
22
Bracket to be made for overhauling lift to rotating stand (mark tool with No. 50155 -- measurements in mm) Make in Aq 42 material -- (*) Area for fixing bore to rotating stand.
56
145 20372
3 Modification to make to a 36 mm wrench for removing, overhaul and re--fitting the controlled draft sensor (mark tool with No. 50155 -- measurements in mm)
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
6
27860
4 Bracket to be made for lifting the lift (use with 50155 -- mark tool No. 50163 -- Measurements in mm) make in Fe 42C material -- (1) Area for bore, see tool 50155 page 5.
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
7
27158
5 1. 2. 3. 4. 5.
Cross--sectional view of lift arms drive shaft 6. Left--hand bush shaft support (5). Right--hand arm. 7. Left--hand seal. Right--hand arm thrust washer. 8. Left--hand arm thrust washer. Right--hand seal. 9. Left--hand arm. Right--hand bush shaft support (5). 10. Internal arm. Lift arm control shaft.
6 1. 2.
Cylinder sleeve. Cylinder oil delivery pipes.
Longitudinal cross--sectional view of lift 3. Lifting piston.
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
8
27327
7 Longitudinal and cross--sectional views of lift 1. 2.
Anti--extrusion seal and ring. Anti--extrusion seal and ring.
87666787A -- 11 -- 2007
3. 4.
Cylinder safety valve. Cylinder oil delivery union.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
1
2
9
3
27328
4
8 Position of controls G= 1.5รท5.42 mm. End float of flex bar. 1. Right--hand arm. 2. Position sensor. 3. Position sensor tie rod. 4. Draft reading sensor. 5. Draft transmission rod.
6. 7. 8. 9. 10.
Draft transmission lever. Flexion bar. Spacer. Seal. Ball bushing.
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
10
A B 1
2
27866A
3
4
5
9 Electronic lift controls positions 1. 2. 3.
External lower/lift switch on both mudguards. Electronic control unit and connector for troubleshooting. Inside controls: operator control console.
87666787A -- 11 -- 2007
4. 5.
Problem code indicator. Inside controls: working depth, draft and Lift -- O Matic control console.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
11
A B 1
2
27866B
3
a
4
5
b
10 Electronic lift controls positions (models T4040 Deluxe, and T4050 Deluxe for the version with front electronic lift) 1. 2. 3.
External lower/lift switch on both mudguards. Electronic control unit and connector for troubleshooting. Inside controls: operator control console.
4. 5.
a. Front lift adjustment knobs. b. Rear lift adjustment knobs. Problem code indicator. Inside controls: working depth, draft and Lift -- O Matic control console.
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
12
27867
3
1
11 Control valve and sensors positions 1. 2.
Hydraulic control valve. Position reading sensor.
87666787A -- 11 -- 2007
3.
Draft reading sensor.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
13
DESCRIPTION AND OPERATION One way of obtaining a more constant control of the working depth is to take advantage of the fact that the towing load increases with the depth of the implement. If the implement is maintained at a fixed draft, depending on the type of ground being worked, the depth of the implement will vary (given that the tractor speed remains constant). The electronically controlled hydraulic lift provides a precise method for controlling the implement draft and ground penetration depth, independently of whether the implement is totally or partially carried. The operating principle of the electronic draft control lift is the measurement of the implement draft variation, using a load--measuring pin that reads each load variation by means of a draft transmission rod. A microprocessor converts these variations into electric signals that activate the hydraulic control valve, lifting or lowering the arms and, therefore, maintaining a constant draft on the implement. The smoothness and accuracy provided during operation gives this system a clear advantage over conventional mechanical systems. The electrical signals received by the microprocessor, to lift or lower the hydraulic lift arms according to the requests for position and draft control, are provided by four main sources: the lift control push button, the lift arm position sensor potentiometer, the load measuring pin on the draft transmission rod and the draft and position controls on the control panel. The input signal is also influenced by ulterior signals from the arm descent speed and maximum lifting height controls. When the control push button is activated to lift or lower the arms, the processor transmits a signal to the hydraulic control valve, which accordingly lifts or lowers the implement. Whilst the position of the lift arms changes, the microprocessor receives a feedback signal from the arm position sensor potentiometer.
When the lift arms reach the selected position, the control signal from the microprocessor to the hydraulic control valve is deactivated, leaving the lift arms in the required position. When draft control is selected, the working depth of the implement is also controlled by the draft applied to the implement by means of the lower arms, and measured by the flex bar and transmitted to the load measuring device by the transmission rod. If the implement draft increases, exceeding the value selected by the operator, the microprocessor sends a signal to the hydraulic control valve, raising the implement so as to maintain the draft at the selected values.
ELECTRONICALLY CONTROLLED HYDRAULIC LIFT OPERATION Neutral phase When in neutral, the electronically controlled hydraulic lift microprocessor does not send lifting or lowering signals to the control solenoid valves, and the elastic force applied, by each spring (17) to each end of the control valve block pin, maintains the pin in the central neutral position, preventing the oil from the pump from arriving at the hydraulic lift. When the control valve block pin is in the neutral position, the right--hand end of the lift valve (16) and the pipe (14, low pressure circuit) are in communication with the rear transmission casing discharge. Under these conditions, the hydraulic lift non--return valve (8) remains closed and the oil in the hydraulic lift cylinder (1) is stopped, thereby maintaining the lift arms in a stationary position. When the hydraulic lift is in the neutral position, the oil delivery flow from the pump flows through the hole on the load maintaining valve (3), overcoming the spring resistance and moving the valve so as to allow communication between the pump delivery oil compartment (4) and the discharge (5) in the rear transmission casing. Under these conditions, the entire hydraulic pump flow returns to the rear transmission casing.
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
14
1
2
3 4
5
17
18
8
6
7
9
16
TIA35081
15
14
13
12
11
10 12
Electronically controlled lift functional diagram. Neutral phase 1. 2. 3. 4. 5. 6. 7. 8. 9.
Hydraulic lift. Lift cylinder safety valve. Load Holding Valve. Hydraulic pump flow. Discharge in transmission casing. Load measuring line. To hydraulic lift. Non--return valve. Pump flow to hydraulic control valve.
10. 11. 12. 13. 14. 15. 16. 17. 18.
Solenoid valve (Lowering). Control valve block pin infeed dosage device. Control valve block pin return to tank dosage device. Oil discharge hole. Low pressure circuit pilot pressure. Pilot valve. Solenoid valve (Lifting). Control valve block pin centring spring. Lifting valve.
Pump delivery oil.
Pilot oil at a pressure of 16 bar.
Discharge oil.
Oil at static rest.
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 Lifting phase When the lift control push--button is activated to lift the hydraulic lift arms (1), the microprocessor identifies this variation and transmits a signal to the hydraulic control valve lifting solenoid valve (16). The solenoid valve receives the signal and moves the pilot valve (15) to the right. This allows the oil in the pipe (14, low pressure circuit), to arrive at the left--hand end of the control valve block pin. The control valve block pin moves to the right, allowing the pump delivery oil to flow past the control valve block pin infeed dosage device (11), to arrive at the non--return valve (8) and the lifting valve (18). The lifting valve (18) moves to the left, opening the pipe (6) and allowing the delivery oil to arrive at the load maintaining valve (3). The oil pressure moves the load maintaining valve (3), which closes the discharge (5) and directs all the
15
delivery oil, through the pipe (9), to the hydraulic control valve, and the on to the hydraulic lift (1), through the pipe (7). The lifting speed is controlled by the signal from the lift solenoid valve (16) which, by opening and closing the pilot valve (15), allows the control valve block pin to constantly adjust the volume of oil to be sent to the hydraulic lift cylinder (1). When the lift arms (1) reach the desired height, the resistance of the lift arm position sensor potentiometer is equivalent to the setting made with the lift controls then the microprocessor cuts off the signal to the lifting solenoid valve (16). The control valve block pin returns to the neutral position and the non--return valve (8) closes, leaving the oil trapped in the hydraulic lift cylinder (1).
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
16
1
2
3 4
5
17
18
8
6
7
9
TIA35082
16
15
14
13
12
11
10 13
1. 2. 3. 4. 5. 6. 7. 8. 9.
Electronically controlled lift functional diagram. Lifting phase Hydraulic lift. 10. Solenoid valve (Lowering). Lift cylinder safety valve. 11. Control valve block pin infeed dosage device. Load Holding Valve. 12. Control valve block pin return to tank dosage device. Hydraulic pump flow. 13. Oil discharge hole. Discharge in transmission casing. 14. Low pressure circuit pilot pressure. Load measuring line. 15. Pilot valve. To hydraulic lift. 16. Solenoid valve (Lifting). Non--return valve. 17. Control valve block pin centring spring. Pump flow to hydraulic control valve. 18. Lifting valve. Pump delivery oil. Discharge oil.
87666787A -- 11 -- 2007
Pilot oil at a pressure of 16 bar.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 Lowering phase When the lift control push button is activated to lower the hydraulic lift arms (1), the microprocessor identifies this variation and transmits a signal to the hydraulic control valve lowering solenoid valve (10). The solenoid valve receives the signal and moves the pilot valve to the left. This allows the oil in the pipe (14, low pressure circuit), to arrive at the right--hand end of the control valve block pin. The control valve block pin moves to the left, stopping the pump delivery oil in the pipe (9). The oil in the pipe (14), by means of the control valve block pin, arrives at the lifting valve (18), moving it to the right to act on the non--return valve (8) ball. With the ball moved, the hydraulic control valve oil can flow through the pipe (7) and arrive at the control valve, and then, by means of the pipe (13), on to the rear transmission casing.
17
The lowering speed is controlled by the signal from the lowering solenoid valve (10) which, by opening and closing the pilot valve, allows the control valve block pin to constantly adjust the volume of oil to be sent to the hydraulic lift cylinder (1). When the tractor operates with controlled draft, the microprocessor lowers the hydraulic lift arms, but measures the draft variations transmitted to the implement, by means of the load measuring pin on the draft transmission rod. If the draft on the implement exceeds the value set by the operator, the microprocessor sends a signal to the lifting solenoid valve (16) and gradually raises the implement until the conditions selected by the operator are obtained. If, after having lifted the implement, the draft drops below the set value, the microprocessor sends a similar signal to increase the working depth of the implement.
When the oil is discharged from the lift cylinder, the arms can lower.
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
18
1
2
3 4
5
17
18
8
6
7
9
TIA35083
16
15
14
13
12
11
10 14
1. 2. 3. 4. 5. 6. 7. 8. 9.
Electronically controlled lift functional diagram. Lowering phase Hydraulic lift. 10. Solenoid valve (Lowering). Lift cylinder safety valve. 11. Control valve block pin infeed dosage device. Load Holding Valve. 12. Control valve block pin return to tank dosage device. Hydraulic pump flow. 13. Oil discharge hole. Discharge in transmission casing. 14. Low pressure circuit pilot pressure. Load measuring line. 15. Pilot valve. To hydraulic lift. 16. Solenoid valve (Lifting). Non--return valve. 17. Control valve block pin centring spring. Pump flow to hydraulic control valve. 18. Lifting valve. Pump delivery oil. Discharge oil.
87666787A -- 11 -- 2007
Pilot oil at a pressure of 16 bar.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
19
Operation 35 110 30 ELECTRONICALLY CONTROLLED HYDRAULIC LIFT Removal -- Installation
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted. 27837
Proceed as follows.
15
1. Carry out operation 90 100 22 Bonnet, only removal (see section 90). 2. Lock the front wheels using chocks. 3. Using a hoist and cable (1) raise the rear part of the tractor, positioning two fixed stands under the final drives, then remove the right--hand (2) and left--hand wheels. 4. Remove the pins and disconnect both vertical rods (1) on the lift arms.
27876
16 5. Remove the pin and remove the top link of the third point. 6. Disconnect the auxiliary control valve rods, unscrew the support plate (2) and pipe (1), then remove the rod unit,
27877
17
87666787A -- 11 -- 2007
20
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
7. Remove the retaining bolts and remove the stop bracket (1) on the top link of the third point.
27878
18 8. Remove the PTO connection (1).
revs
reading
sensor
27879
19 9. Disconnect connections (1 and 3) and the hydraulic control valve pipe (2).
27880
20 10. Unscrew and remove the load maintaining pipe (1).
27881
21 87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
21
11. Slacken the cab front retaining screws, attach a nylon sling to a hoist and to tool 380000294, positioned in the cab, and allow the sling to take the weight. Unscrew and remove the rear bolts, raise the cab by 50 รท 60 mm, check that all parts are free and insert two wooden blocks (1) under the rear cab supports.
27882
22 12. Loosen the union (1) to free the pipe.
27883
23 13. Unscrew the union (1), remove any clamps and extract the oil delivery pipe (2).
27884
24 14. Disconnect the ground lead (1) from the lift body.
27885
25 87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
22
15. Disconnect the lift arm position potentiometer connection (1).
27886
26 16. Unscrew all retaining bolts (1) that secure the lift to the rear transmission casing and, using a lever, detach the lift from the casing.
27887
27 17. Fit tool 50155 (2) (see page 5) and tool 50163 (1) (see page 6) on the lift.
27888
28 18. Using tool 380000224 (1) remove the hydraulic lift, complete with auxiliary control valves. 19. To refit the electronically controlled lift, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
27889
29 87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 --
Before reassembling the hydraulic lift on the rear transmission casing, carefully clean and degrease the mating surfaces, then apply sealing compound (approx. 2 mm) along the marked line shown in the drawing.
--
Fit the lift, complete with auxiliary control valves, using tools 50155, 50163 and 380000224.
--
Secure the lift in position by means of the bolts.
--
Connect the lift arm position potentiometer connection.
--
Connect the ground lead to the lift body.
--
Fit and secure the lift feed pipe.
--
Remove the wooden blocks, lower and secure the cab in position.
--
Fit the load maintaining pipe.
--
Connect the hydraulic control valve connections.
--
Connect the PTO revs reading sensor.
--
Fit the stop bracket on the third point top link.
--
Fit the auxiliary control valve rods.
--
Fit the third point top link.
--
Connect the vertical rods to the lift arms.
--
Fit and secure the rear wheels.
--
Carry out operation 90 100 22 Bonnet, only installation (see sect. 90).
23
Diagram showing application of sealing compound when fitting the hydraulic lift on the transmission casing--gearbox. The types of sealing compound are listed on page 1, Sect. 00.
27155
30
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
24
Operation 35 110 53 DRAFT SENSOR SUPPORT Removal -- Installation (with lift removed)
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 1. Carry out operation 35 110 30 Electronically controlled hydraulic lift, only removal (see page 19). 2. Carry out operation 35 130 56 Draft sensor, only removal (see page 29). 3. Remove the safety stop transmission rod pivot pin (1).
on
the
27144
31
drive
4. Remove the safety pin on the draft sensor control lever (1). 5. To refit the support on the transmission casing--gearbox, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Insert the safety pin.
--
Fit the safety stop on the drive transmission rod pivot pin.
--
Carry out operation 35 130 56 Draft sensor, only installation (see page 29).
--
Carry out operation 35 110 30 Electronically controlled hydraulic lift, only installation (see page 19).
27145
87666787A -- 11 -- 2007
32
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
25
Operation 35 130 30 LIFT ELECTRONIC CONTROL CENTRE Replacement
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. To remove the control unit, proceed as follows. 1. Carry out operation 55 404 14 Direction indicator switch, only removal (see Section 55). 2. Disconnect the electrical connections (1) and remove the dashboard (2).
25762
33
3. Remove the retaining bolts that secure the electronic lift control centre (1) to the support and disconnect the electrical connections. 4. To refit the control unit, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Connect the electrical connections to the control centre and secure to the support using the bolts.
--
Connect the electrical connections to the dashboard and fit the dashboard.
--
Carry out operation 55 404 14 Direction indicator switch, only installation (see Section 55).
27161
34
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
26
Op. 35 130 36 LIFT ARM POTENTIOMETER Replacement
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows 1. Turn the switch to position A (OFF).
27301
35
2. Position a support stand under the right--hand side final drive and remove the wheel. 3. Detach the connector (1).
1
27370 36 4. Remove the connecting rod (1) between the arm and the sensor.
27319
37
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
27
5. Remove the cover retaining bolts (1).
1
27317 38 6. Remove the circlip (1) from the sensor pin, then extract the lever.
27316
39 7. Remove the sensor retaining nuts (1).
1
27193
40 8. Extract the sensor (1) from its seat. 9. To refit the potentiometer, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Fit the potentiometer and secure in position.
--
Connect the lever, fit the cover and connect the connections.
--
Fit the wheel and remove the stand.
27323
41 87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
28
Operation 35 130 56 DRAFT SENSOR Removal--Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows 1. Turn the switch to position A (OFF).
27301
42
2. Position a support stand under the right--hand side final drive and remove the wheel. 3. Detach the connector (1).
27307
43 4. Loosen the retaining nut, (1) using wrench 50070 then unscrew and extract the draft sensor.
27303
44
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
29
5. Position the retaining nut on the new sensor at a distance (A) of 18 รท 20 mm.
27306
45 6. Tighten (by hand) the draft sensor (1) into its seat, bringing the retaining nut into contact against the sensor support.
1
7. Connect the connector (2) to the draft sensor (1). 8. Make sure that the lower lifting arms are not loaded.
27368 46
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
30
Operation 35 134 42 ELECTRONICALLY CONTROLLED HYDRAULIC LIFT Disassembly--Assembly
ATTENTION Handle all parts carefully. Do not put your hands between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. To disassemble the lift, proceed as follows. 1. Position the lift on a rotating stand 380000301 using the bracket 50155 to be made in the workshop (see page 5). Remove the control valves support, with the relative oil delivery to the hydraulic cylinder and the cylinder safety valve. 27147
47 2. Unscrew the front bolts (1), the rear union (2) and separate the oil delivery pipe (3) from the lift cylinder.
27148
48 3. Unscrew the three lift cylinder retaining bolts
1
25459
49
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
31
4. Remove the lift cylinder (1).
1
25460
50 5. Free the rod (1) that connects the right--hand lifting arm and position sensor.
27319
51 6. Remove the cover retaining nuts, lever circlip, sensor retaining nut (1) and remove the sensor.
27322
52 7. Unscrew the retaining bolt (3) and recover the thrust washer (2) and the lifting arm (1). Carry out this operation on both sides.
1 25465
3
2 53
87666787A -- 11 -- 2007
32
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
8. Straighten the securing ring and unscrew the internal arm (9) ring--cam retaining bolt.
1
25466
54 9. Using a brass drift, strike the end of the shaft (2), extract the shaft and the internal arm(1), the ring--cam and the seal (3).
1
3
2 25467
55 10. Use compressed air to remove the piston (2) from its cylinder (1).
1
2
26297
56 11. Using tool 380001627 (1) insert the piston (3) in the cylinder (2).
1
2
3
25634
57 87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 12. Fit the lift arm shaft (2), the ring--cam and the internal arm (1) inside the lift box, matching up the reference marks. Tighten the bolt that secures the ring--cam to the internal arm.
33
1
2 25468
58 13. To avoid damaging the internal seal lips (2), use a flexible brass sheet (1) dimensions: 200 x 90 mm and 0.05รท0.1 mm. Roll up the sheet and insert the seal inside. Position the unit on the spline and push the seal manually into its seat, then remove the sheet.
1
26300
2 59
14. Using the drift 380001628 (1), complete the fitting of the seal into the relative seat on the arm shaft.
1
26326
60 15. Fit the lift arms (1) on the shaft, matching up the reference marks. Secure in position with the bolts and washers. Fit the oil delivery pipe to the control cylinder.
1
25469
61 87666787A -- 11 -- 2007
34
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
CYLINDER SAFETY VALVE CALIBRATION
1
2
3
1. Fit the cylinder safety valve (1) on the valve union 380000218 (2) and connect to the hand pump 380000215 (3). 2. Operate the hand pump (3) and check that the cylinder safety valve opens at a pressure of 210 รท 215 bar (214 รท 219 kg/cm2). If the valve setting is not to specification, the best thing to do is to replace the valve. If necessary it can be adjusted by turning the threaded cap, using wrench 380000230. Tighten to increase the valve setting value or loosen to reduce the value. 3. Assemble the oil delivery union, complete with the cylinder safety valve. Fit the position sensor and the rod that connects the right--hand lifting arm. Use the drift 380000260 to fit the needle bearings on the lower draft lever. Fit the draft sensor rod and relative control kinematics. Assemble the support and relative draft sensor. Assemble the auxiliary control valves, the O--RING seals and the connecting pipe to the lift hydraulic control valve. Complete assembly operations by connecting the pipes and electrical connections to the various sensors and solenoid valves.
87666787A -- 11 -- 2007
25720
62 1
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
35
Op 35 138 20 HYDRAULIC CONTROL VALVE Removal -- Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows.
27868
63
1. Lower the hydraulic lift arms. 2. Thoroughly clean the area around the control valve before starting disassembly operations. 3. Disconnect the electrical connections (1 and 4) and the pipes (2 and 3) on the control valve. 4. Remove the four (2) retaining bolts and detach the hydraulic control valve (1) from the lift. 5. To refit the hydraulic control valve on the lift, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Replace the â&#x20AC;?O Ringâ&#x20AC;? seals and make sure that they are fitted correctly in their seats.
--
Position the control valve on the lift and secure with the bolts.
--
Connect the pipes and electrical connections.
27869
64
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
36
Operation 35 138 24 HYDRAULIC CONTROL VALVE Disassembly -- Assembly Solenoid valve and pilot valve.
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 27196
1. Mark the lowering (L) and raising (R) solenoid valves in order to facilitate re--fitting.
65
2. Carry out operation 35 138 20 Hydraulic control valve, only removal (see page 37). 3. Remove and, if necessary, disassemble the solenoid valves.
1
2
3
4
5
NOTE: The solenoid valve is only supplied as a complete unit.
6 12
7
Exploded view of solenoid valve components 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Piston. O Ring seal. Core. Plunger. O Ring seal. Plate. Cover. Coil. Plate. O Ring seal. Cap. Countersunk screws.
4. Remove the pin (1) and the spring (2) from the pilot valve. Make sure that the pins move freely when pushed against the spring.
11
10
9
8
TIA35088
66
1
2
TIA35164
67
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
37
5. Insert a 5/16 UNF screw into the end of the pilot valve body. Extract the pilot valve from its housing. 6. Solenoid valve assembly and re--fitting operations follow the disassembly procedure in reverse order, making sure that the bolts are tightened to a torque value of 2 Nm. Do not exceed this value.
TIA35170
68 Control valve block pin 1. Mark the right and left hand regulators (8 and 3) in relation to the hydraulic control valve body.
1
2
3
4
NOTE: Do NOT disassemble the regulators (8 and 3). 2. Remove the units from the regulators and extract the control valve pin, the centring spring and the seats. Check that the spring and seats remain coupled with each regulator.
8
7
6
5
TIA35171
IMPORTANT: do not disassemble or zero--set the regulator units. The hydraulic control valve is factory set. Make sure that the control valve pin is correctly set for the neutral position.
69
Control valve pin 1. 2. 3. 4. 5. 6. 7. 8.
Seat. Spring. Regulator unit. Valve housing. Control valve pin. Seat. Spring. Regulator unit.
The control valve pin (1) is specially machined near the neck in order to modulate the differential pressure between the pump and the load valve circuit, in order to guarantee operation.
1
TIA35080
70
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
38 Non--return valve
1. Remove the load non--return valve caps and extract the components from the valve. NOTE: The pin (7), is rounded at one end. When re--fitting the control valve, check that the rounded end is inserted in the head (2).
1
2
3
4
Non--return valve. 1. 2. 3. 4. 5. 6. 7. 8. 9.
Roll Pin. Piston. Cap and O--Ring seal. Valve casing. Mushroom head. Ball. Guide Piece. Spring. Cap and O--Ring seal
INSPECTION AND RE--FITTING 1. Wash all parts, apart from the solenoid valves, with a suitable solvent and check that none of the components are damaged. 2. Minor imperfections can be corrected using abrasive cloth or fine abrasive paste. When using abrasive materials, make sure that all abrasive particles are removed from the control valve housing. 3. If deep scoring or pitting are detected, replace the control valve. 4. To assemble, follow the disassembly operation in reverse order. 5. Lubricate all components with oil and check that the pins move freely in the relative seats. 6. Replace the â&#x20AC;?O Ringâ&#x20AC;? seals. 7. Tighten all caps and locknuts to the prescribed torque value. 8. Whilst installing the solenoid valves, check that they are assembled correctly in the body and that the screws are progressively and alternately tightened to a torque value of 2 Nm. Do not exceed this value.
87666787A -- 11 -- 2007
5
9
8
7
6
TIA35163
71
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
1
SECTION 35 -- HYDRAULIC SYSTEMS Chapter 5 -- Non--stop flow gear pump CONTENT Operation
Description
Page
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque settings -- Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Lift -- Chap. 1 35 104 30
Lift circuit hydraulic pump Disassembly -- Assembly. (With the pump removed) . . . . . . . . . . 4
MAIN SPECIFICATIONS OF HYDRAULIC PUMP C 42 Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotation (as seen from drive side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum speed of rotation (with engine at maximum power 2300 rpm) . . . . . . . . . . . rpm Corresponding rated output . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (I/min) Rated output at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (I/min) Diameter of driven and driving gear shafts . . . . . . . . . . . . . . . . . . . . . . . Internal diameter of seats in supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearance between gear shafts and seats . . . . . . . . . . . . . . . . . . . . . . . . -- maximum clearance due to wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm mm mm mm
gear type with oil suction from rear transmission casing on RH side of engine C 42 NEW HOLLAND driven by engine shaft clockwise 1 : 1,08 2484 47.36 19.06 17.400 ÷ 17.418 17.450 ÷ 17.475 0.032 ÷ 0.075 0.1
Radial clearance of gears in pump body . . . . . . . . . . . . . . . . . . . . . . . . . mm Maximum wear on pump body, suction side at position of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
0.020 ÷ 0.064
Width of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm Width of supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm Width of pump body for gear seats and supports . . . . . . . . . . . . . . . . . . Axial clearance of gears complete with supports in pump body (recondition if necessary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
30.800 ÷ 30.815 24.490 ÷ 24.510 79.935 ÷ 79.960
0.1
0.100 ÷ 0.180
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
2
MAIN SPECIFICATIONS OF BOSCH 25 HYDRAULIC PUMP Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
gear type with oil suction from rear transmission casing.
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
on RH side of engine
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . . . . . . . . . . Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum speed of rotation (with engine at maximum power 2300 rpm) . . . . . . . . . . . . . . . . . . . . . . . . rpm Corresponding rated output . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (I/min) Rated output at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (I/min)
Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOSCH 25 BOSCH driven by engine timing clockwise 1 : 1,08 2484 63.84 25.7
full--flow, with replaceable paper cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTS TO BE TIGHTENED
Thread
Pump control coupling hub locknut . . . . . . . . . . . . . . . . . . . . . . . . . .
7/16 20 UNF
on pump intake
Tightening torque Nm
kgm
29
3
DESCRIPTION AND OPERATION The front hydraulic pump serves the hydraulic lift, the trailer brake valve and the auxiliary control valves. The different types of pump shown above are of the gear type with spur gears and function with non--stop flow according to the engine rpm.
87666787A -- 11 -- 2007
They are fitted on the right hand engine support and are driven by a shaft gear unit. The oil is taken from the rear transmission casing, passing through a filter.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
3
25719
1 Components of C 42 pumps, BOSCH 25 1. 2. 3. 4. 5. 6. 7.
Nut. Lock washer. Circlip. Driving shaft seal. Control side cover. Cover seals. Gear support.
8. 9. 10. 11. 12. 13.
Driven and driving gear shafts. Gear support. Pump body. Front cover. Lock washer. Cylinder Screw.
87666787A -- 11 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
4
PUMP MODELS C 42, BOSCH 25 OP. 35 104 30 LIFT OIL PUMP Disassembly -- Assembly
(With the pump removed) Disassembly
ATTENTION
2
Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
Proceed as follows:
25227
2 1. Remove the bolts and the relative safety washers (12) on the cover (13, fig. 1). 2. Remove the nut (1) that secures the sleeve to the pump driving shaft and the safety washer (2). 3. Remove the front cover (5), the circlip (3) and the seal (4). 4. Mark the parts (7, 8, 9 and 10), in order to re--fit them in the same position, if in good condition. 5. Remove the supports (7 and 9) and gears (8) from the front cover (5) and the pump body (10). 6. Recover the seals (6) and the back up rings. Once the parts are removed, proceed as follows: 7. Check that the gear contact surfaces are flat and perpendicular to their supports. Interpose a thin layer of carbon black; small rough spots can be removed using extremely fine and adequately lubricated abrasive paper. 8. Check that the axial clearance of the gear--support unit in the pump body is 0.100 รท 0.180 mm The distance (2, fig. 2) must be 0.100 รท 0.180 mm less than the distance (1). If necessary, true the flat surfaces involved using lubricated abrasive paper to remove extremely small quantities of material. 9. Clean all constituent parts thoroughly. 10. Replace the seals (4 and 6). 11. Lubricate the parts with the same oil used in the system.
87666787A -- 11 -- 2007
Assembly Procedure
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
12. To re--fit the pump carry out operations from no. 6 to no. 1, in reverse order, referring to fig. 1 and proceeding as follows: --
always ensure maximum cleanliness to prevent foreign matter from entering, as this could damage the pump;
--
fit together the previously marked parts (10, 7, 8 and 9), referring to operation 4, in the original positions;
--
mount the gear supports (7 and 9) in the pump body, positioning as shown in fig. 1;
--
insert the plastic anti--extrusion rings on the seals (6);
--
mount the seals (4), on the control side cover (5) facing towards the inside;
--
Fit the covers (5) and (11), position the washers (12) and tighten the retaining bolts (13);
--
Fit the washer (2) and the locknut (1).
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
1
SECTION 35 -- HYDRAULIC SYSTEMS Chapter 6 -- Front power take--off and electronic lift (for T4040 Supersteer and T4050 Supersteer models) CONTENT Operation
31 140 30 31 140 34 31 140 43 31 140 46 31 162 52
Description Page Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Front power take--off transmission shaft R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Front power take--off transmission shaft D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Front power take--off electromagnetic coupler R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Front power take--off electromagnetic coupling D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Front lift support R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
MAIN SPECIFICATIONS OF FRONT ELECTRONIC LIFT Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in position control
Lift lowering and raising adjustment . . . . . . . . . . . . . . . . . . . . . . . . .
using the knobs (11) and (12, fig. 8) located on the multi--indicator panel
Raising and lowering push--button . . . . . . . . . . . . . . . . . . . . . . . . . .
allows fast lifting/lowering operations using push--buttons, (3, fig. 8), without using knobs (11) and (12)
Front lift function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
is controlled by the same ECU as the rear lift
Single--acting cylinder: --
rated diameter and stroke: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
55 x 110
--
rod diameter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
25
--
capacity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cm3
207
Operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
bar
190 (194 kg/cm2)
Maximum pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
bar
250 (254 kg/cm2) (continued)
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
2
MAIN SPECIFICATIONS OF ELECTRONICALLY CONTROLLED FRONT LIFT (overleaf)
Diameter of arm lifting shaft (14, fig. 4) in relation to bushings . .
mm
34.936 ÷ 34.975
Internal diameter of bushings (15) fitted on lift body . . . . . . . . . . .
mm
35.140 ÷ 35.180
External diameter of bushings (15) fitted on lift body . . . . . . . . . . .
mm
40.060 ÷ 40.090
Clearance between lifting arm shaft (14) and relative bushings .
mm
0.165 ÷ 0.244
Bushing seat diameter (15) in support . . . . . . . . . . . . . . . . . . . . . . .
mm
40.000 ÷ 40.025
Interference between bushings (15) and relative seats . . . . . . . . .
mm
0.035 ÷ 0.090
Endfloat between lifting arm shaft and support . . . . . . . . . . . . . . . .
mm
1.8 ÷ 2.2
Power take--off mechanical engagement return spring (10, fig. 7): --
Spring length under load of 15 N (1.53 kg) . . . . . . . . . . . . . . . .
mm
84
--
Spring length under load of 200 N (20.4 kg) . . . . . . . . . . . . . . .
mm
139
Splined shaft (1, fig. 6 with 6 splines): --
External diameter of splines . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
34.700 ÷ 34.870
--
Internal diameter of splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
27.890 ÷ 28.140
Splined shaft (1, fig. 6 with 6 splines): --
External diameter of two bearings (3) . . . . . . . . . . . . . . . . . . . .
mm
34.884 ÷ 35.000
--
External diameter of flange bearings (7) . . . . . . . . . . . . . . . . . .
mm
29.987 ÷ 30.000
Bearing seat diameter on connector flange (4) . . . . . . . . . . . . . . . .
mm
71.979 ÷ 72.009
Bearing seat diameter on flange (7) . . . . . . . . . . . . . . . . . . . . . . . . .
mm
61.985 ÷ 62.004
Spacer thickness (10, with ± 0.05 mm tolerance) for assembly clearance (G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
1.5 -- 1.75 -- 2.00 -- 2.25 -- 2.5 -2.75 -- 3.00
Tapered roller bearing seat (14, fig. 7) diameter on driving shaft .
mm
46.520 ÷ 46.535
Tapered roller bearing seat (14) diameter on power take--off casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
25.002 ÷ 25.015
Ball bearing seat (6) diameter on driving shaft . . . . . . . . . . . . . . .
mm
24.987 ÷ 25.000
Ball bearing seat (6) diameter on power take--off casing . . . . . . .
mm
51.979 ÷ 52.009
Front ball bearing seat diameter on driven shaft with union (13) .
mm
41.961 ÷ 42.000
Rear ball bearing seat diameter on driven shaft with union (13) .
mm
30.002 ÷ 30.015
Front ball bearing seat diameter on driven shaft with union (13) . on power take--off casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
71.979 ÷ 72.009
Rear ball bearing seat diameter on driven shaft with union (13) on power take--off casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
62.010 ÷ 62.029 (continued)
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
3
IMPLEMENT HITCHING DEVICE DATA (overleaf)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
three--point linkage 1st
Category: Working depth control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of the knob (11, fig. 8) located on the multi--indicator panel
Maximum lift capacity with lifting attachment third point
(1, fig. 15) connected to the upper hole on the lifting attachment support for the full lifting stroke at link ends of horizontal arms: --
arms pivoted in position (A, fig. 16) . . . . . . . . . . . . . . . . . . . . . .
kg
1230
--
arms pivoted in position (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
kg
1430
with centre of gravity at 610 mm. from link ends: --
arms pivoted in position (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
kg
1330
--
arms pivoted in position (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
kg
1500
BOLT TORQUES PARTS TO BE TIGHTENED
Thread
Tightening torque Nm
kgm
Front power take--off Power take--off clutch coupler flange retaining bolts (C1, fig. 1) . . . . .
M8
24
2.5
Power take--off guard retaining bolts (C2) . . . . . . . . . . . . . . . . . . . . . . .
M8
24
2.5
Flange/coupler retaining bolts (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M8
32
3.3
Guard retaining bolts (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M8
24
2.5
Power take--off driving flange retaining bolts (C5) . . . . . . . . . . . . . . . .
M 10
49
5
Upper guard retaining nuts (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M8
24
2.5
Power take--off gearbox casing retaining bolts (C7) . . . . . . . . . . . . . . .
M8
24
2.5
Gearbox/support retaining bolts (C8) . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 10
49
5
Electromagnetic clutch/coupler flange retaining bolts (C9) . . . . . . . . .
M 12
88
9
Electromagnet/coupler flange retaining bolts (C10) . . . . . . . . . . . . . . .
M8
24
2.5
Spring/clutch ring retaining bolts (C11) . . . . . . . . . . . . . . . . . . . . . . . . . .
M8
24
2.5
Electromagnet rotor/coupler flange retaining bolts (C12) . . . . . . . . . . .
M8
32
3.3
Lower guard retaining bolts (C13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M8
24
2.5
Lift arms position sensor support retaining bolts (C1, fig 2) . . . . . . . .
M8
24
2.5
Cylinder pivot front pin retaining bolts (C2) . . . . . . . . . . . . . . . . . . . . . .
M8
24
2.5
Hydraulic cylinder bolt (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M8
24
2.5
Arms pivot pin retaining bolts (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 10
31
3.2
Cylinder pivot rear pin retaining bolts (C5) . . . . . . . . . . . . . . . . . . . . . . .
M8
24
2.5
Implement linkage support retaining bolts (C6) . . . . . . . . . . . . . . . . . . .
M 18
304
31
Front lift implement linkage
87666787A - 11 - 2007
4
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
1 87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
5
MDC0801A
2 87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
6
3 1. 2. 3. 4.
Longitudinal and cross--sectional views of implement linkage assembly Implement linkage third point hook. 5. Attaching Bolts. Third point top link. 6. Lift arms. 7. Arms lateral clearance return bolt. Implement linkage assembly. Arms longitudinal position pin. 8. Lift arms implement linkage hook.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
7
4 9. 10. 11. 12.
Longitudinal and cross--sectional views of implement linkage assembly Lift arms position sensor. 13. Pin retaining bolt (14). Top link third point pivot pin. 14. Lift arms pivot pin. 15. Pin bushings (14). Lifting hydraulic cylinder. Lift arms/cylinder pivot pin. 16. Grease Nipple.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
8
5 1. 2. 3. 4.
Longitudinal and cross--sectional views of front power take--off Power take--off shaft guard 5. Constant velocity joint guard. Power take--off shaft 6. Constant velocity joint. 7. PTO gears casing. Electromagnetic Clutch. Electromagnetic clutch bearings. 8. Mechanical power take--off.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
9
6 1. 2. 3. 4. 5. 6.
Longitudinal views of shaft with front power take--off electromagnetic clutch 7. Constant velocity joint coupler flange. Power take--off shaft 8. Clutch ring/spring retaining bolts. Thrust washer with snap ring 9. Constant velocity joint. Power take--off electromagnetic clutch bearings.. 10. Clearance adjustment shims G. Electromagnetic clutchcoupler flange. 11. Power take--off clutch release springs. Power take--off electromagnetic clutch.. 12. Attaching Bolts. Clutch ring
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
10
7 1. 2. 3. 4. 5. 6. 7.
Longitudinal views of front power take--off casing Gearbox. 8. Retaining Ring. Seal. 9. Thrust washer. Retaining Ring. 10. Engagement sleeve return spring. Engagement shaft and sleeve. 11. Power take--off driven gear. Power take--off driving flange. 12. Seal. Ball Bearing. 13. Constant velocity joint. Power take--off driving shaft. 14. Roller bearing.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
11
ELECTROMAGNETICALLY ENGAGED FRONT LIFT AND POWER TAKE--OFF
Description And Operation The mechanical lift can operate with the implement in the controlled position, after having adjusted the travel and raising limits with potentiometers (11) and (12), located on the panel to the left of the operator.
Using the pushbutton (3) the implement can be raised and lowered without using the previously adjusted potentiometers (11) and (12). The pushbutton (2) also engages or releases the power take--off electromagnet.
1
12 11
2
3
10 540E
1000
9 8
1500
540
2000
4
1000
500 2500 O
5
7 6
MDB1840A
8 1. Function indicators.
7. Power Shuttle control lever.
2. Front Power take--off control.
8. Flashing hazard warning lights switch.
3. Front lift arms raise switch.
9. clock adjustment switch.
4. Front wheel drive mode switch.
10. Dashboard electronic mode selection switch (optional).
5. Rear horizontal arms stabiliser rods adjustment control switch. 6. Light control lever with horn incorporated.
11. Front lift working depth adjustment knob. 12. Front lifting arms upper limit adjustment knob.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
12
FRONT LIFT
Operation controls Two potentiometers (1 and 2 fig. 9) are located on the left--hand side of the dashboard, allowing the upper limit and working position to be stabilised. Switch (1, fig. 10), on the right--hand side, allows the implement to be raised and lowered. Adjustments 9 Upward travel adjustment knob --
turn the knob (1, fig. 9) fully clockwise to totally raise the lift arms;
--
turn the knob (1) fully counter--clockwise to progressively reduce the upward stroke to zero.
Working position adjustment knob --
turn the knob (2) fully clockwise to set the minimum working depth,
--
turn the knob (2) counter--clockwise, progressively increase the working depth.
to
Up/Down switch To raise and lower the implement, use button (1, fig. 10), which has two positions: --
A = Down position.
--
B = Up position.
A
B
10
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
13
FRONT POWER TAKE OFF
DANGER Before using the tractor, check that the plastic guard (1, fig. 11) is in perfect condition and fitted on the universal joint.
11
DANGER In order to ensure longer life for the coupling and the electromagnetic clutch, when the front power take--off is not being used, select the neutral position by turning the screw (1, fig. 12) counter--clockwise.
12 Driving To engage the power take--off, press push--button (1, fig. 13) and pull the knob (2) upwards. The clutch is electromagnetically operated (3, fig. 5). Indicator (1 fig. 14) remains illuminated to indicate that the PTO is engaged. To disengage the PTO, press knob (2, fig. 13) downwards.
13 In the event of slippage due to peaks in torque caused by the implement shutting down or particularly firm ground, the control unit causes the coupling to disengage automatically via a sensor in the clutch. Disengagement takes place when the sensor reads a difference of three revs in 5 seconds between the driving and driven shaft. In this event the indicator (1 fig. 14) flashes slowly to indicate that the coupling is disengaged. To re--engage the power take--off, press knob (2, fig. 13) fully down to disengage the clutch, and then pull upwards to re--engage.
MDC0807
14 87666787A - 11 - 2007
14
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
IMPLEMENT ATTACHMENT AND POWER TAKE--OFF 1. Adjustable top link third point. 2. Power take--off shaft. 3. Adjustable lower lift arms. Note -- When working with hitched implements, dampen the cross swing by tightening the screw (4, fig. 16). 15
LIFT ARMS
B
In order to adjust to the shape of the implement to be connected, the lift arms can be secured to the support in two different positions using the holes A and B. It is advised to remove the horizontal arms when using the tractor without front--hitched implements. Proceed as follows:
A
1. Extract the safety pin (3) and loosen the lock bolt (4). 2. Extract the safety pin (2), remove the retaining pin (1) and extract the arms. 16 Grease nipples fitted on lift arm shaft.
17 Grease nipples fitted on lift arm shaft.
18
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
15
19 1. 2. 3. 4.
Front lift valve body hydraulic diagram High pressure relief valve. 5. Arms up solenoid valve. Arms down solenoid valve. 6. Arms lifting cylinders. Straight union. 7. Compensated valve for arms descent control. Pressure compensator with by--pass. 8. Non--return valve.
87666787A - 11 - 2007
16
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6 FRONT LIFT TROUBLESHOOTING
Problems
The lift does not rise.
Possible Problem
1. Clogged oil filter.
Solutions
Replace filter.
2. Arms up solenoid valve (5, Release the solenoid valve. fig. 19) locked in discharge position.
The lift moves in jerks.
The lift raises too slowly.
3. Hydraulic pump inefficient.
Overhaul or replace the pump.
1. Clogged oil filter.
Replace filter.
2. Air in the pump suction line.
Check that the unions are airtight and the seals are efficient.
1. Clogged oil filter.
Replace filter.
2. Oil leakage through the seals Replace damaged seals. with consequent pressure drop: cylinder seals or on the delivery unions to the cylinders.
3. Hydraulic pump inefficient.
4. Pressure compensator fig. 19) faulty.
Overhaul or replace the pump.
(4, Disassemble and clean the pressure compensator.
5. Maximum pressure valve (1) Carry out calibration on work bench not calibrated.
The lift lowers too slowly.
1. Pressure compensator fig. 19) faulty.
(7, Disassemble and clean the pressure compensator.
The lift lowers too quickly.
1. Pressure compensator fig. 19) faulty.
(7, Disassemble and clean the pressure compensator. (continued)
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
17
FRONT LIFT TROUBLESHOOTING (overleaf)
Problems
Possible Problem
Solutions
The lift is unable to keep the load 1. Faulty seal on check valve (8, Dismantle, check and replace the parts concerned, if necessary. raised (with the engine running, fig. 19). the load moves up and down rhythmically; with the engine turned off, the load lowers). 2. Oil leakage through solenoid Clean or replace the solenoid valve. valve (2). 3. Oil leaking past the lift cylinder Replace seals. seal or the seals on the cylinder oil delivery fitting. 4. Defective seal or maximum Check calibration and adjust or pressure valve set to very low replace if necessary. value (1). The pressure relief valve cuts in 1. Calibration data incompatibili- Carry out lift arm when the lift arms reach the operations correctly. ty of front lift potentiometer. completely raised position. The lift has poor lifting capacity.
calibration
1. Maximum pressure valve (1) Renew it. not calibrated. 2. System safety valve on pump Renew it. incorrectly calibrated. 3. Poor pump efficiency(general- Overhaul or replace the pump. ly combined with a considerable increase in lift time).
The lift arms do not fully raise or lower.
1. Calibration data lost or incor- Repeat the lift arms calibration rect. operation.
Miscellaneous faults
1. For various reasons.
See faults code.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
18
Op. 31 140 30 FRONT POWER TAKE--OFF TRANSMISSION SHAFT R.I.
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted. Proceed as follows. 1. Raise the bonnet. 2. Loosen the battery securing bolts on the front side. 3. Using the handles (1), fitted on both ends of the battery, lift and remove the battery from its housing.
28003
20 4. Remove the split pin (1), the pin (3) and the top link of the third point (2).
21 5. Remove the split pin (1), the retaining bolts (2) and disassemble the lift lower arms (3).
22
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
19
6. Remove the retaining bolts (1) and disassemble the guard (2) on the front power take--off.
23 7. Remove the retaining bolts (1) and disassemble the upper guard (2) on the front lift. 8. Carry out operation 10 406 10 : Radiator, only removal (see Sect. 10, Chapter 1, page 91).
24 9. Remove the retaining brackets (1) and the electric cable clamps (2) that supply the electromagnetic coupling and the front lift arms position sensor, from the power steering piping.
25 10. Disconnect the electrical connection (1) on the electromagnetic coupling.
26 87666787A - 11 - 2007
20
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
11. Remove the retaining bolts, disconnect the electrical connection (1) and remove the front lift arms position sensor (2).
27 12. Disconnect the front lift cylinders oil supply piping (1).
28 13. Hitch the lift support (2), using hook (1), to a hoist, remove the four retaining bolts (3) and disassemble the support, complete with hydraulic cylinders and power take--off.
29 14. Unscrew the power take--off lower guard (1) and power take--off (2) retaining bolts.
30 87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
21
15. Unscrew the power take--off upper guard (1) retaining bolts.
31 16. Remove the retaining nuts (2) from the battery support (1) and extract the two pins (3) from the front axle tie rods (4).
32 17. Remove the power take--off lower guard (1).
33 18. Remove the split pin and the drive engagement shaft (1).
34 87666787A - 11 - 2007
22
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
19. Position two stands (1) under the cab front support brackets.
35 20. Hitch the battery support (1) to a hoist, using the hook and chain (2).
36 21. Unscrew the retaining bolt (3) on the lower pivot pin, the rest (4), the retaining nuts (1) and the lower bracket (2).
37 22. Remove the lower pivot pin (1).
38 87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6 23. Remove the retaining bolts and detach the rear guard (1).
23
1
25643
39 24. Remove the circlip (2) and move the rear sleeve forwards (1).
1
2
25646
40 25. Remove the circlip (2) and move the front sleeve forwards (1).
1
2
25647
41 26. Unscrew the bearing support retaining bolts (1) from the clutch box and remove the drive shaft and support.
1
25648
42 87666787A - 11 - 2007
24
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
27. Remove the upper bracket (1) and stud bolts.
43 28. Unscrew the retaining bolts (1) of the cardan shaft support (2).
44 29. Disassemble the support (1) and cardan shaft (2).
45 30. Hitch the battery support (2) to a hoist with a hook and chain (1), raise the front part of the tractor, so the front power take--off (3) can be removed.
46 87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6 31. To refit the front power take--off unit, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
For the correct assembly of the various parts, refer to the previous illustrations.
--
Apply the torque settings listed on page 3.
--
Refit the lower guard and the front power take--off unit, complete with universal joint, to the battery support and tighten the four retaining bolts.
--
25
--
Assemble the power take--off upper guard and tighten the retaining bolts.
--
Hitch the battery support to a hoist, raise and remove the two stands from under the cab front support brackets.
--
Hitch the lift support, complete with hydraulic cylinders and power take--off, to a hoist and re--attach to the front axle casing, tightening the four retaining bolts.
--
Assemble the front lift cylinders oil supply piping.
--
Assemble the electrical connection and the front lift arms position sensor, tightening the retaining bolts.
--
Assemble the electromagnetic coupler electrical connection.
Assemble the lower support and cardan shaft, tightening the retaining bolts.
--
Assemble the upper bracket with stud bolts.
--
Assemble the lower pivot pin.
--
Carry out operation 10 406 10: Radiator, only installation (see Section 10, Chapter 1, page 93).
--
Assemble the lower bracket, the rest and the retaining bolt on the lower pivot pin.
--
Assemble the battery.
--
Attach the electromagnetic coupler and front lift arms position sensor electrical power supply cables, to the power steering piping, using the bracket and clamp.
--
Assemble the front lift upper guard and tighten the retaining bolts.
--
Assemble the power take--off guard and tighten the retaining bolts.
--
Assemble the drive shaft support and tighten the retaining bolts.
--
Move the front sleeve forwards and assemble the circlip.
--
Move the rear sleeve forwards and assemble the circlip.
--
Assemble the drive shaft guard and tighten the retaining bolts.
--
Assemble the drive engage shaft and split pin.
--
Assemble the lift lower arms, the retaining bolts and the split pins.
--
Insert the two front axle tie rods on the tank support, then tighten the retaining nuts.
--
Assemble the third point top link, the pin and split pin.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
26
OPERATION 31 140 34 FRONT POWER TAKE--OFF DRIVE SHAFT D.A.
ATTENTION
7. To reassemble the front power take--off casing, proceed as follows:
--
Carefully check all disassembled parts, replacing components that show signs of wear.
--
Refer to figure 47 for correct parts assembly, proceeding as follows.
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
Apply the torque settings listed on page 3.
For disassembly operations, refer to figure 47 and proceed as follows.
--
Fit the seal on the front casing, then the constant velocity joint, the relative ball bearings and the power take--off driven gear unit.
--
Fit the thrust washer and bearings snap ring on the front casing.
--
Assemble the seal, the ball bearing, the bearing snap rings, shaft and the roller bearing.
--
Assemble the return spring, shaft and the engaging sleeve.
--
Carefully clean the contact surfaces, apply LOCTITE 518 (or LOCTITE 5205) and reassemble the front and rear casings, then tighten the retaining bolts.
--
Refit the plug and fill up the gearbox with oil.
Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
ATTENTION
1. Remove the plug and drain off the oil from the gearbox.
2. Remove the retaining bolts and separate the front and rear casings.
3. Remove the spring (10), shaft and engaging sleeve (4) from the rear casing.
4. Remove the Seeger rings (3) and disassemble the bearing (6), shaft (7), seal (2) and roller bearing (14) from the rear casing.
5. Remove the snap ring (8) and thrust washer (9) from the front casing.
6. Disassemble the constant velocity joint (13) and relative ball bearings, the power take--off driven gear unit (11) and the seal (12).
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
27
47 1. 2. 3. 4. 5. 6. 7.
Longitudinal views of front power take--off casing Gearbox. 8. Retaining snap ring. Seal. 9. Thrust washer. Retaining snap ring. 10. Engagement sleeve return spring. Engagement shaft and sleeve. 11. Power take--off driven gear. Power take--off driving flange. 12. Seal. Ball Bearing. 13. Constant velocity joint. Power take--off driving shaft. 14. Roller bearing.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
28
OPERATION 31 140 43 FRONT POWER TAKE--OFF ELECTROMAGNETIC COUPLER R.I.
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted. Proceed as follows. 1. Remove the split pin (1), the pin (3) and the top link of the third point (2).
48 2. Remove the retaining bolts (1) and disassemble the power take--off guard (2).
49 3. Remove the retaining bolts (1) and disassemble the upper guard (2) on the front lift.
50
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
29
4. Remove the three retaining bolts (1) and the right--hand safety grating (2).
51 5. Remove the retaining brackets (1) and the electric cable clamps (2) that supply the electromagnetic coupling and the front lift arms position sensor, from the power steering piping.
52 6. Disconnect the electrical connection (1) on the electromagnetic coupling.
53 7. Unscrew the four retaining bolts and remove the front power take--off (1) complete with electromagnetic coupler (2) and universal joint (3).
54 87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
30
8. To refit the electromagnetic coupler the front power take--off, proceed as follows:
--
Assemble the electromagnetic coupler and front lift arms position sensor electrical cable brackets and clamps from the power steering piping.
--
Assemble the right--hand safety grill and the retaining bolts.
--
Assemble the front lift upper guard and the retaining bolts.
--
Assemble the power take--off front guard and the retaining bolts.
--
Assemble the third point top link, the pin and split pin.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
For the correct assembly of the various parts, refer to the previous illustrations.
--
Apply the torque settings listed on page 3.
--
Assemble the front power take--off complete with electromagnetic coupler and universal joint on the lift body and tighten the four retaining bolts.
--
Connect the electromagnetic coupler electrical connection.
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
31
OPERATION 31 140 46 FRONT POWER TAKE--OFF ELECTROMAGNETIC COUPLER D.A.
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Unscrew the four retaining bolts (2) and the cardan shaft (1).
55 2. Remove the Seeger ring (1).
56 3. Remove the two washers (1).
57
87666787A - 11 - 2007
32
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
4. Using a punch, tap the shaft (1) to release it from the coupler flange (2).
58 5. Remove the coupler flange (1).
59 6. Remove the Seeger ring (2) and bearing (3) from the coupler flange (1). 7. Remove the four clutch disk (5) retaining bolts (4) from the springs, recovering the retaining nuts and washers. 8. Remove the four retaining bolts (6) on the coupler flange springs (1), recovering the retaining bolts and the springs.
60 9. Remove the six retaining bolts (1) on the magnetic rotor (2).
61
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
33
10. Using an extractor (1) extract the magnetic rotor (2).
62 11. Remove the circlip (1) and recover the thrust washer (2).
63 12. Extract the PTO shaft (1), by tapping the end, as shown in the drawing.
64 13. Remove the six retaining bolts (1) and remove the electromagnet (2).
65 87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
34
14. To assemble the front power take--off electromagnetic coupler, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
For the correct assembly of the various parts, refer to the previous illustrations.
--
Apply the torque settings listed on page 3.
--
Assemble the electromagnet and tighten the six retaining bolts, after having smeared the surfaces with LOCTITE 242 (or LOCTITE 243).
--
Install the PTO shaft.
--
Fit the ring and the retaining snap ring on the shaft.
--
Assemble the magnetic rotor on the shaft and tighten the six retaining bolts, after having smeared the surfaces with LOCTITE 242 (or LOCTITE 243).
87666787A - 11 - 2007
--
Assemble the bearing and the snap ring on the universal joint flange.
--
Assemble the universal joint flange springs and tighten the four retaining bolts, after having smeared the surfaces with LOCTITE 242 (or LOCTITE 243).
--
Assemble the four clutch disk spring retaining bolts, complete with washers and nuts, after having smeared the surfaces with LOCTITE 242 (or LOCTITE 243).
--
Fit the universal joint flange on the shaft.
--
Insert the shaft on the universal joint flange.
--
Fit the two washers and the snap ring.
--
Assemble the cardan shaft and tighten the four retaining bolts on the flange, after having smeared the surfaces with LOCTITE 242 (or LOCTITE 243).
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
35
Op. 31 162 52 FRONT LIFT SUPPORT R.I.
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted. Proceed as follows. 1. Raise the bonnet. 2. Remove the split pin (1), the retaining bolts (2) and disassemble the lift lower arms (3).
66 3. Remove the retaining bolts, disconnect the electrical connection (1) and remove the front lift arms position sensor (2).
67
87666787A - 11 - 2007
36
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
4. Disconnect the front lift cylinders oil supply piping (1). 5. Carry out operation 31 140 43 Front PTO electromagnetic joint, only removal (see page 28).
68 6. Hitch the lift support (2), using a sling and hook (1), to a hoist, remove the four retaining bolts (3) and disassemble the support and hydraulic cylinders.
69 7. With the lift on a work bench, disassemble the rear retaining pins (1) on the lift hydraulic cylinders (2), disconnecting the relevant piping.
70 8. Remove the retaining bolts and disassemble the rear retaining pins (1) on the lift hydraulic cylinders (2) and the lift front arms (4) retaining pins (3), then remove the hydraulic cylinders and lift front arms supports.
71
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6 9. To refit the front lift support, proceed as follows:
37
--
Hitch the lift support, using slings and a hook, to a hoist, assemble the support. complete with hydraulic cylinders and the four retaining bolts.
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
Carry out operation 31 140 43 Front PTO electromagnetic joint, only refitting (see page 30) and tighten the four retaining bolts.
--
For the correct assembly of the various parts, refer to the previous illustrations.
--
Assemble the front lift cylinders oil supply piping.
--
Apply the torque settings listed on page 3.
--
Assemble the front lift arms position sensor, tighten the retaining bolts and connect the electric power supply connection.
--
Assemble the lift front arms supports with relative pins and retaining bolts, then the hydraulic cylinders with relative pins and front and rear retaining bolts.
--
Assemble the lift lower arms, the retaining bolts and the split pins.
ATTENTION
87666787A - 11 - 2007
38
87666787A - 11 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
1
SECTION 35 - HYDRAULIC SYSTEMS Chapter 7 - Front lift and power take-off (for mod. T4030 Deluxe, T4040 Deluxe and T4050 Deluxe) CONTENT Operation
35 162 52 31 146 40 31 146 44 31 164 30 31 160 52 31 160 40
Description Page Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cross-sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Front power take-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Front mechanical lift (description and operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Front electronic lift (description and operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Front lift troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Front electronic lift operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Smooth ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Front lift calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Front lift (mechanical/electronic). Removal-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Front power take-off. Removal-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Front power take-off. Removal-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Front power take-off. Disassembly - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Front electronic lift control unit. Removal-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Front electronic lift control valve Removal - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Fault code indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Location of the electronic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
MAIN SPECIFICATIONS OF FRONT MECHANICAL LIFT Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in position control
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
lever located on right-hand side of operator
Single-acting cylinder: -
quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
no.
2
-
rated diameter and stroke: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
63 x 155
-
rod diameter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
28
capacity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cm3
2483
Operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
bar
190 (194 kg/cm2)
Maximum pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
bar
250 (254 kg/cm2)
-
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2
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7 MAIN SPECIFICATIONS OF ELECTRONICALLY CONTROLLED FRONT LIFT
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
pressure, mixed and position control
Lift lowering and raising adjustment . . . . . . . . . . . . . . . . . . . . . . . . .
with the knobs on the right-hand side of the operator
Up/down buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
allows fast lifting/lowering operations using push-button (B, fig. 22) or (1 and 2, fig. 24), without using the height and depth adjustment knobs
Front lift function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
managed by an independent electronic control unit.
Single-acting cylinder: -
quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
no.
2
-
rated diameter and stroke: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
63 x 155
-
rod diameter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
28
capacity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cm3
483
Operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
bar
190 (194 kg/cm2)
Maximum pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
bar
250 (254 kg/cm2)
-
MAIN SPECIFICATIONS OF FRONT POWER TAKE-OFF Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
coupling with hydraulic clutch
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with lever located under the control panel
Speed of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rpm
1000 13/
Diameter of driven shaft at grooved terminal . . . . . . . . . . . . . . . . .
8â&#x20AC;?
(6 grooves)
IMPLEMENT HITCHING DEVICE DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
three-point linkage
Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1st
Maximum lift capacity with lifting attachment third point connected to the upper hole on the lifting attachment support for the full lifting stroke: -
at link ends of horizontal arms . . . . . . . . . . . . . . . . . . . . . . . . . .
kg
1756
-
with centre of gravity at 610 mm from link ends . . . . . . . . . . .
kg
1120
87666787A1 - 03 - 2008
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
3
FRONT POWER TAKE-OFF
1
BOLT TORQUES Tightening torque PARTS TO BE TIGHTENED
Thread
Power take-off clutch coupler flange retaining bolts (C1). . . . . . . . . .
Nm
kgm
M 12
110
11,2
Front shaft to flexible coupling retaining bolts (C2). . . . . . . . . . . . . . . .
M 12
120
12,2
Crankshaft front flange to shaft retaining bolts (C3). . . . . . . . . . . . . . .
M 10
69
7
Rear shaft to flexible coupling retaining bolts (C4). . . . . . . . . . . . . . . .
M 12
120
12,2
Power take-off clutch to shaft retaining bolts (C5). . . . . . . . . . . . . . . .
M8
28
2,9
Chassis frame to front power take-off support retaining bolts (C6). .
M 20
425
43,3
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4
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7 FRONT LIFT
2
BOLT TORQUES
Tightening torque PARTS TO BE TIGHTENED
Thread
Bolts securing lift to axle (C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nm
kgm
M 20
410
41,8
Bolts securing lift arm joints (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 10
45
4,6
Bolts securing cylinder upper pin (C3) . . . . . . . . . . . . . . . . . . . . . . . . . .
M 10
45
4,6
87666787A1 - 03 - 2008
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
5
3
Longitudinal sectional views of the front power take-off assembly 1. 2. 3. 4. 5. 6. 7. 8. 9.
Reduction unit. Front power take-off clutch assembly. Input shaft. Flexible coupling. Crankshaft front pulley to assembly retaining bolts. Reduction unit driving shaft. Shaft splining key. Clutch coupling piston. Clutch driving flange.
10. 11. 12. 13. 14. 15. 16. 17. 18.
Clutch driven shaft retaining bolt. Clutch disengagement springs. Clutch friction disc. Belleville washer. Piston O-ring. Clutch assembly retaining bolts. Reduction unit driven gear. Power take-off coupling shank. Guard. 87666787A1 - 03 - 2008
6
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
4
Longitudinal sectional views of the front lift assembly. 1. 2. 3. 4. 5.
Third point. Tractor tow hook. Bolts securing assembly to chassis frame. Lift lower arm. Lower arms quick hitch.
87666787A1 - 03 - 2008
6. 7. 8. 9. 10.
Arm lift detection device. Rod to plunger security dowel. Piston. Seals. Link rod.
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
7
FRONT POWER TAKE OFF Description and operation The front power take-off receives drive straight from the engine, the coupling is made with a hydraulically controlled clutch. To engage the power take-off, pull the stop ring (1) downwards and move the lever (2) into the horizontal position. To disengage the front power take-off just push the lever (2) downwards.
5 The power take-off engagement lever acts, via a flexible cable, on the control valve stem alongside the right-hand rear reduction gear. This control valve receives oil at a pressure of 15.7 (16) bar (kg/cm2) from the rear power take-off servo control outlet.
6 With the lever (2, fig. 5) in the vertical the oil is drained off, whereas with the lever horizontal and PTO engaged the oil is diverted, by the control valve rod, to the PTO engagement clutch.
7 When the front power take-off is engaged the indicator (1) lights up on the control panel. The direction of rotation of the front power take-off is clockwise with the tractor seen from the rear.
8
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8
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
9
A = 0.50รท0.65 mm Clearance between the fork (3) and support (4). B = 30รท50 mm Travel of control lever (1). Front power take-off control adjustment. 1. 2.
3.
4.
5.
Turn the locknut (6) until it is at the end of its travel on the thread. Screw down the nut (5) to take the fork (3) into contact with the support (4) (zone shown by the arrow and asterisk *). Slightly raise the lever (1) and insert the feeler gauge (A = 0.50รท0.65 mm) between the fork (3) and the support (4) (zone shown by the arrow and asterisk *). Check that the feeler gauge is held between the fork (3) and the support (4). If this does not occur, turn the nut (5) to lock the gauge. With the feeler gauge locked, turn the nut (5) to free the gauge and, then, check it can easily be extracted. After
87666787A1 - 03 - 2008
6.
7.
8.
9.
removal check there is the prescribed clearance between the fork (3) and the support (4). Taking care not to turn the nut (5) check that the nut rests with its base on the support (4) then, still without turning the nut (5), tighten the locknut (6). After tightening, check that the clearance between the fork (3) and the support (4) has remained as prescribed. Operate the plate (2), have the lever (1) make the travel (B = 30รท50 mm), release the lever and check it returns to its initial position by itself. Check there is the prescribed clearance between the fork (3) and the support (4).
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
9
10
Front power take-off control valve A . Oil delivery to the power take-off clutch. T . Oil delivery to outlet. P . Oil supply at 15.7 (16) bar (kg/cm2) from the rear power take-off servo control. 1. Control valve. 2. Front power take-off clutch oil delivery union.
3. 4. 5. 6. 7.
Oil discharge pipe. Control valve rod operating lever. Control valve rod. Power take-off engaged indicator light switch. Control valve supply union.
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10
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
1
2
3
A B
10
9
7
8
11
7
6
5
4
MDG1451A
11 Front PTO engagement clutch A . Clutch disengaged.
8.
Piston.
B . Clutch engaged.
9.
Clutch driving shaft.
1.
Clutch pressure plate.
10. Clutch assembly tightening bolts.
2.
Clutch release springs.
11. Oil inlet union.
3.
Clutch driving shaft.
4.
Centring dowels.
5.
Friction material disc.
6.
Belleville washer.
7.
Seal.
87666787A1 - 03 - 2008
Oil at static rest.
Pressurised oil.
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
11
FRONT MECHANICAL LIFT
Description and operation The front lift is secured to the axle support and is governed with the lever (1, fig. 13) located to the right of the operator.
12 To be able to operate the front lift it is necessary to raise the safety ring (2) then push the lever (1) forwards to lower the lift arms or pull the lever backwards to raise the arms.
13 The lever (1, fig. 13), via a cable, operates a hydraulic control valve (4) that sends oil to the lifting cylinders. If the implement fitted to the lift needs an additional pressurized oil inlet it is possible to hook up to the hydraulic control valve (3). The hydraulic control valve (3) is governed with the lever (1, fig. 13): raise the safety ring (2, fig. 13) and move the lever to the right or left.
14
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12
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7 FRONT ELECTRONIC LIFT
Description and operation. The front lift functions control is governed by an electronic control unit located to the left of the driving seat. When the engine is started, the indicator (1, fig. 15) illuminates to run an operating test on the lift and on the error code indicator light, which stays on and will go out the first time there is lifting or lowering with the up and down button on the right-hand mudguard (1, fig. 23).
15 Safety switch. The switch (1) has two settings: - Switch pressed in position A = In which all the lift controls are active. - Switch pressed in position B = In which all the front lift controls are disabled. This condition is essential for travelling on roads, or when you are not using the front lift.
16 Lift arm automatic raise switch. The switch (1) has two settings: - manual operation: The switch must be pressed in position A. - In this position, when you apply the lift control, with the push-button (1 fig. 23), the arms of the lift stop at the height limit set with the potentiometer (1, fig. 19). - automatic operation for driving on roads: the switch must be pressed in position B. - In this position, the switch cancels the height limit set with the potentiometer (1, fig. 19). In this condition, when operating the lift control with the up and down button on the right-hand mudguard (1, fig, 23) the lift arms stop automatically at the maximum height.
87666787A1 - 03 - 2008
17
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
13
Lift arm down speed control potentiometer. Rotate the knob clockwise for maximum lift arm descent speed. Turn the knob (1) anticlockwise to reduce the lift arm down speed progressively until they stop (knob turned fully anticlockwise).
18 Lift arm up limit control potentiometer. Turn the knob clockwise to set maximum upward lift arm travel. Turn the knob anticlockwise to progressively reduce the ascent of the lift arms.
19 Working depth control potentiometer. With the knob turned fully anticlockwise, the lift works at maximum depth. In this condition the connected implement follows the contours of the ground (floating position). Progressively turning the knob clockwise, progressively decreases the working depth.
20 Pressure/mixed/position control potentiometer. There is position control with the knob turned fully clockwise. There is mixed control with the knob turned halfway anticlockwise, after which there is pressure control. There is maximum pressure control sensitivity with the knob turned fully anticlockwise.
21
87666787A1 - 03 - 2008
14
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
Lift arm up/down switch on the dashboard. After setting lift operation with the various potentiometers available, use the switch (1) to move the implement. - Press the switch in position (A) to lower the implement. - Press the switch into position (B) to raise the implement.
22 Lift arm up/down switches on the right-hand mudguard. To lower and raise the implement fitted to the lift, besides using the switch (1, fig. 22), you can control the up/down movement with the push-button (1, fig. 23), on the right-hand mudguard. - Press the switch in position (A) to raise the implement. - Press the switch into position (B) to lower the implement.
23 External lift arm up/down switches. 1. Arms down control button. 2. Arms up control button.
DANGER Before operating the lift with the external buttons, get outside the range of action of the lift arms.
24 Lift arms position sensor The sensor (1) detects the position of the lift arms.
25
87666787A1 - 03 - 2008
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
15
26
Front lift hydraulic control valve diagram A. B. N. P. R. Y. 1. 2. 3. 4. 5. 6. 7.
Front lift cylinder supply. Trailer brake quick hitch supply. Oil outlet not used by the system component. Oil inlet by the pump or by a system component. Discharge oil outlet. Signal from rear brakes. Lower solenoid valve. Cylinder inlet check valve. Lifting solenoid valve. Front electronic lift block. Pressure compensator valve. Trailer brake valve. Pressure regulating valve.
8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Pump assembly. Filter. Pressure switch. Accumulator solenoid valve 14 bar. Accumulator 14 bar. Accumulator block. Accumulator 40 bar. Accumulator solenoid valve 40 bar. Ventral control valve assembly. Electronic rear lift. Control valve assembly. Front lift cylinders.
87666787A1 - 03 - 2008
16
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
27 Front lift hydraulic control valve assembly 1. 2. 3. 4. 5. 6.
Oil outlet not used by the front lift hydraulic control valve. Discharge oil outlet. Oil inlet from pump. Front lift cylinder supply. Accumulator 40 bar. Front lift hydraulic control valve.
87666787A1 - 03 - 2008
7.
Lower solenoid valve.
8.
Lifting solenoid valve.
9.
Accumulator solenoid valve 14 bar.
10. Accumulator 14 bar. 11. Pressure switch. 12. Accumulator solenoid valve 40 bar.
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
17
Description and operation of accumulator control valve. In parallel between the front electronic lift (1) and the cylinders there is a second control valve (2) with two solenoid valves, two accumulators (one 14 bar and the other 40 bar) and a pressure switch.
28 The pressure switch is constantly subjected to the loading pressure by the lifting cylinders and is used, by the control unit, as a signal transmitter for pressure control The sensor is designed to withstand a pressure of from 0á200 bar, it is supplied, by the control unit, with a current of 9.5 V. The output signal changes in proportion to the operating pressure to which it is subjected (it increases as the pressure increases). 1 - Ground, 2 - Signal, 3 - Supply (9.5V). 29 At a pressure of approximately 0 bar, the voltage signal (a) is approximately 25% of the supply voltage (approximately 2.4 V). The voltage signal output from the sensor can come within a range of from 25% to 75% of the supply voltage. Y - Supply (9.5 V = 100%), X - Pressure, a - Output signal
30 The two solenoid valves are coupled with the related accumulators: solenoid valve M2, in the neutral position, is connected with a check valve to the circuit and to the accumulator with 14 bar. The solenoid valve M1 separates the circuit from the 40 bar accumulator: they are both connected by a constriction of â&#x2C6;&#x2026; 1 mm. A - Oil to the cylinders, N - Oil to the other services, P - Oil from the pump, R - Outlet, 1 - Front lift control valve.
31
87666787A1 - 03 - 2008
18
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
1
2
3
4
5
6
7
14
13
12
11
10
9
8
MDE0628A
32 Front electronically controlled lift functional diagram. Neutral phase 1. 2. 3. 4. 5. 6. 7.
Lowering solenoid valve. Lowering control valve fixed seat. Discharge compartment. Lowering control valve actuator. Lowering control valve. Lowering control valve compartment. To lifting cylinder.
Oil at static rest. Pressurised oil. Discharge oil.
87666787A1 - 03 - 2008
8. 9. 10. 11. 12. 13. 14.
Pressure compensator valve. Excess pressure discharge chamber. Oil coming from the pump. Lifting control valve. Valve calibration spring (11). Non-return valve. Lifting solenoid valve.
DESCRIPTION AND OPERATION Neutral phase The oil from pump (10) meets the closed lifting valve (11), therefore the full pump delivery will be discharged in chamber (9). The lowering valve (5) is closed and the lifting cylinder oil remains trapped between the valve and the check valve (13), maintaining the implement in the desired position.
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
19
1
2
3
4
5
6
7
14
13
12
11
10
9
8
MDE0629A
33 Front electronically controlled lift functional diagram. Lifting phase 1. 2. 3. 4. 5. 6. 7.
Lowering solenoid valve. Lowering control valve fixed seat. Discharge compartment. Lowering control valve actuator. Lowering control valve. Lowering control valve compartment. To lifting cylinder.
Pressurised oil. Discharge oil.
8. 9. 10. 11. 12. 13. 14.
Pressure compensator valve. Excess pressure discharge chamber. Oil coming from the pump. Lifting control valve. Valve calibration spring (11). Non-return valve. Lifting solenoid valve.
DESCRIPTION AND OPERATION Lifting phase The solenoid valve (14), overcomes the resistance of the spring (12) and moves the lifting valve (11), the oil from pump (10) flows through the check valve (13), to lifting cylinder (7) and the pressure compensating valve (8), which adjusts the pressure by discharging any excess pressure through discharge duct (9). 87666787A1 - 03 - 2008
20
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
1
2
3
4
5
6
7
14
13
12
11
10
9
8
MDE0630A
34 Front electronically controlled lift functional diagram. Lowering phase 1. 2. 3. 4. 5. 6. 7.
Lowering solenoid valve. Lowering control valve fixed seat. Discharge compartment. Lowering control valve actuator. Lowering control valve. Lowering control valve compartment. To lifting cylinder.
Pressurised oil. Discharge oil.
DESCRIPTION AND OPERATION Lowering phase The solenoid valve (1) overcomes the resistance of the relative spring and moves the actuator (4) inside 87666787A1 - 03 - 2008
8. 9. 10. 11. 12. 13. 14.
Pressure compensator valve. Excess pressure discharge chamber. Oil coming from the pump. Lifting control valve. Valve calibration spring (11). Non-return valve. Lifting solenoid valve.
the lowering valve (5). This allows the oil from chamber (6) to discharge through chamber (3), thereby decreasing the pressure inside chamber (5). In these conditions the oil pressure generated by the implement on the lifting cylinder, through the duct (7), will move the lowering valve (5) permitting the oil from the lifting cylinder to discharge through the chamber (3). The oil from pump (10) meets the closed lifting valve (11), therefore the full pump delivery will be discharged in chamber (9).
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
21
FRONT LIFT TROUBLESHOOTING
Problems The lift does not rise.
Possible Problem 1. Clogged oil filter.
Solutions Replace filter.
2. Arms up solenoid valve locked Release the solenoid valve. in discharge position (for electronic lift).
The lift moves in jerks.
The lift raises too slowly.
3. Hydraulic pump faulty.
Overhaul or replace the pump.
1. Clogged oil filter.
Replace filter.
2. Air in the pump suction line.
Check that the unions are airtight and the seals are efficient.
1. Clogged oil filter.
Replace filter.
2. Oil leakage through the seals Replace damaged seals. with consequent pressure drop: cylinder seals or on the delivery unions to the cylinders. 3. Hydraulic pump faulty.
Overhaul or replace the pump.
4. Pressure compensator faulty Disassemble and clean the pressure (for electronic lift). compensator. 5. Pressure relief valve Carry out calibration on work bench calibration incorrect (for electronic lift). The lift lowers too slowly.
1. Pressure compensator faulty Disassemble and clean the pressure (for electronic lift). compensator.
The lift lowers too quickly.
1. Pressure compensator faulty Disassemble and clean the pressure (for electronic lift). compensator. (overleaf)
87666787A1 - 03 - 2008
22
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7 FRONT LIFT TROUBLESHOOTING (overleaf)
Problems
Possible Problem
Solutions
The lift is unable to keep the load 1. Faulty seal on check valve (for Dismantle, check and replace the parts concerned, if necessary. raised (with the engine running, electronic lift). the load moves up and down rhythmically; with the engine 2. Oil seepage through Clean or replace the solenoid valve. turned off, the load lowers). the solenoid valve (for electronic lift). 3. Oil leaking past the lift cylinder Replace seals. seal or the seals on the cylinder oil delivery fitting. 4. Defective seal or pressure relief Check calibration and adjust or valve set very low (for replace if necessary. electronic lift). The pressure relief valve cuts in 1. Calibration data incompatibilâ&#x20AC;? Carry out lift arm when the lift arms reach the ity of front lift potentiometer. operations correctly. completely raised position. Poor lifting capacity.
calibration
1. Pressure relief valve set Renew it. incorrectly (for electronic lift). 2. System safety valve on pump Renew it. incorrectly calibrated. 3. Poor pump efficiency Overhaul or replace the pump. (generally combined with a considerable increase in lift time).
The lift arms do not fully raise or lower.
1. Calibration data lost or Repeat the lift arms calibration incorrect (for electronic lift). operation.
Miscellaneous faults
1. For various reasons electronic lift).
87666787A1 - 03 - 2008
(for See faults code.
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
23
FRONT ELECTRONIC LIFT OPERATING INSTRUCTIONS
Position control Start the machine and make the following settings with the potentiometers. -
Turn the pressure/mixed/position potentiometer (1) fully clockwise (to its limit stop).
-
Set the desired lifting limit with the potentiometer (2).
-
Set the lowering speed limit according to the implement fitted on the lift with the potentiometer (3).
-
Set the desired depth limit with the potentiometer (4).
35
Select the most appropriate gear. - Press the switch (1), on the right-hand mudguard, in position (B) to lower and start work.
36 The control unit will check the state of the lifting and lowering solenoid valves, continually comparing the setting with the potentiometers with the actual value read by the arm lift sensor. In the conditions of position control, the solenoid valves connected to the accumulators do not come into operation.
87666787A1 - 03 - 2008
24
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
Pressure test Start the machine and, after hooking the implement to the lift, calibrate the implement weight (see page 27). Set the potentiometer (1) as follows:
37 -
Starting with the knob turned fully clockwise (100% position control), turn it halfway anticlockwise, the mixed position (increasingly less position control with increasingly greater pressure control). Turning it anticlockwise, for the second half of the adjustment, will produce pressure control (the further the potentiometer turns anticlockwise the greater the sensitivity of the pressure control). a - 100% Pressure control (Maximum control sensitivity), b - Pressure control, c - Mixed control, d - 100% Position control, A - Pressure control graph, B - Position control graph. 38 -
-
Set the desired lifting limit with the potentiometer (1). Set the lowering speed limit according to the implement fitted on the lift with the potentiometer (2). Set the desired depth limit with the potentiometer (3).
39 NOTE: Consider that from the potentiometer (3) turned fully anticlockwise (maximum depth in position control) you pass, by turning it clockwise, from a condition of minimum discharge pressure (lift fully lowered in conditions of pressure control) to one of maximum pressure discharge, turned fully clockwise (lift fully raised in conditions of pressure control).
87666787A1 - 03 - 2008
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
25
With the pressure/mixed/position control potentiometer (1) in conditions of mixed or pressure control the green indicator light (2) signals the working condition.
40 Select the most appropriate gear. - Press the switch (1), on the right-hand mudguard, in position (B) to lower and start work.
41 The lift control unit, in the conditions of mixed or pressure control, compare the pressure measured by the sensor on the block of accumulators with the settings of the various potentiometers. If the implement, for example a mowing conditioning machine resting on the ground with slides or wheels, should overcome a ditch (condition associated with an increase in pressure), or overcome a hump (condition associated with a decrease in cylinder pressure), in these conditions the control unit, considering the settings made with the pressure/mixed/position potentiometers, will energize the solenoid valves of the 14 bar accumulator or that of the 40 bar accumulator to keep the cylinder pressure at the value set by the potentiometers.
87666787A1 - 03 - 2008
26
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7 SMOOTH RIDE CONTROL
The front lift control unit has a smooth ride control device. Pressing the up button on the right-hand mudguard the implement reaches the upper limit stop, after approximately 2 seconds the control unit energizes the solenoid valve connected to the 40 bar accumulator. Smooth ride control is now operative. NOTE: When the pressure/mixed/position potentiometer is turned fully clockwise (100% position control) the 40 bar accumulator is not connected to the circuit so the vibration-damping device is not on. Simply turn the potentiometer slightly anticlockwise and move it into pressure control for the vibration-damping device to work.
42
87666787A1 - 03 - 2008
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
27
FRONT LIFT CALIBRATIONS Implement weight calibration. Whenever an implement is hitched onto the front lift it is necessary to do these calibrations to obtain the rated value of the pressure in the lift cylinders. With the tractor parked on a level surface, with the implement fitted on the lift, start up the engine. Using the switch (1) on the right-hand mudguard, press in position (A) to raise the arms until the implement is off the ground.
43 Using the height limiting potentiometer (1) limit the height of the implement,
44 Pressing the lifting switch on the right-hand mudguard again (1, fig. 43) will not produce any lifting because the height has been limited by the potentiometer (1, fig. 44), continuing to keep the switch pressed for 10 seconds the diagnostics warning light blinks for 5 seconds with a frequency of 4 Hz, the operation of saving the calibration has now ended. NOTE: During calibration you must never reach the upper limit stop. If the pressure is <14 bar during calibration the calibration setting is not saved. 45
87666787A1 - 03 - 2008
28
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
Calibrating the lift arms height sensor. The calibration procedure is necessary if: - The control unit is powered up for the first time. - The sensor has shut down once (for at least 3 seconds). - The sensor is faulty (fault code 25). During calibration it is vital for the lift to make a full travel, so set the potentiometers. 1. 2. 3. 4.
Pressure/mixed/position control potentiometer turned fully clockwise (position control). Height limit potentiometer turned fully clockwise (maximum lift). Down speed potentiometer turned fully clockwise (maximum down speed). Working depth potentiometer turned fully anticlockwise (maximum depth)
46 Turn the key onto start, the control unit diagnosis indicator light blinks for 4 seconds at 8 Hz to signal that calibration is necessary.
47 Start the machine and, with the tractor stationary, press button (1) into position B to lift the arms to the maximum height. In these conditions you will see the overpressure valve trip. Keep the switch pressed for 2 seconds, the diagnosis LED will blink for 2 seconds at 8 Hz to signal that the upper limit stop has successfully been saved.
48
87666787A1 - 03 - 2008
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
29
Press switch (1) into position A to take the lift arms to the lower mechanical limit stop, keep the button pressed for 2 seconds, the diagnosis LED blinks as follows; -
2 seconds at 8 Hz to signal that calibration has taken place correctly.
-
8 seconds at 8 Hz to signal that calibration has not taken place correctly. The calibration must be repeated correctly.
49 NOTE: If, for whatever reason, you are going to repeat calibration, you need to cut off the supply to the arm position sensor, with the key inserted, for at least three seconds.
87666787A1 - 03 - 2008
30
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
Op. 35 162 52 FRONT LIFT (MECHANICAL/ELECTRONIC) Removal - Installation
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no-one is in the vicinity of the load to be lifted. Proceed as follows. 1. Disconnect the front lift arm raising control line (1) (on both sides).
50 2. Disconnect the connection of the sensor (1) for detecting the lifting arm position (electronic lift only).
51 3. Disconnect the connections of the external lift control buttons (1) and (2) (electronic lift only).
52
87666787A1 - 03 - 2008
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31
4. Fasten a chain (1) to the hoist, to the pivot pin of the third point and make it take up the strain.
53 5. Unscrew the retaining bolts (1) (on both sides) and remove the front lift. 6. Refit the front lift, taking account of the following warnings.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. -
Position the front lift in its seat and secure it.
-
Connect the connections of the external control buttons and that of the lifting arm position sensor (electronic lift only).
-
Connect the arm lifting control hydraulic piping.
54
87666787A1 - 03 - 2008
32
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
Op. 31 146 40 - 31 146 44 FRONT POWER TAKE-OFF Removal - Installation
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no-one is in the vicinity of the load to be lifted. Proceed as follows. 1. Carry out operation 35 162 52 Front lift (mechanical/electronic), removal only (see page 33). 2. Disconnect both battery cables, unscrew the battery retaining bolts (1) and take out the battery.
55 3. Disconnect the power take-off clutch control line (1).
56 4. Unscrew the bolts fastening the battery support (1) to the front axle support and to the air filter.
57
87666787A1 - 03 - 2008
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33
5. Extract the condenser (1) of the air-conditioning system and remove the battery support (2).
58 6. Connect the front power take-off (1) to the hoist, unscrew the bolts fastening it to the front axle support and remove it.
59 7. Unscrew the relative retaining bolts and remove the flexible coupling (1). 8. Refit the front power take-off, taking account of the following warnings.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. -
Position and secure the flexible coupling.
-
Insert the power take-off in its seat and secure it.
-
Position the battery support, secure it and fit the condenser of the air-conditioning system in front of the radiator.
-
Connect the front PTO clutch control line.
-
Position the battery in its seat and secure it; connect the cables to the battery.
60
87666787A1 - 03 - 2008
34
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
Op. 31 164 30 FRONT POWER TAKE-OFF Disassembly - Assembly
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Unscrew the retaining bolts and remove the front PTO end shaft guard (1). 61 2. Unscrew the caps (1) and (2) for oil level and drainage respectively and drain the oil from the PTO.
62 3. Unscrew the retaining bolts (2) and remove the shaft (1) transmitting drive to the front PTO clutch.
63 4. Unscrew the retaining bolt (1) and remove the hydraulic clutch assembly (2) governing the front power take-off.
64 87666787A1 - 03 - 2008
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
35
5. Unscrew the retaining bolts and remove the front power take-off rear cover (1).
65 6. Remove the bearing (2) and the circlip (1) and retrieve: thrust washer, bearing, gear, splined shaft and driving shaft. 7. Refit the front power take-off, taking account of the following warnings.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. -
On the front power take-off rear cover, fit the driving shaft, splined shaft, gear, bearing, thrust washer, circlip and bearing.
-
Apply the sealing compound, position the power take-off rear cover in its seat and secure it.
-
Position the hydraulic clutch assembly and secure it.
-
Position the drive shaft and secure it.
-
Refill the front power take-off with oil and screw on the drain plug and filler cap.
-
Position and secure the grooved end shaft guard.
66
87666787A1 - 03 - 2008
36
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
Op. 35 160 52 FRONT ELECTRONIC LIFT CONTROL UNIT Removal - Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Unscrew the retaining bolts (1) and remove the cover (2).
67 2. Lift the retaining clip and disconnect the connection (3) from the control unit (1), unscrew the retaining bolts (2) and remove the control unit. 3. Refit the electronic front lift control unit, taking account of the following warnings.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 68 -
Position the control unit in its seat and secure it.
-
Connect the connection to the control unit.
-
Position the cover and secure it.
87666787A1 - 03 - 2008
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7
37
Op. 35 160 40 FRONT ELECTRONIC LIFT CONTROL VALVE Removal - Installation
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no-one is in the vicinity of the load to be lifted. Proceed as follows. 1. Raise the tractor at the rear, place a mechanical stand under the final drive casing (right-hand side), unscrew the retaining bolts and remove the right-hand rear wheel (1).
69
2. Disconnect the connection from the solenoid valves (1) and (2).
3. Disconnect the hydraulic piping (1), unscrew the related retaining bolts and remove the hydraulic control valve assembly (2). 4. Refit the hydraulic control valve, taking account of the following warnings.
ATTENTION
-
70 Position the hydraulic control valve and secure it.
-
Connect the hydraulic lines.
-
Connect the electrical connections to the relative solenoid valves.
-
Fit and secure the right-hand rear wheel.
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
87666787A1 - 03 - 2008
38
SECTION 35 - HYDRAULIC SYSTEMS - CHAPTER 7 FAULT CODE INDICATION
If electrical or electronic faults occur, the illuminated indicator (1) underlines the fault code by means of a system of indicator flashes.
Fault code decoding In order to read the fault code, close attention must be paid to the number of indicator flashes (1) and the order in which these flashes are transmitted. In order to read the fault code transmitted by the control unit, proceed as follows: phase 1: before transmitting the code, the control unit carries out a 2 second (approx.) pause; phase 2: after the pause, the first digit of the code is transmitted by means of a certain number of flashes in rapid succession; phase 3: after the transmission of the first digit, the control unit makes a one second (approx.) pause;
71 4th phase: after the pause, the second digit of the code is transmitted by means of a certain number of flashes in rapid succession. The control unit only indicates one code at a time, giving priority to the most serious fault. In order to check whether other fault codes are in progress, the fault must be eliminated so that the control unit may pass on to the successive code.
IMPORTANT: In the event of a fault that disables the lift controls, the corresponding code will be given priority over any other codes that were previously issued.
- Example - Interpretation of fault code number 24 -
1st phase
2nd phase
3rd phase
4th phase
pause
FF
pause
FFFF
first digit 2s
second digit 1s
2
4 fault code composition 24
87666787A1 - 03 - 2008
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 7
39
DIAGNOSTICS
WARNING Notes to help the operator make diagnosis and troubleshooting easier. 1. The measurements taken to read: voltage; resistance; frequency must be carried out with a digital tester.
NOTE: the resistance values shown are valid for a temperature of 20 °C (ambient temperature). With higher or lower tractor temperatures, the relative resistance values shown in the manual should vary accordingly. 2. The “short to ground” message refers to a resistance value of less than 5 Ohm (Ω). 3. When a fault occurs, before carrying out any kind of service operations, check that the specific connections (control unit, sensors, switches, etc.) are correctly connected. A faulty connection could be the cause of incorrect tractor operation. 4. The faults are listed in progressive order.
LOCATION OF THE ELECTRONIC CONTROL UNIT The electronic control unit (1) is secured at the bottom on the left−hand side of the driver’s seat and is accessible by removing the protective cover.
72
87666787A2 − 06 − 2009
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 7
40
SERIOUS FAULT CODES Fault codes
Description
Pin no.
Cause of error
11
Lifting solenoid valve.
37 / 35 − Faulty electromagnet. − Open circuit at the solenoid valve.
12
Lowering solenoid valve.
19 / 53 − Faulty electromagnet. − Open circuit at the solenoid valve.
13
Short circuit at the solenoid valves.
37 / 35 − Short circuit at the solenoid valve coil. 19 / 53 − Short circuit at the power supply cables.
14
Open circuit at the solenoid valves.
37 / 35 − Open circuit at the solenoid valve coil. 19 / 53 − Open circuit at the power supply cables.
15
Ground control buttons and up/down switch on the dashboard.
9 19 − Faulty contacts on the push−buttons. 36 − Switches not connected. − Short circuit or open circuit on the wiring.
17
Battery. Battery voltage > 18 Volt.
29 47
− Faulty charging system. − ECU fault.
18
Up and down switch on the right−hand mudguard and automatic lift switch.
21
− Faulty contacts on the push−buttons. − Switches not connected. − Short circuit or open circuit on the wiring.
MEDIUM FAULT CODES Fault codes
Description
Pin no.
Cause of error
23
Working depth potentiometer.
22
− Potentiometer not supplied correctly. − Faulty cable or potentiometer not connected. − Break or short circuit on the signal line.
24
Arm lifting limit potentiometer.
3
− Potentiometer not supplied correctly. − Faulty cable or potentiometer not connected. − Break or short circuit on the signal line.
25
Arms position sensor.
25
− Sensor not supplied correctly or faulty. − Break or short circuit on the signal line. − Incorrect position sensor setting.
87666787A2 − 06 − 2009
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 7
41
LIGHT FAULT CODES Fault codes
Description
Pin no.
Cause of error
33
Battery. Battery Voltage < 12Volt.
29 / 47 − Low Vee belt tension. − Faulty battery or generator. − Wiring transfer resistances too high.
34
Lowering speed potentiometer.
23
− Potentiometer not supplied correctly. − Faulty cable or potentiometer not connected. − Break or short circuit on the signal line.
36
Pressure/mixed/position control potentiometer.
4
− Potentiometer not supplied correctly. − Faulty cable or potentiometer not connected. − Break or short circuit on the signal line.
38
Pressure sensor.
8
− Potentiometer not supplied correctly. − Break or short circuit on the signal line. − Pressure at the sensor > 2900 psi (200 bar).
87666787A2 − 06 − 2009
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 7
42 ERROR CODE 11
The lifting solenoid valve (SOL−615) is faulty or the relevant circuit is open. The front lift does not work.
Replace the solenoid valve if interrupted
Turn the ignition switch onto OFF. Detach the guard located under the dashboard. Is F21 broken? YES
Replace fuse.
NO
Disconnect the lift solenoid valve connection. Is the solenoid valve coil electrical resistance ∼ 1.6 Ω?
NO
YES
Remove the electronic control unit guard and disconnect the relative connection. Is there electrical continuity on wire (S) between pin (37) on control unit connection (MOD−601) and the lifting solenoid valve connection (SOL−615)?
NO
YES
Is there electrical continuity on wire (M) between pin (35) on control unit connection (MOD−601) and the lifting solenoid valve connection (SOL−615)? YES
Replace the control unit.
Check the wiring and eliminate the cause of the open circuit.
For the wiring diagrams and connectors, see section 55, chapter 11.
87666787A2 − 06 − 2009
NO
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 7
43
ERROR CODE 12 The lowering solenoid valve (SOL−610) is faulty or the relevant circuit is open. The front lift does not work.
Replace the solenoid valve if interrupted
Turn the ignition switch onto OFF. Detach the guard located under the dashboard. Is F21 broken? YES
Replace fuse.
NO
Disconnect the lowering solenoid valve connection. Is the solenoid valve coil electrical resistance ∼ 1.6 Ω?
NO
YES
Remove the electronic control unit guard and disconnect the relative connection. Is there electrical continuity on wire (S) between pin (19) on control unit connection (MOD−601) and the lowering solenoid valve connection (SOL−610)?
NO
YES
Is there electrical continuity on wire (M) between pin (53) on control unit connection (MOD−601) and the lowering solenoid valve connection (SOL−610)?
NO
YES
Replace the control unit. Check the wiring and eliminate the cause of the open circuit.
For the wiring diagrams and connectors, see section 55, chapter 11.
87666787A2 − 06 − 2009
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 7
44
ERROR CODE 13 The lifting and lowering solenoid valves (SOL−610) and (SOL−615) are shorted. The front lift does not work.
Turn the starter key to the OFF position. Disconnect the connections of the lifting and lowering solenoid valves (SOL−615) and (SOL−610). Is the electrical resistance on both coils ∼ 1.6 Ω?
NO
Replace the short circuited solenoid valve.
NO
Is the lowering solenoid valve connection (SOL−610) (wiring side) in short circuit?
YES
Is the lifting solenoid valve connection (SOL−615) (wiring side) in short circuit? YES
YES
Check the wiring and eliminate the cause of the short circuit.
Check the wiring and eliminate the cause of the short circuit.
Replace the electronic control unit.
For the wiring diagrams and connectors, see section 55, chapter 11.
87666787A2 − 06 − 2009
NO
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 7
45
ERROR CODE 14 The wiring on the lifting and lowering control solenoid valves (SOL−610) and (SOL−615) is disconnected or the solenoid valves are faulty. The rear lift does not work.
Turn the ignition switch onto OFF. Disconnect the connections of the lifting and lowering solenoid valves (SOL−615) and (SOL−610). Is the electrical resistance on both solenoid valve coils ∼ 1.6 Ω?
NO
Replace the faulty coil.
NO
Check the wiring and eliminate the cause of the open circuit.
NO
Check the wiring and eliminate the cause of the open circuit.
NO
Check the wiring and eliminate the cause of the open circuit.
YES
Remove the electronic control unit guard and disconnect the relative connection (MOD−601). Is there electrical continuity on wire (S) of the lifting solenoid valve connection (SOL−615) and pin (37) of the control unit connection (MOD−601)? YES
Is there electrical continuity on wire (S) of the lowering solenoid valve connection (SOL−610) and pin (19) of the control unit connection (MOD−601)? YES
Is there electrical continuity on wire (M) on solenoid valve connections (SOL−610) and (SOL−615) and pin (53), (35) on control unit connection (MOD−601)? YES
Replace the electronic control unit.
For the wiring diagrams and connectors, see section 55, chapter 11.
87666787A2 − 06 − 2009
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 7
46
ERROR CODE 15 The cables of the external push−buttons for lifting (SW−607) and lowering (SW−608) and the lifting/lowering switch on the dashboard (SW−603A) are in short circuit, open circuit or faulty. The front lift does not work.
Turn the starter key to the OFF position. Disconnect the connections on push−buttons (SW−607), (SW−608) and on switch (SW−603A). Test, with the aid of a tester, whether the cable (S) of the lowering button (SW−608) and of the switch (SW−603A) is in short circuit?
NO
Eliminate the cause of the short circuit between the connections on push−buttons (SW−607, SW−608) and on switch (SW−603A) and pin (9) on control unit connection (MOD−601).
Remove the electronic control unit guard and disconnect the relative connection (MOD−601). Eliminate the cause of the short circuit between the connections on push−button (SW−608) and on switch (SW603A) and pin (36) on control unit connection (MOD−601).
Is the cable (S) of the lifting push−button (SW−607) and of the switch (SW−603A) in short circuit? YES
Eliminate the cause of the short circuit between the connections on push−button (SW−607) and on switch (SW−603A) and pin (17) on the control unit connection (MOD−601).
NO
Is there electrical continuity on wire (S) on push−button (SW−607) and on switch (SW−603A) and pin (17) on control unit connection (MOD−601)? YES
Check the wiring and eliminate the cause of the open circuit.
NO
Is there electrical continuity on wire (S) on push−button (SW−608) and on switch (SW−603A) and pin (36) on control unit connection (MOD−601)? YES
Check the wiring and eliminate the cause of the open circuit.
NO
Is there electrical continuity on wire (C) on push−buttons (SW−608, SW−607) and on switch (SW−603A) and pin (9) on control unit connection (MOD−601)? YES
Replace the electronic control unit.
For the wiring diagrams and connectors, see section 55, chapter 11.
87666787A2 − 06 − 2009
NO
YES
YES
Check the wiring and eliminate the cause of the open circuit.
Is the cable (C) of push−buttons (SW−607, SW−608) and of switch (SW−603A) in short circuit ?
NO
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 7
47
ERROR CODE 17 The supply voltage on the electronic control unit (1) is > 18V. The front lift does not work.
Start the engine and, using a digital tester, check the battery charge voltage. Is the voltage reading > 18V?
NO
Replace the electronic control unit (1).
YES
Repair the recharging system.
For the wiring diagrams and connectors, see section 55, chapter 11.
87666787A2 − 06 − 2009
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 7
48
ERROR CODE 18 Up and down switch on the right−hand mudguard (SW−602A) and lift arm automatic raise switch (SW−604A) not connected, open circuit or short circuit. The front lift does not work.
Turn the starter key to the OFF position. Remove the electronic control unit guard and disconnect the relative connection (MOD−601). Is the cable (S) of pin (21) on control unit connection (MOD−601) in short circuit? YES
Eliminate the cause of the short circuit between pin (21) on control unit connection (MOD−601) and pin (10) on control panel connection (MOD−614).
NO
Is there electrical continuity on wire (S) of pin (21) on control unit connection (MOD−601) to pin (10) on the control panel connection (MOD−614)?
YES
NO
Check the wiring and eliminate the cause of the open circuit.
Is there electrical continuity on wire (C) from pin (2−3) on connection (SW−602A) to pin (19) on the control panel connection (MOD−614)?
YES
NO
Check the wiring and eliminate the cause of the open circuit. Is there electrical continuity on wire (S) from pin (4) on connection (SW−602A) to pin (20) on the control panel connection (MOD−614)?
YES
NO
Check the wiring and eliminate the cause of the open circuit.
Is there electrical continuity on wire (S) from pin (1) on connection (SW−604A) to pin (13) on the control panel connection (MOD−614)?
YES
NO
Check the wiring and eliminate the cause of the open circuit. continued
For the wiring diagrams and connectors, see section 55, chapter 11.
87666787A2 − 06 − 2009
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 7
49 cont.
Is there electrical continuity on wire (S) from pin (3) on connection (SW−604A) to pin (14) on the control panel connection YES (MOD−614)? NO
Check the wiring and eliminate the cause of the open circuit. Eliminate the cause of the short circuit between connection (SW−602A) and pin (2) on connection (SW−604A). Eliminate the cause of the short circuit between connection (SW−602A) and pin (19) on the control panel connection (MOD−614).
YES
NO YES
Is the cable (C) of pin (2−3) on connection (SW−602A) in short circuit? NO
Eliminate the cause of the short circuit between connection (SW−602A) and pin (20) on the control panel connection (MOD−614).
YES
Eliminate the cause of the short circuit between connection (SW−604A) and pin (13) on control panel connection (MOD−614).
YES
Eliminate the cause of the short circuit between connection (SW−602A) and pin (14) on the control panel connection (MOD−614).
Is the cable (S) of pin (1) on connection (SW−602A) in short circuit?
Is the cable (S) of pin (4) on connection (SW−602A) in short circuit? NO
Is the cable (S) of pin (1) on connection (SW−604A) in short circuit? NO
YES
Is the cable (S) of pin (3) on connection (SW−604A) in short circuit? NO
If the fault persists, replace the control panel; if the fault still persists, change the control unit.
For the wiring diagrams and connectors, see section 55, chapter 11.
87666787A2 − 06 − 2009
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 7
50
ERROR CODE 23 The working depth adjustment potentiometer is faulty. The front lift does not work.
Turn the starter key to the OFF position. Remove the electronic control unit guard and disconnect the relative connection (MOD−601). Is there electrical continuity on wire (V) between pin (15) on the lift control panel connection (MOD−614) and pin (22) on control unit connection (MOD−601)?
NO
Check the wiring and eliminate the cause of the open circuit.
NO
Replace the control panel. Does the fault persist?
YES
Is cable (V) in short circuit? YES
Check the wiring and eliminate the cause of the short circuit.
YES
Replace the electronic control unit.
For the wiring diagrams and connectors, see section 55, chapter 11.
87666787A2 − 06 − 2009
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 7
51
ERROR CODE 24 The lift arms upper limit adjustment potentiometer is faulty. The front lift does not work.
Turn the starter key to the OFF position. Remove the electronic control unit guard and disconnect the relative connection (MOD−601). Is there electrical continuity on wire (V) between pin (16) on the lift control panel connection (MOD−614) and pin (3) on control unit connection (MOD−601)?
NO
Check the wiring and eliminate the cause of the open circuit.
NO
Replace the control panel. Does the fault persist?
YES
Is cable (V) in short circuit? YES
Check the wiring and eliminate the cause of the short circuit.
YES
Replace the electronic control unit.
For the wiring diagrams and connectors, see section 55, chapter 11.
87666787A2 − 06 − 2009
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 7
52
ERROR CODE 25 The wiring on the lift arm position sensor (SEN−606) is disconnected, broken, in short circuit or the sensor is faulty. The rear lift does not work.
Turn the starter key to the OFF position. Is the sensor connection (SEN−606) correctly connected?
NO
Connect the connection correctly and calibrate the lift arms height sensor.
NO
Check the wiring and eliminate the cause of the open circuit. If the diagnosis indicator light blinks requesting calibration, calibrate the lift arms height sensor.
NO
Replace the arm position sensor. Does the fault persist?
YES
Remove the electronic control unit guard and disconnect the relative connection (MOD−601). Is there electrical continuity on wires (M), (V), (C) and pins (38), (8), (39) on control unit connection (MOD−601)? YES
Is one of the two cables (V) and (C) in short circuit? YES
Check the wiring and eliminate the short circuit. If the diagnosis indicator light blinks requesting calibration, calibrate the lift arms height sensor.
YES
Replace the electronic control unit; if the diagnosis indicator light blinks requesting calibration, calibrate the lift arms height sensor.
For the wiring diagrams and connectors, see section 55, chapter 11.
87666787A2 − 06 − 2009
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 7
53
ERROR CODE 33 The supply voltage on the electronic control unit (1) is < 12 Volt.
Start the engine and, using a digital tester, check the battery charge voltage. The voltage is < 12 V. YES
Repair the recharging system.
NO
NO
Remove the electronic control unit guard and disconnect the relative connection (MOD−601). Using the tester, measure on pins (29), (47), on connection (MOD−601), and ground is there a voltage < 12 Volt? YES
Examine the wiring and, if necessary, replace it. Replace the electronic control unit (1).
For the wiring diagrams and connectors, see section 55, chapter 11.
87666787A2 − 06 − 2009
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 7
54
ERROR CODE 34 The arms descent speed adjustment potentiometer is faulty. The front lift works but it is not possible to adjust the arms descent speed.
Turn the starter key to the OFF position. Remove the electronic control unit guard and disconnect the relative connection (MOD−601). Is there electrical continuity on wire (V) between pin (17) on the lift control panel connection (MOD−614) and pin (23) on control unit connection (MOD−601)?
NO
Check the wiring and eliminate the cause of the open circuit.
NO
Replace the control panel. Does the fault persist?
YES
Is cable (V) in short circuit? YES
Check the wiring and eliminate the cause of the short circuit.
YES
Replace the electronic control unit.
For the wiring diagrams and connectors, see section 55, chapter 11.
87666787A2 − 06 − 2009
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 7
55
ERROR CODE 36 The pressure/mixed/position mixing control potentiometer is faulty. The front lift works.
Turn the starter key to the OFF position. Remove the electronic control unit guard and disconnect the relative connection (MOD−601). Is there electrical continuity on wire (V) between pin (18) on the lift control panel connection (MOD−614) and pin (4) on control unit connection (MOD−601)?
NO
Check the wiring and eliminate the cause of the open circuit.
NO
Replace the control panel. Does the fault persist?
YES
Is cable (V) in short circuit? YES
Check the wiring and eliminate the cause of the short circuit.
YES
Replace the electronic control unit.
For the wiring diagrams and connectors, see section 55, chapter 11.
87666787A2 − 06 − 2009
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 7
56
ERROR CODE 38 The wiring on the pressure sensor (SEN−613) of the accumulator assembly is disconnected, broken, in short to ground or the sensor is faulty.
Turn the starter key to the OFF position. Is the sensor connection (SEN−613) correctly connected?
NO
Correctly connect the connection.
NO
Check the wiring and eliminate the cause of the open circuit.
NO
Replace the arm position sensor. Does the fault persist?
YES
Remove the electronic control unit guard and disconnect the relative connection (MOD−601). Is there electrical continuity on wires (M), (V) and pins (38), (8), (39) on control unit connection (MOD−601)? YES
Is one of the two cables (V) and (C) in short to ground? YES
Check the wiring and eliminate the cause of the short circuit to ground.
YES
Replace the electronic control unit.
For the wiring diagrams and connectors, see section 55, chapter 11.
87666787A2 − 06 − 2009
SECTION 41 -- STEERING -- CHAPTER 1
1
SECTION 41 -- STEERING Chapter 1 -- Steering CONTENT Operation
Description
Page
Torque settings main data -- tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 41 204 10
Hydrostatic steering wheel. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
41 204 30
Hydrostatic steering control valve. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . 10
41 204 34
Hydrostatic steering control valve removed. Disassembly -- Assembly . . . . . . . . . . . . . . 13
41 204 38
Hydrostatic steering
41 216 10
Steering control cylinder. Removal -- Installation
32
41 216 18
Steering control cylinder. Disassembly -- Assembly
34 .
control valve -- Bench testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
87666787A - 11 - 2007
2
SECTION 41 -- STEERING -- CHAPTER 1 SPECIFICATIONS
HYDROSTATIC STEERING Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
hydrostatic control
Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
independent, fed by services hydraulic pump
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
paper cartridge on pump intake side
Control valve, manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OGNIBENE or DANFOSS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with the rotating valve controlled directly by the steering column; the steering continues to function even if the pump is damaged
Outfit code: Two and four wheel drive models (OGNIBENE) . . . . . . . . . . . . . .
STH ON 80 G170 LNV
Two and four wheel drive models (DANFOSS) . . . . . . . . . . . . . . .
OSPC 80 ON -- 150 N 1058
pressure relief valve calibration (24, fig. 2) . . . . . . . . . . . . . . . . . . .
bar
165÷170 (168÷173.4 kg/cm2)
Cylinder safety valve calibration (33, fig. 2) . . . . . . . . . . . . . . . . . . .
bar
230÷240 (234÷244 kg/cm2)
BOLT TORQUES PARTS TO BE TIGHTENED
Thread
Bolt securing cover to power steering housing . . . . . . . . . . . . . . . . . . . .
Tightening torque Nm
kgm
M8 x 1
24÷36
2.5÷3.7
Steering column flange retaining nut (1, fig. 12) . . . . . . . . . . . . . . . . . . .
M8 x 1
23
2,40
Bolt (2, fig. 12) securing power steering unit to tractor . . . . . . . . . . . . .
M10 x 1.5
44
4.5
Hydrostatic steering control pump retaining bolt . . . . . . . . . . . . . . . . . .
M6 x 1
8
0.8
Nut for pump housing cover retaining bolt . . . . . . . . . . . . . . . . . . . . . . . .
M10 x 1.25
39
4
Nut for securing thrust sleeve to pump drive shaft . . . . . . . . . . . . . . . . .
7/16”--20UNF --2B
28
2.8
SPECIAL TOOLS Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual.
87666787A - 11 - 2007
List of specific tools required for the various operations described in this Sect. X 380000223 Steering wheel extractor. X 380000307 Power steering rotor retaining lever. X 380000240 Universal pressure testing kit. 380000306 Plug for fitting the power steering rotating valve return springs. X 380000281 Tool for fitting power steering Rotoglyd seal. X 380000836 Tool for fitting power steering Varisel seal.
SECTION 41 − STEERING − CHAPTER 1
3
OPERATION
Neutral Position When the steering wheel (V, fig. 2) is not moving, the rotating valve (5) is located in the neutral position in relation to the sleeve (6). In this position, retained by springs (2, sect. A−A), the following occurs: − the pin (1, sect. B−B) will be in the central position in relation to the holes on the valve (5); − the ducts (13 and 14) are aligned (sect. C−C) and the oil, from the pump (P), flows freely to and from the reservoir; − the grooves (15, 17 and 19) on valve (sect. D−D, E−E) are not aligned with the ducts (16,18 and 20) on the sleeve, therefore all connecting lines with the cylinder remain closed (See diagrams A and d, fig. 2). Right−hand steering control B, R−ht, e, f, (see figure 2 and 3). By turning the steering wheel (V) clockwise, the springs (2, sect. A−A) allowing the valve (5) to rotate in relation to the sleeve (6), until the clearance G1 is recovered (sect. B−B). Under these conditions the following occurs: − the ducts are not aligned (13 and 14, sect. C−C), therefore the oil discharge flow is interrupted; − the six grooves are aligned (15, sect. D−D) with the same number of ducts (16), that are connected with the compartments on the rotor in the suction phase; − the six delivery grooves are aligned (17, sect. E−E) with the ducts (18) connected to the cylinder and, at the same time, the grooves are aligned with the remaining ducts (16, sect. D−D), that are connected with the compartments on the rotor in the delivery phase; − the six discharge grooves (19) are aligned with the ducts (20, sect. E−E) connecting to the cylinder. Once the clearance (G1) has been recovered, the valve (5) rigidly transmits the steering wheel rotation to the sleeve (6) and rotor (9, fig. 2), by means of the internal pin and related shaft. The details (e, f, fig. 3), illustrate how the mechanism operates at the start of a turn to the right and after a certain number of steering wheel rotations. Note that there is an uninterrupted connection between the oil from the pump with the compartments on the rotor in the suction phase (and with oil when the compartments on the rotor are in the delivery phase) and the relative duct connected to the cylinder. 15714
1 Hydrostatic steering operation sectional view a. Cross−sectional views with the valve (5) in the neutral position − b. Cross−sectional views with the valve (5) rotated for a right−hand turn (for a left−hand turn, the valve rotates symmetrically in the opposite direction) − G1 and G2. Clearances between pin (1) and hole on valve (5) −1. Sleeve trim pin (6) and internal shaft − 2. Sleeve return springs (6) − 5. Rotating valve − 6. Valve seat sleeve (5) − 13 and 14. Oil lines in neutral position − 15. Delivery grooves (no.6) to the rotor compartments on suction − 16. Lines (no.12) communicating alternately with the grooves (15 and 17) − 17. Delivery grooves (no.6) to the cylinder communicating with the rotor compartments on delivery and lines (18 and 20) − 18. Cylinder right−hand chamber discharge or delivery lines (no.6) − 19. Cylinder discharge grooves (no.6) communicating with the lines (18 and 20) − 20. Cylinder left−hand chamber discharge or delivery lines (no.6) − 22. Supply lines for grooves (15).
87666787A2 − 06 − 2009
SECTION 41 − STEERING − CHAPTER 1
4
M
S 14
13
V
16
5 13714
A
P
G Z
R D H
F
27 21
24
23 4
9
26
15
R− ht
17
19
6
5
16
21
33
V
33 34
B L− ht
13723
Delivery oil to control cylinder Delivery oil to rotor Intake oil, low pressure delivery or discharge Static rest oil
D M
El− ht
S
23 Er−ht 4
13722
C 87666787A2 − 06 − 2009
2
SECTION 41 -- STEERING -- CHAPTER 1
17
Left--hand steering control (B, L--ht, fig. 2) By turning the steering wheel in an anticlockwise direction, the movement of the parts is inverted, the delivery grooves (17, sect. E--E, fig. 1) direct the oil to the ducts (20), and control the left--hand turning action.
15 D-- D
F-- F
21 16
17
9
d
15
e 17
15
7884
5
Emergency hydraulic control (C, Er--ht, El--ht, fig. 2) In the event of feed faults, steering is still possible by turning the steering wheel. The valve (5) remains in the same position as with normal control and the rotor works in the same way as a hand pump, directing the oil to the control circuit. The non--return valve (4) opens and cuts off the feed pump, allowing the oil to flow directly from the reservoir to the rotor. The valve (23) remains closed in order to prevent oil leaks from faulty connecting pipes between the hydraulic pump and the power steering unit. Cylinder safety valve and backflow valve (see, fig. 2) The safety valves (33), when open, discharge the pressure created by the piston (H) on one of the cylinder chambers as a result of the strong external stress on the wheels. At the same time, the lack of pressure in the opposite chamber is compensated by the flow of oil from the open backflow valve (34). Pressure on one of the cylinder chambers caused by weak external stress, insufficient to open the cylinder safety valve, is discharged by means of normal control valve leakage, whereas the lack of pressure in the opposite chamber is compensated by the backflow valve (34), as shown in fig. 2.This valve, as well as eliminating continuous steering corrections, prevents vibrations on front wheels (shimmy), hydraulic circuit failure and steering rod distortion.
f
3
Power steering operation circuit sectional views (*see fig. 1) A. Neutral position operation diagram. B. Right--hand turn (R--ht) and left--hand turn (L--ht) operation diagram. C. Emergency right--hand turn (Er--ht) and emergency left--hand turn (El--ht) operation diagram. d. Operation diagram for sections D--D and E--E in neutral conditions*. D. DANFOSS OSPC control valve. e, f. Operation diagrams for sections D--D and E--E in two successive right--hand turn phases*. F. Filter. H. Control cylinder. M. Pump delivery. N. Backflow valves (34) operation diagram with control valve (D) in neutral and cylinder (H) piston under external stress (indicated by the black arrow). P. Pump. R. Flow regulator. S. Discharge to gearbox. V. Steering wheel. Z. Resonance attenuator filter.
4. Non--return valve. 5. Rotating valve. 6. Valve seat sleeve (5). 9. Rotor. 13 and 14. Oil flow ducts in the neutral position. 15. Delivery grooves (no. 6) to the compartments on the rotor in the suction phase. 16. Ducts (no.12) alternately connecting with the grooves (15 and 17). 17. Delivery grooves (n.6) to the cylinder connecting with the compartments on the rotor in the delivery phase and the ducts (18 and 20)*. 19. Discharge grooves (n.6) to the cylinder connecting with the ducts (18 and 20)*. 21. Ducts connecting the holes (16) with the compartments on the rotor in suction delivery phases. 23. Non--return valve. 24. Pressure relief valve (setting: page 2). 26. Left--hand cylinder chamber connecting duct. 27. Right--hand cylinder chamber connecting duct. 33. Cylinder safety valve (setting: page 2). 34. Backflow valve.
87666787A - 11 - 2007
6
SECTION 41 -- STEERING -- CHAPTER 1
Hydrostatic steering control valve components 1. Dust ring. 2. Control valve body, rotating valve and rotating valve seat sleeve. 3. Check valve ball. 4. Seal. 5. Non--return valve threaded plug. 6. Thrust bearing components. 7. Retaining ring for springs (17) (Danfoss only). 8. Rotor drive shaft -- sleeve trim pin. 9. Rotor drive shaft.
87666787A - 11 - 2007
10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
O--ring. Shim ring. Cover retaining screws. Washers. Cover. O--rings. Rotor and fixed ring for rotor. Springs for returning sleeve to neutral position. Pressure relief valve. Cylinder safety valve.
SECTION 41 -- STEERING -- CHAPTER 1
7
HYDROSTATIC STEERING TROUBLESHOOTING Problems Oil leaking from the hydrostatic steering unit: a. Control side. b. Cover side.
Possible Problem Solutions 1. Rotoglyd seal (4, page 6) Replace the ROTOGLYD seal using the specific tool 380000281 or defective. 380000836 for VARISEL seals. 2. Bolts insufficiently tightened. 3.
Hard steering.
1. 2. 3. 4. 5.
Excessive steering wheel play.
1.
2. 3. 4. 5. The steering wheel turns normally, but the steering is: a. Low. b. Null.
1.
With the engine stopped, the steering wheel can be turned without turning the wheels.
1.
2. 3.
Tighten the bolts to the prescribed torque (24รท36 Nm -- 2.5รท3.7 kgm). Sealing washers or O--rings Replace the washers and seals. defective. Hydraulic pump faulty. Repair the pump. Non--return valve held open Eliminate foreign bodies and clean by foreign bodies or due to filter; put a new ball into the seat (if absence of ball. missing). Pressure relief valve (24) Calibrate the valve correctly. incorrectly set. Pressure relief valve jammed Eliminate foreign bodies and clean or held open by foreign the filter. bodies. Steering column has become Eliminate the causes. stiff on its bushing due to rusting, seizing, etc. Excessive play between the Replace the power steering control steering column and the valve. coupling with the rotating valve. Excessive play in the coupling Replace the power steering control between the shaft and the trim valve. pin. Excessive play in the splined Replace the power steering control coupling between the shaft valve. and the rotor. Combination of excessive Replace the power steering control play as described in the valve. previous points. Leaf springs damaged or Replace springs. fatigued. Inadequate control cylinder Replace seal. seal. Cylinder rod broken. Replace the damaged part. Rotor drive shaft or pin Replace the damaged part. broken. Excessive wear between rotor Replace the power steering control and fixed ring. valve.
2. Non--return valve damaged.
Replace the power steering control valve. 3. Cylinder safety valve held Remove the foreign bodies and open by foreign bodies or clean the filter or renew the control damaged. valve. (continued)
87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
8
HYDROSTATIC STEERING TROUBLESHOOTING (overleaf)
Problems
Possible Problem
Solutions
Steering wheel jolts, uncontrollable steering, wheels turning in the opposite direction to that desired.
1. Incorrect synchronisation of Synchronise correctly. hydrostatic steering. Correct the connections. 2. Pipes to cylinder inverted.
The wheels do not maintain the desired alignment and steering must be continually corrected with the steering wheel.
1. Hydraulic cylinder piston seal worn. 2. Cylinder safety or backflow valves held open by foreign bodies or damaged. 3. Mechanical wear of control valve.
Replace seal. Remove the foreign bodies and clean the filter or renew the control valve. Replace control valve assy.
Neutral phase of power steering 1. Leaf springs, for sleeve return Replace the leaf springs assembly. unobtainable. to neutral position, damaged or fatigued. During manual control, operation is normal; when stopping manual 2. Sleeve and rotating valve Eliminate foreign bodies and clean control the steering wheel tends locked in delivery position the filter. to move on its own, or remain because of the presence of stationary, but steering continues foreign bodies. slowly in the direction that was 3. Sleeve crushed on the rotating Check the pressure relief valve initially selected (motoring), valve due to excessive calibration. therefore steering must be pressure. continually corrected with the steering wheel. Vibrations on front wheels (shimmy).
1. Air pockets in the hydraulic cylinder. 2. Wear on mechanical joints on steering rods. 3. Cylinder safety or backflow valves held open by foreign bodies or damaged.
Difficulty in steering in general, or 1. Insufficient pressure. only in one direction. 2. Excessive leakage inside the control valve. 3. Cylinder safety valve incorrectly calibrated or soiled with deposits that interfere with the seal of one of the two valves.
87666787A - 11 - 2007
Bleed the air and eliminate the causes of possible infiltration. Replace the worn parts. Remove the foreign bodies and clean the filter or renew the control valve. Check the hydraulic pump and the pressure relief valve calibration. Replace control valve assy. Eliminate foreign bodies and clean filter or replace the control valve.
SECTION 41 -- STEERING -- CHAPTER 1
9
OP. 41 204 10 HYDROSTATIC STEERING WHEEL Removal -- Installation
Removal
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 27822
Proceed as follows. 1. Using a sharp tool, remove the NEW HOLLAND symbol at the centre of the steering wheel, unscrew the nut and the central knob (1).
4
2. Remove the retaining nut and the steering wheel (1).
Installation
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
25758
5
Proceed as follows.
3. Install the steering wheel (1, fig. 5) then the lock nut.
4. Fit the central knob (1, fig. 4), the knob retaining nut and the NEW HOLLAND logo at the centre of the steering wheel.
87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
10
OP. 41 204 30 HYDROSTATIC STEERING CONTROL VALVE Removal -- Installation
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. To remove the power steering control valve, proceed as follows: 1. Carry out operation 90 100 22 Bonnet, only removal (see section 90). 2. For tractors with cabs, it is advised to remove the door stop pins in order to fully open the door and improve access during removal operations. 3. Carry out operation 90 110 14 Instrument panel lower guard, only removal (see Sect. 90). 4. Carry out operation 41 204 10 Hydrostatic steering wheel, only removal (see sect. 41). 5. Carry out operation 55 418 10 Multi--indicator panel, only removal (see Sect. 55). 6. Remove the retaining bolts on the dashboard, detach the electrical connections (1), the light control switch (2) from their seats, complete with the dust guard (3). 7. Remove the electrical connections (1) connected to the dashboard and remove the dashboard (2).
25761
6
25762
7 8. Remove the four retaining bolts (1) on the fuse box (2) support.
25763
8 87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
11
9. Remove the two retaining bolts (1), disconnect the electrical connection (2) and remove the shuttle control lever, complete with the support (3).
25764
9 10. Remove the retaining bolts and the power take--off clutch control lever (1).
25765
10 11. Detach the four pipes (1) on the power steering control valve (2).
25766
11 12. Remove the two nuts (1) and the four bolts (2) that secure the steering column.
25767
12 87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
12
13. Remove the steering column (1).
25768
13 14. Detach the power steering control valve (1).
25769
14
To re--fit the power steering control valve, proceed as follows: --
Re--fit the power steering control valve.
--
Re--fit the steering column shaft on the power steering control valve and secure with the nuts and bolts.
--
Re--connect the power steering delivery and return pipes.
--
Assemble the power take--off clutch control lever.
--
Assemble the electrical connection and the shuttle control lever.
--
Assemble the fuse box support.
--
Assemble the dashboard electrical connections and the dashboard.
87666787A - 11 - 2007
--
Assemble the electrical connections and the light control switch, complete with dust cover.
--
Carry out operation 55 418 10 Multiple indication panel, only installation (see Section 55).
--
Carry out operation 41 204 10 Hydrostatic steering wheel, only installation (see sect. 41).
--
Carry out operation 90 110 14 Instrument panel lower guard, only installation (see Sect. 90).
--
On tractors with cabs, refit the door stop pin.
--
Carry out operation 90 100 22 Bonnet, only installation (see Sect. 90).
SECTION 41 -- STEERING -- CHAPTER 1
13
OP. 41 204 34 HYDROSTATIC STEERING CONTROL VALVE Disassembly -- Assembly (with control valve removed) To disassemble the power steering control valve, proceed as follows: 1. Remove the cover retaining bolts.
24701
15 2. Remove the cover by sliding to the side.
24702
16 3. Remove the rotor fixed ring, the rotor and the inner spacer.
4. Remove the two O--rings on the rotor fixed ring.
24703
17 5. Extract the rotor drive shaft.
24704
18 87666787A - 11 - 2007
14
SECTION 41 -- STEERING -- CHAPTER 1
6. Extract the thrust washer.
24705
19 7. Remove the threaded plug on the non--return valve seat.
24706
20 8. Extract the O--ring seal from the control valve body.
24707
21 9. Rotate the control valve body and extract the non--return valve ball, the two balls with the relative pins and the backflow valve springs.
27856
22 87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
15
10. Position the control valve body and the rotor drive shaft so that the sleeve--control shaft trim pin is in a horizontal position.
11. Push the rotating valve inwards, so that the valve, the valve seat sleeve and the thrust bearing can be extracted from the control valve body. 24709
23 12. Extract the thrust bearing from the rotating valve, complete with the two external rings, and remove the spring retaining ring from the valve seat sleeve.
24710
24 13. Extract the valve--sleeve trim pin.
24711
25 Warning -- On assembly, two reference marks were made on the rotating valve and the sleeve, corresponding to the neutral position maintained by the springs. Before removing the springs, check that the marks are clearly visible, otherwise renew them.
24712
26 87666787A - 11 - 2007
16
SECTION 41 -- STEERING -- CHAPTER 1
14. Extract the rotating valve from the valve seat sleeve.
24713
27 15. Remove the springs from the neutral position, extracting them from their seats.
24714
28 16. Remove the dust seal and the O--ring seal from their seats in the control valve body.
20428
29 17. Using a 6 mm Allen wrench, remove the threaded plugs from the cylinder safety valves.
20429
30 87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
17
18. Remove the seal washers.
27857
31 19. Using a 6 mm Allen wrench, remove the calibration adjuster screws on the cylinder safety valve.
27858
32 20. Turn the control valve body over, extract the springs and the balls from the two cylinder safety valves.
20432
33 Cylinder safety valves components (order of disassembly--assembly). 1. Cylinder safety valve ball. 2. Pressure spring. 3. Calibration adjuster screw. 4. Seal. 5. Blanking plug.
1
2
3
4
5
25790
34 87666787A - 11 - 2007
18
SECTION 41 -- STEERING -- CHAPTER 1
21. Using a 6 mm Allen wrench, remove the threaded plug on the pressure relief valve and extract the washer.
20434
35 22. Remove the pressure relief valve adjuster screw.
27859
36 23. Turn the control valve body over and complete disassembly by extracting the spring and the pressure relief valve piston.
20436
37 Pressure relief valve components disassembly--assembly). 1. Pressure relief valve. 2. Pressure spring. 3. Calibration adjuster screw. 4. Seal. 5. Blanking plug.
(order
of
1
2
3
4
5
27099
38 87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
19
24. Thoroughly clean all control valve component parts. 25. Replace the washers and seals. 26. Carefully check all mechanical parts, replacing components that show signs of wear. 27. Before re--fitting, lubricate the components with hydraulic oil.
28. Re--fit the rotating valve on the sleeve, checking that the reference marks indicated in the drawing coincide.
24712
39 29. Use tool 380000306 to insert the flat and curved springs (12, fig. 3). Diagram for fitting springs (12, fig. 3 neutral position).
24728
40 30. After inserting the springs in the seat, align and centre (as shown in the drawing).
24729
41
87666787A - 11 - 2007
20
SECTION 41 -- STEERING -- CHAPTER 1
31. Fit the neutral position spring retaining ring on the valve seat sleeve, remembering that the ring must rotate freely without being impeded by the springs.
24730
42 32. Insert the sleeve--rotor drive shaft trim pin.
24731
43 33. Fit the thrust bearing, following the order and indications shown in the drawing below.
24732
44 1. Bearing external ring. 2. Thrust bearing. 3. Bearing internal ring with bevel facing the shim on part (5). 4. Rotary valve. 5. Rotary valve seat sleeve.
1 2 3 4 5 24733
45 87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
21
34. Position the control valve body so that the housing seat on the rotating valve sleeve is positioned horizontally.
35. For the ROTOGLYD seal (OGNIBENE hydrostatic steering) insert the guide bushing (1) of tool 380000281 in the rotary valve seat.
24734
1 46
36. Lubricate the ROTOGLYD seal (1) with hydraulic fluid and position it on the head of tool 380000281 with the flat portion of the ring facing in front of the tool.
1
24735A
47 37. Insert tool 380000281 in the guide bushing positioned beforehand. 38. Whilst holding the external bushing with the hands, press fully down and simultaneously rotate the tool 380000281 in order to facilitate the entry of the ROTOGLYD seal in the control valve body seat. 39. Extract the parts on tool 380000281 (external bushing and punch); NOTE: the support and seal ring support head remains on the control valve body. 24736
48 40. For the VARISEL seal (DANFOSS hydrostatic steering) grease the seal (3) and insert it on the outer edge of the guide bushing (1) of tool 380000836.
27824
49 87666787A - 11 - 2007
22
SECTION 41 -- STEERING -- CHAPTER 1
41. Position the tool 380000836 complete with components (1) and (2) and the VARISEL seal (3) on the power steering control valve body (4). 42. Press fully down, whilst simultaneously rotating the outer bushing (1) on the tool, in order to facilitate the entry of the VARISEL seal (3) in the control valve body seat. 43. Using the bushing (1), press on the shaft (2), in the direction indicated by the arrow, in order to overcome the pressure exerted by the inner spring. Extract the tool from the body of the power steering when the tapered portion of the shaft (2) comes free from the seal (3).
27825
50 44. Insert the parts that were previously fitted in operations 26รท31, on the control valve body, holding the sleeve--rotor drive shaft trim pin in a horizontal position, to prevent it from slipping out and jamming in the slots inside the control valve body.
24739
51 45. Press the rotating valve so as to bring the thrust bearing into contact with the control valve body; this will simultaneously expel the head (1) of tool 380000281.
27826
52 46. Rotate the control valve body and insert the non--return valve ball into the seat indicated by the arrow.
24741
53 87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
23
47. Screw the threaded plug into the non--return valve seat until the upper surface is below the coupling surface of the control valve body.
24742
54 48. Insert the non--return valve balls into the two seats indicated by the arrows.
27861
55 49. Insert the springs on the backflow valve pins.
27862
56 50. Position the pins, complete with springs, in the backflow valve seats.
27863
57 87666787A - 11 - 2007
24
SECTION 41 -- STEERING -- CHAPTER 1
51. Lubricate the O--ring seal and insert into the seat on the control valve body.
24746
58 52. Fit the thrust washer, so that the holes coincide with the holes on the control valve body.
24748
59 53. Make a reference mark on the upper part of the teeth (1), near the seat (2), to indicate the exact position of the valve--sleeve trim pin.
1
2
24748
60 54. Fit the rotor drive shaft into the control valve body, insert tool 380000307 for retaining and centring the rotor drive shaft, between the rotor drive shaft and the thrust washer, rotating the shaft so as to facilitate coupling between the seat (2, fig. 60) and the trim pin installed on the sleeve.
24749
61 87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 1 55. To re--fit the rotor, proceed as follows: a) each time the hydrostatic steering is disassembled, turn the rotor over so as to limit wear to the splined coupling; b) in the following drawing, the rotor shaft has been removed in order to show the timing between the rotor, rotor drive shaft and the trim pin; c) fit the rotor on the drive shaft, remembering that correct timing is obtained by aligning the teeth (1), on the trim pin axis plane (shown in drawing 59) with the centre line of one compartment on the rotor.
25
1
24750
62 56. Lubricate the two O--ring seals (1) with hydraulic oil and insert them in the rotor fixed ring seat, fix in position by aligning the retaining holes (2) with those present on the thrust washer.
24751
63 57. Fit the cover, aligning the retaining holes with those on the rotor fixed ring.
24753
64 58. Remove retaining tool 380000307 and fit the special screw and washer in the non--return valve seat, shown in the drawing.
24754
65 87666787A - 11 - 2007
26
SECTION 41 -- STEERING -- CHAPTER 1
59. Fit the other six cover retaining bolts with the washers and tighten in diagonal sequence to the torque setting value shown in the table on page 2.
24755
66 60. Turn over the control valve body and insert (see component details in fig. 38) the pressure relief valve piston in the seat indicated in the drawing.
24756
67 61. Insert the pressure relief valve spring.
24757
68 62. Using an 8 mm Allen wrench, insert the pressure relief valve calibration screw. NOTE: calibration will be carried out on the workbench or on the tractor to the values shown in the table on page 2.
24758
69 87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 1 63. Tighten the plug (2) with the relative seal, using an 8 mm Allen wrench, and tighten to the prescribed torque value of 40รท60 Nm (4.1รท6.1 kgm), after having carried out the calibration operation on the workbench or on the machine. 64. Insert the two balls (1) into the cylinder safety valve seats, indicated by the arrows (see component details in fig. 74).
27
1 2
25789
70 65. Insert the springs (2, fig. 74) in the cylinder safety valve seats.
27865
71 66. Using a 6 mm Allen wrench, tighten the two cylinder safety valve calibration adjuster bolts (3, fig. 74). Note -- Calibration will be carried out on the workbench or on the tractor to the values shown in the table on page 2.
20475
72 67. Tighten the two plugs (5, fig. 74 ) and the relative seals (4) using a 6 mm Allen wrench. Once calibration is completed, tighten to the prescribed torque value of 30 Nm (3 kgm).
20429
73 87666787A - 11 - 2007
28
SECTION 41 -- STEERING -- CHAPTER 1
Cylinder safety valves components (order of disassembly--assembly) 1. Cylinder safety valve ball. 2. Pressure spring. 3. Calibration adjuster screw. 4. Seal. 5. Blanking plug.
1
2
3
4
5
25790
74 68. When the unit has been assembled, insert the dust seal in the seat on the control valve body.
24764
75
87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 1 OP. 41 204 38 POWER STEERING CONTROL VALVE
Bench testing A -- CHECKING ROTATING VALVE WEAR 1. Make the connections shown in fig. 76 and complete the circuit as in fig. 76. Using the splined drive shaft (1, fig. 77) hold the power steering control valve in the steering position (right or left). 2. Using the handwheel (5), increase the circuit pressure to approach the pressure relief valve setting (page 2), without allowing the valve to intervene. 3. Apply a torque wrench (2) to the drive shaft (1) and tighten to a setting of approx. 34 Nm (3.5 kgm), check that the rotating valve takes more than ten seconds to complete one full rotation. If less than ten seconds, replace the complete control valve. Test Conditions. Oil type . . . . . . . . . . . . . . . . . . . IDRAULICAR AP51 Oil viscosity . . . . . . . . . . . . . . . . . . . . . . . SAE 20 W Oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . 60_C Hydraulic pump capacity . . . . . . . . . . . . . . dm3/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (litres/min) 12 Electric motor speed . . . . . . . . . . . . . . . . . 1450 rpm
1
29
1 7 6
2
5 3
24911
4 76
1. Splined shaft -- 2. Plug G 1/2” -- 3. To the constriction -4. Outlet -- 5. Three--way union G 1/2” -- 6. From the delivery -7. Outlet union G 1/2”.
2
3
5 4 24912
77
Installation diagram of equipment for testing the rotating valve, seals and for pressure relief valve calibration. 1. Splined drive shaft. 4. Restriction. 2. Torque wrench. 5. Pressure adjustment handwheel. 3. Delivery.
87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
30
B -- CHECKING RETURN TO NEUTRAL POSITION In the same test conditions as A, check that the rotating valve automatically returns to the neutral position when the drive shaft (1, fig. 77), is released after each simulated steering movement. C -- SEAL CHECK In the same test conditions as A, hold the rotating valve in the steering position with the drive shaft (1) for approx. three minutes and check the seals for leaks. D -- PRESSURE RELIEF VALVE CALIBRATION 1. Make the connections as shown in the diagram in fig. 77 and complete the circuit as in the drawing 76. 2. Using the drive shaft (1, fig. 77) simulate a turn (to the left or to the right) so as to interrupt the oil flow to the discharge. 3. Gradually increase the in the circuit by turning the handwheel (5), and check on the pressure gauge that the pressure relief valve (24, fig. 3) is activated at the pressure shown on page 2, If not, increase or reduce the pressure relief valve setting by tightening or slackening the adjuster screw.
E -- CYLINDER SAFETY VALVE CALIBRATION For steering to the left 1. Make the connections as shown in the diagram in fig. 77, and complete the circuit as in fig. 78. 2. Using the drive shaft (1, fig. 77), simulate a turn to the left (anticlockwise rotation) so as to interrupt the oil flow to the discharge. 3. Gradually increase the pressure in the circuit by turning the handwheel (5), and check on the pressure gauge that the pressure relief valve (26, fig. 3), is activated at the pressure shown on page 2. If the pressure differs from the prescribed value, increase or reduce the valve setting (26, fig. 3), by tightening or slackening the adjuster screw. For steering to the right Make the connections as shown in the diagram fig. 77 and complete the circuit as in fig. 79. Proceed in the same manner as described above, by simply reversing the direction of rotation of the drive shaft (1).
1 1
2 2
3
25800
25799
78 Cylinder safety valve calibration for steering to the left 1. From the delivery -- 2. To the constriction -- 3. Outlet.
87666787A - 11 - 2007
3 79
Cylinder safety valve calibration for steering to the right 1. From the delivery -- 2. To the constriction -- 3. Outlet.
SECTION 41 -- STEERING -- CHAPTER 1
31
CHECKING THE HYDROSTATIC STEERING PRESSURE RELIEF VALVE WITH CONTROL VALVE INSTALLED ON TRACTOR Proceed as follows:
1. Start the engine and perform a few steering movements with the tractor, until the oil reaches a temperature of approx. 50oC.
2. Switch off the engine and detach the oil delivery pipe union (1) on the hydraulic cylinder (2).
27151
80 1. 2. 3.
3. Replace the original union with unions (4 and 3), and connect the pressure gauge (5) with a scale of 0รท150 kg/cm2 with kit 380000240.
4. 5.
Hydraulic cylinder oil delivery pipes. Hydraulic Cylinder. Union 380000613 (supplied in kit 380000240 ) to be connected to the pressure gauge (5). Union 380000618 (supplied in kit 380000240) to be fitted in the place of the original union. Pressure gauge supplied with kit 380000240.
4. Start the engine again, bring the speed to medium rpm and apply full steering lock to bring the hydraulic cylinder to the stroke end position.
In this condition, the pressure relief valve (24, fig. 3) should intervene, with the pressure gauge showing the value prescribed on page 2.
5. If the pressure value is slightly different, the valve can be calibrated (24, fig. 3) by means of the adjuster screw.
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SECTION 41 -- STEERING -- CHAPTER 1
32
Op. 41 216 10 STEERING CONTROL CYLINDER Removal -- Installation (models T4040 Supersteer and T4050 Supersteer)
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
NOTE: The steering control cylinder can be removed from either the complete tractor or with the front axle removed. Its removal from the tractor with the front axle removed is described here. Proceed as follows. 1. Unscrew the ball joints (1) and remove them from the shaft (2) (on both sides).
81
2. Disconnect the steering cylinder control pipes (1 and 3) and unscrew the union (2).
82 3. Unscrew the ring nut (1) fastening the steering control cylinder to the front axle.
83
87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
33
4. Levering with a crowbar between the union (1) and the axle body, extract the steering control cylinder (2). 5. To install the steering control cylinder, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Position the steering control cylinder in its seat on the front axle.
--
Screw on the union and the cylinder control pipes.
--
Screw on the ring nut fastening the cylinder to the axle.
--
Screw the ball joints onto the cylinder shaft.
--
Check the alignment of the leading wheels (see section 25, chap. 2, page 39).
84
87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
34
Op. 41 216 18 STEERING CONTROL CYLINDER Disassembly -- Assembly (models T4040 Supersteer and T4050 Supersteer)
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Remove the snap ring (1).
85
2. Push the ring (1) with the seals into the cylinder.
86 3. Remove circlip (1).
87 4. Extract the shaft (2) with the seal holder ring (1).
88 87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
35
5. Check the seals removed beforehand and also the ones on the cylinder (1); replace them if deteriorated. 6. To fit the steering control cylinder, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Lubricate all components.
--
Insert the shaft with the seal holder ring onto the cylinder.
--
Lock the seal holder ring with the stop ring.
--
Fit the fastening circlip.
89
87666787A - 11 - 2007
36
87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
SECTION 41 -- STEERING -- CHAPTER 2
1
SECTION 41 -- STEERING Chapter 2 -- Non--stop flow gear pump CONTENT Operation
41 206 20
Description Page Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque settings -- Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Lift -- Chap. 1 Section 35 Hydrostatic steering oil pump D.A. (With the pump removed) . . . . . . . . . . . . . . . . . . . . . . . . 5
MAIN SPECIFICATIONS OF HYDRAULIC PUMP A 25 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
gear type with oil suction from rear transmission casing
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . . . . . . . . . . . Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum speed of rotation (with engine at maximum power 2300) . . . . . . . . . . . . . . . . . rpm Corresponding rated output . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min--l/min Rated output at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min
on right--hand side of engine A 25 NEW HOLLAND driven by engine shaft anticlockwise 1:1.08 2484 28.19 11.35
Diameter of driven and driving gear shafts . . . . . . . . . . . . . . . . . . . . . . . Internal diameter of seats in supports . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearance between gear shafts and seats on supports . . . . . . . . . . . . -- maximum clearance due to wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm mm mm mm
17.400 ÷ 17.418 17.450 ÷ 17.470 0.032 ÷ 0.070 0.1
Radial clearance of gears in pump body . . . . . . . . . . . . . . . . . . . . . . . . . Maximum wear on pump body, suction side at position of gears . . . . . Width of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width of supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm mm mm mm
0.020 ÷ 0.064 0.1 18.323 ÷ 18.348 19.796 ÷ 19.812
Width of pump body for gear seats and supports . . . . . . . . . . . . . . . . . mm Axial clearance of gears complete with supports in pump body (recondition if necessary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
58.072 ÷ 58.122 0.100 ÷ 0.200
87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 2
2
MAIN SPECIFICATIONS OF HYDRAULIC PUMP A 31 XRP2 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . . . . . . . . . . Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum speed of rotation (with engine at maximum power 2300 rpm) . . . . . . . . . . . . . . . . . . . . . . . rpm Corresponding rated output . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (I/min) Rated output at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (I/min) Start of flow control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm Flow control output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min Diameter of driven and driving gear shafts . . . . . . . . . . . . . . . . . . . . . . . . mm Internal diameter of seats in supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm Clearance between gear shafts and seats . . . . . . . . . . . . . . . . . . . . . . . . mm -- maximum clearance due to wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm Radial clearance of gears in pump body . . . . . . . . . . . . . . . . . . . . . . . . . . mm maximum wear on pump body, suction side at position of gears . . . . . . mm Width of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm Width of supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm Width of pump body for gear seats and supports . . . . . . . . . . . . . . . . . . . . . Axial clearance of gears complete with supports in pump body (recondition if necessary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
gear type with incorporated regulated output, oil suction from rear transmission casing. on right--hand side of engine A 31 XRP 2 NEW HOLLAND driven by engine shaft anticlockwise 1 : 1.08
Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2484 34.77 14 1216 18 ÷ 22 17.400 ÷ 17.418 17.450 ÷ 17.470 0.032 ÷ 0.070 0.1 0.020 ÷ 0.064 0.1 24.000 ÷ 24.015 24.490 ÷ 24.510 73.135 ÷ 73.160 0.100 ÷ 0.180
full--flow, with replaceable paper cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTS TO BE TIGHTENED
Thread
Pump control coupling hub locknut . . . . . . . . . . . . . . . . . . . . . . . . . .
7/16 20 UNF
87666787A - 11 - 2007
on pump intake
Tightening torque Nm
kgm
29
3
SECTION 41 -- STEERING -- CHAPTER 2
3
25719
1 A 25 pump components 1. 2. 3. 4. 5. 6. 7.
Nut. Lock washer. Circlip. Driving shaft seal. Control side cover. Cover seals. Gear support.
8. 9. 10. 11. 12. 13.
Driven and driving gear shafts. Gear support. Pump body. Front cover. Lock washer. Screw.
87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 2
4
25720
2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Plug. Sealing Washer. Cursor seat (12). Spring. Washer. Screw. Plug. Sealing Washer. Safety ring. Sealing Washer. Fifth wheel Cursor. Flow control valve body.
A 31 XRP 2 pump components 14. Seals (13). 15. Spacer. 16. Cover seals. 17. Pump body. 18. Gear support. 19. Driven and driving gear shafts. 20. Gear support. 21. Control side cover. 22. Driving shaft seals. 23. Circlip. 24. Lockwasher. 25. Nut.
DESCRIPTION AND OPERATION
The hydraulic pump is of the gear type with spur gears and function with non--stop flow according to the engine rpm. It is fitted on the rear side of the right hand engine support and are driven by a shaft gear unit. The oil is taken from the rear transmission casing, passing through a filter.
87666787A - 11 - 2007
The rear hydraulic pump controls the hydrostatic steering and various services: front and rear differential lock, power take--off and relative brake, four wheel drive engagement, POWER SHUTTLE gear. Supplied with a control valve to reduce the quantity of oil sent at high speeds.
SECTION 41 -- STEERING -- CHAPTER 2
5
A 31 XRP 2 PUMP MODEL OP. 41 206 20 HYDROSTATIC STEERING OIL PUMP Disassembly -- Assembly (With the pump removed) Disassembly
ATTENTION
2
Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows: 1. Remove the bolts (6, fig. 2) and the relative safety washers (5). 2. Remove the nut (25) that secures the sleeve to the pump driving shaft and the safety washer (24). 3. Remove the control side cover (21), the circlip (23) and the seal (22). 4. Mark the parts (17, 18, 19 and 20), in order to re--fit them in the same position, if in good condition. 5. Remove the supports (18 and 20), and gears (19) from the control side cover (21) and the pump body (17). 6. Recover the seals (16 and 14) and the back up rings. 7. Remove the plugs (1 and 7) with the relative seals, remove the flow control components from the body (13), i.e.: the cursor seat (3), the cursor (12), the spring (4). Once the parts are removed, proceed as follows: 8. Check that the gear contact surfaces are flat and perpendicular to their supports. Interpose a thin layer of carbon black; small rough spots can be removed using extremely fine and adequately lubricated abrasive paper. 9. Check that the axial clearance of the gear--support unit in the pump body is 0.100 รท 0.180 mm The distance (2, fig. 3) must be 0.100 รท 0.180 mm less than the distance (1). If necessary, true the flat surfaces involved using lubricated abrasive paper to remove extremely small quantities of material. 10. Clean all constituent parts thoroughly. 11. Replace seals (16 and 22, fig. 2). 12. Lubricate the parts with the same oil used in the system.
25227
3 Assembly Procedure
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 13. To re--fit the pump carry out operations from no. 7 to no. 1, in reverse order, referring to fig. 2 and proceeding as follows: to re--fit the pump carry out operations from no. 7 to no. 1; always ensure maximum cleanliness to prevent foreign matter from entering, as this could damage the pump; fit together the previously marked parts (17, 18, 19 and 20), referring to operation 4, in the original positions; mount the gear supports (18 and 20) in the pump body, positioning as shown in fig. 2; mount the seals (22), on the control side cover (21), facing towards the inside and insert the circlip (23); insert the plastic back up rings on the seals (14 and 16), fitting between parts (13) (15) (17) (21), as shown in fig. 2; fit the washers (5) and tighten the retaining bolts (6); fit the washer (24) and the locknut (25).
87666787A - 11 - 2007
6
87666787A - 11 - 2007
SECTION 41 -- STEERING -- CHAPTER 2
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
1
SECTION 44 -- AXLES AND WHEELS Chapter 1 -- Axles and wheels CONTENT Section
Description
Page
44 000
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
44 101 22
Front axle hub. Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
44 101 30
Front axle. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
44 101 46
Stub axle. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
44 511 46
Checking the alignment of the leading wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SPECIFICATIONS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
inverted U--section, U section, telescopic and oscillating at centre
Camber angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
2°, corresponding to approx. 15 mm for 16” rims
Toe--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
0÷5
Diameter of stub axle pin (7, page 3) atbushings (6) . . . . . . . . . . .
mm
37.961÷38.000
Internal diameter of fitted bushings (6) . . . . . . . . . . . . . . . . . . . . . .
”
38.050÷38.140 (*)
Clearance between stub axle pin and bushings . . . . . . . . . . . . . . .
”
0.050÷0.179
Diameter of axle articulation pin (1, page 3) axle articulation . . . .
mm
37.961÷38.000
Internal diameter of fitted bushings (2) . . . . . . . . . . . . . . . . . . . . . .
”
38.050÷38.140 (*)
Clearance between stub axle pin and relative bushings . . . . . . . .
”
0.050÷0.179
Stub axle articulation
Axle articulation
(*) Value to be obtained without refacing.
(continued)
87666787A - 11 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
2
SPECIFICATIONS (overleaf)
Wheel tracks (mm) Models
Tyres
A
B
C
D
E
F
G
1349
1449
1549
1649
1749
1849
1949
1357
1457
1557
1657
1757
1857
1957
1431
1531
1631
1731
11831
1931
2031
6.0016 6.5--16 6.50--16 F2 7.50--16 7.50--16 F2 T4040 T4050
9.15L 15 F2 27X9.5--15 F2 27X9.5--15 HF 11L--15 I1 11L--15 F3 25/10LLX15 TT
2WD front wheel track diagram
A B C D
27460
G F E mm 1
87666787A - 11 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
3
SECTIONS
1
2
3
4
5
6
7
18
8 9
17
14
13
12
16
25990
11
10
15
4 2 Sections of stub axle, articulation pin and front axle
1. 2. 3. 4. 5. 6. 7. 8. 9.
Axle articulation pin. Axle articulation bushings. Steering transverse tie--rod. Stub axle pin control lever. Axle support. Bushings. Swivel pin. Support ring grub screw (13). End Cap.
10. 11. 12. 13. 14. 15. 16. 17. 18.
Bronze thrust ring. Seal. Wheel hub. Tapered roller bearing for wheel. Cover for bearing greasing and adjustment. Steel thrust ring. Grub screw for cap (11) and thrust washer (12). Control cylinder fulcrum pin (18). Control cylinder installation position.
87666787A - 11 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
4 BOLT TORQUES
C1 -- 49 Nm
C2 -- 115 Nm C6 -- 186 รท 206 Nm
C5 -- 186 รท 206 Nm
C3 -- (*)
C5 -- 49 รท 68.7 Nm
C4 -- 186 รท 257.7 Nm
25991
3 Torque settings -- front axle wheel hub side C1 C2 C3 C4 C5
Axle pivot pin retaining bolt. Disk to hub retaining bolt. Bearings adjuster nut. Axle end retaining nut. Cover for wheel hub bearing greasing.
87666787A - 11 - 2007
C6 Stub axle pin control lever retaining bolt nut. C7 Nut securing cylinder to fulcrum pin. (*) See operations 12 and 13, page 13
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
5
C8 -- 102 รท 123.5 Nm
C9 -- 125 รท 154.5 Nm
C10 -- 29.4 รท 46.4 Nm 25992
4 Torque settings front axle steering tie--rod side C8 Stub head locknut for steering transverse tie--rod. C9 Locknut for steering transverse tie--rod.
C10Nut securing power steering cylinder pipes.
87666787A - 11 - 2007
6
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1 BOLT TORQUES Tightening torque PARTS TO BE TIGHTENED
Thread Nm
kgm
Front Shaft Axle articulation pin retaining bolt (C1, page 4) . . . . . . . . . . . . . . . . .
M 10x1.25
49
5
Nut (C2) securing leading wheel to hub . . . . . . . . . . . . . . . . . . . . . . .
M 18x1.5
115
11,7
Nut (C3) for bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 20x1.5
(*)
(*)
Nut (C4) for pin securing end of axle . . . . . . . . . . . . . . . . . . . . . . . . .
M 20x1.5
186÷257.7
19÷26.3
Cover (C5) for wheel hub bearing greasing . . . . . . . . . . . . . . . . . . . .
--
49÷68.7
5÷7
Nut (C6) for stub axles left and right--hand levers retaining bolt . . .
M 14x1.5
186÷206
19÷21
Nut (C7) securing cylinder to fulcrum pin . . . . . . . . . . . . . . . . . . . . . .
M 18x1.5
186÷206
19÷21
Stub head locknut (C8, page 5) for steering transverse tie--rod . . .
M 16 x 1.5
102÷123.5
10.4÷12.6
Locknut (C9) for steering transverse tie--rod . . . . . . . . . . . . . . . . . . .
M 20x1
Nut (C10) securing power steering cylinder pipes . . . . . . . . . . . . . . .
--
125÷154.5 12.7÷ 15.7 29.4÷46.4
3÷4.75
(*) See operations 12 and 13, page 13
SPECIAL TOOLS Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual.
87666787A - 11 - 2007
List of specific tools required for the various operations described in this Sect. 380000237
Wheel lifting hook.
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
7
27855
5 Tool to be made for extracting the front axle articulation pin (to be used with an extracting tool -Stamp tool with No. 50145 -- Measurements in mm) Construct in C40 material -- Pin 3 x 20 mm.
TROUBLESHOOTING Problems Abnormal tyre wear.
Possible Problem 1. Wrong inflation pressure.
2. Wrong front wheel toe--in. Poor tractor stability.
1. Wrong inflation pressure.
Solutions Inflate the tyres to the correct pressure, referring to the recommended pressures in the Use and Maintenance handbook, and the pressures indicated by the tyre manufacturers. Correct the toe--in. Inflate the tyres to the correct pressure, following the instructions given above.
87666787A - 11 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
8
Op. 44 101 22 FRONT AXLE HUB Disassembly--Assembly
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. The wheel hubs can be removed without removing the axle from the tractor. Proceed as follows for each wheel, bearing in mind that the wheel hubs can be removed without removing the axle from the tractor.
25993
6
1. Lock the front wheels using chocks. 2. Lift the front of the tractor. 3. Place a mechanical stand (1) under the engine sump and insert a wooden block between the engine sump and the stand.
25994
7 4. Remove the front wheel retaining bolts (1).
24767
8
87666787A - 11 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
9
5. Remove the cover (1) for wheel hub bearing greasing.
24775
1 9
6. Remove the wheel hub bearing adjuster nut securing ring (1).
24776
10 7. Using a socket wrench, unscrew the wheel hub bearing adjuster nut.
24777
11 8. Remove the wheel hub (2) and recover the bearings (1 and 3).
1
2
3
24778
12 87666787A - 11 - 2007
10
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
9. Replace worn bearings and faulty seals using suitable extractors and punches.
24780
13 10. Fill the wheel hub with AMBRA GR9. 11. Refit the wheel hub (2), complete with bearings (1 and 3).
1
2
3
24778
14 12. Using a torque wrench, tighten the nut to a torque of 98 Nm (10 kgm), whilst rotating the wheel hub (1) to correctly seat the bearings. 13. Loosen the nut, then tighten again to a torque of 24 รท 29 Nm (2.5 รท 3 kgm) whilst continuing to rotate the wheel hub.
1
NOTE: The nut must be replaced each time the wheel hub is fitted. 14. Check the rolling torque R, bearing in mind that: 24779
15 R โ ค 0.8 kgm 15. Secure the nut (1) by notching. 16. Refit the cover (1, fig. 17) for wheel hub bearing greasing.
24776
16 87666787A - 11 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
11
Op. 44 101 30 FRONT AXLE Removal--Installation
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted. To totally remove the front axle from the tractor, proceed as follows. 1. Lock the front wheels using chocks.
25993
2. Lift the front of the tractor.
17
3. Place a mechanical stand (1) under the engine sump and insert a wooden block between the engine sump and the stand.
25994
18 4. Remove the front wheel retaining bolts (1).
24767
19
87666787A - 11 - 2007
12
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
5. Disconnect the power steering cylinder (2) hoses (1).
25995
20 6. Remove the axle articulation pin retaining bolt (1).
25996
21 7. Secure the axle by means of a sling (1).
25997
22 8. Extract the axle articulation pin using an extractor tool (1) fitted with adapter 50145 (see page 7) and extension.
25998
23 87666787A - 11 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
13
9. Remove the complete axle (1).
1
24772
24 10. To refit the complete axle on the tractor, follow the disassembly procedure in reverse order. Proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 11. Using a bronze punch fit the axle articulation pin (1). 12. Fit the axle articulation pin retaining bolt (1).
25996
25
13. Connect the hoses (1) of the power steering cylinder (2). 14. Fit the front wheels. 15. Remove the support stand. 16. Lower the tractor and remove the sling. 17. Connect the battery negative lead.
25995
26
87666787A - 11 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
14
Op. 44 101 46 STUB AXLE Overhaul
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows for each wheel, remembering that the stub axles can be removed without removing the axle from the tractor. 1. Lock the front wheels using chocks. 25993
2. Lift the front of the tractor.
27 3. Place a mechanical stand (1) under the engine sump and insert a wooden block between the engine sump and the stand.
25994
28 4. Remove the front wheel retaining bolts (1).
24767
29
87666787A - 11 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
15
5. Position a hydraulic jack under the stub axle and unscrew the bolt (1) securing the control lever (2) to the stub axle pin.
24782
30 6. Extract the control lever (1) from the stub axle pin (2).
24783
31 7. Lower the hydraulic jack and remove the stub axle (1)
24784
1 32
8. Unscrew the bolts securing the axle end (1).
33 87666787A - 11 - 2007
16
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
9. Remove the axle end (1).
24786
34 10. Clamp the end of the axle in a vice and, using an extractor tool, extract the stub axle pin articulation bushings (1).
1 24787
35 11. To refit the stub axle, follow the disassembly procedure in reverse order, using a striker to fit the new bushings on the axle ends.
24788
36 12. Fit the axle end (1).
24786
37 87666787A - 11 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
17
13. Refit the cap (9, fig. 2), at the base of the stub axle, then the shim adjuster rings (1) inserting them on the stop grub screws (8 and 14, as shown in fig. 2).
24789
38 14. Fit the stub axle on the axle end. 15. Position the control lever (1) on the stub axle pin (2) then tighten the retaining bolt.
24783
39
87666787A - 11 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
18
Op. 44 511 80 CHECKING THE ALIGNMENT OF THE LEADING WHEELS
ATTENTION A
Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
A+X
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
B+0÷5 mm
Check the alignment of the leading wheels, bearing in mind that for driving in a straight line, the wheels must be at an angle of 2° to the ground, corresponding to a difference of approximately 15 mm, for 16” rims, between the top and bottom edges of the rim (fig. a).
B 8821
When driving in a straight line, the wheels must also be parallel to longitudinal axis of the tractor, or have a maximum of 5 mm toe--in at the front, as measured between the edges of the rims. To check the toe--in exactly, proceed as follows: 1. Inflate the front tyres to a pressure of 2.5 bar (kg/cm2). 2. Place the steering wheel at mid--travel, with one spoke along the tractor centre line. 3. Check if wheels are parallel to the tractor centre line. 4. On the horizontal plane passing between the centres of the wheels, measure the distance (B) between the front inside edges of the rims (see fig. b). 5. On the horizontal plane passing between the centres of the wheels, measure the distance between the rear inside edges of the rims, checking that the distance is equal to (B) or exceeds it by up to a maximum of 5 mm. 6. If necessary, correct the toe--in by adjusting the end of the transverse steering tie--rod.
87666787A - 11 - 2007
40
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
1
SECTION 50 -- CAB AIR CONDITIONING SYSTEM Chapter 1 -- Cab air conditioning system CONTENT Operation
Description
Page
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Use of the air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tools and general characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operating principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Main components of the cab air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 50 200 03
Operating control and cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Refrigerant recovery -- recycling and evacuation -- charging stations . . . . . . . . . . . . . . . . 22
50 200 04
Filter/dryer, recharging and cooling control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
50 200 06
Checking for fluid/gas leaks in the air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . 31
50 200 10
Compressor drive belt tension adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
50 206 14
Cab air infeed vents Disassembly--Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
50 206 51
Cab heating/air conditioning system Removal--Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 35
50 206 54
Cab air conditioning system heating unit D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
50 206 56
Cab air conditioning system evaporator unit Disassembly--Assembly. . . . . . . . . . . . . . . . . 38
50 206 66
Cab electric fan unit D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
87666787A - 11 - 2007
2
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
CAB AIR CONDITIONING SYSTEM
CAUTION
--
freezing of the skin caused by contact with liquid refrigerant may be treated by gradually warming the injured area with cold water, followed by the application of a greasy cream. Request medical assistance.
--
the air conditioning system contains a mixture of refrigerant and oil under high pressure; under no circumstances loosen pipe fittings/unions or work on the pipes without having first evacuated the system.
--
for the same reason, never unscrew the compressor oil level plug when the system is charged.
--
do not heat the refrigerant container. If the temperature exceeds 50°C the pressure will increase very rapidly.
--
keep the air conditioning system away from heat sources to prevent explosions as a result of an increase in pressure in the system.
The refrigerant must be handled with great care in order to avoid personal injury; always use safety goggles and gloves. Avoid contact with skin and eyes. Liquid refrigerant can cause freezing of the skin and serious damage to the eyes, sometimes resulting in permanent blindness. Keep the refrigerant container away from heat sources. Heat will cause an increase in pressure of the refrigerant and could cause the container to explode. If refrigerant comes into contact with a naked flame or a hot metal surface it produces a toxic gas. If inhaled, this gas can cause serious poisoning. To avoid the possibility of accidents take the simple precautions described below. The operation of emptying and charging the system must be carried out in a well--ventilated area, well away from any naked flames. During the charging and emptying operations, take the necessary precautions to protect the face and above all the eyes from accidental contact with refrigerant.
When transferring refrigerant from one container to another, only use homologated liquid refrigerant containers equipped with safety valves.
Never fill liquid refrigerant containers over 80% of their maximum capacity.
In the event of an accident, proceed as follows: Do not modify the settings of safety valves and the control devices. --
if refrigerant splashes into the eyes, wash immediately with a few drops of mineral oil, then wash them thoroughly with a solution of boric acid and water (one spoonful of acid in 1/4 cup of water) and seek medical assistance immediately.
87666787A - 11 - 2007
Never connect the recovery/recycling and evacuation/charging stations to electrical power outlets with voltages other than those specified; do not leave the stations powered up unless they are to be used immediately.
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
3
USE OF THE AIR CONDITIONING SYSTEM
Warning -- The air conditioning system will not function when the engine is not running, as the engine drives the compressor.
The air conditioning system provides dehumidified air or warm dehumidified air.
cool,
To operate the system, proceed as follows.
ADJUSTMENT
To obtain correct cab air conditioning, when the system is in operation keep the recirculation vents open, whilst keeping the doors and front and rear windows closed.
For maximum cooling, the knob (3, fig. 13) must be turned fully to the left in an anticlockwise direction.
START UP
Starting the system at low temperatures can damage the compressor. Only operate the air conditioner when the engine is hot and the temperature inside the cab is at least 20 °C.
Warning -- Before starting the engine, make sure that the air conditioning push button (2, fig. 13) is in the ”off” position.
Warning -- Before switching on the conditioner, always switch on the electric fan. When the fan is switched off the air conditioning will not function.
NOTE: In order to increase the pressure inside the cab, and prevent foreign bodies entering when working in extremely dusty conditions, it is advised to keep the recirculation vents closed.
The air--conditioner dehumidifying function operates at all temperatures and can be set by rotating the knob (3, fig. 13).
In order to create optimum temperature conditions, after prolonged idle periods in hot sunshine, it is advised to start the tractor moving, switch on the air conditioning and open the rear window for approximately one minute, to discharge the heated air in the cab.
With the engine running and the electric fan on, press push button (2, fig. 13) to start the air conditioner. SWITCHING OFF After a few minutes of operation, the liquid visible in the sight glass at the top of the filter (3, fig. 2) should be clear and free of bubbles. If not, contact the specialised personnel at your dealer.
Before stopping the engine, always switch off the air conditioner by pressing push button (2, fig. 13), then turn the fan control knob (1) to the ”off” position.
87666787A - 11 - 2007
4
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 TOOLS REQUIRED FOR SERVICING THE CAB AIR CONDITIONING SYSTEM
Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work in safety and to obtain the best possible results whilst saving both time and energy, we recommend that the other specific tools in the list are also used.
List of specific tools required for the various operations described in this Section X 380000315 380000314 X 380000312
Recovery, evacuation and charging station Acoustic gas leak detector Combs for cleaning and straightening the fins on the condenser and evaporator
CAB AIR CONDITIONING SYSTEM CHARACTERISTICS SANDEN SD 5H11 Compressor Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
cm3
110
Maximum rotation speed . . . . . rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6000
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg
6,5
Quantity of lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm3
185
Type of lubricating oil (code) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAG SP20
Air Conditioner System
Gas HRC134a
Quantity of HFC--134a refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . g
800
System delivery side pressure . . . . . . . . . . . . . . . . . . . bar
(kg/cm2)
10 ÷ 22 (10.2 ÷ 22.4)
System suction side pressure bar . . . . . . . . . . . . . . . . . bar
(kg/cm2)
0.2 ÷ 2.5 (0.2 ÷ 2.5)
Pressure switch setting (high pressure) . . . . . . . . . . . . bar
(kg/cm2)
25 (25,5)
Pressure switch setting (low pressure) . . . . . . . . . . . . bar (kg/cm2)
2 (2)
Temperature of refrigerant fluid at compressor outlet . . . . . . . . . oC
60 ÷ 120
Temperature of refrigerant fluid at condenser outlet . . . . . . . . . .
oC
40 ÷ 60
Temperature of refrigerant fluid at evaporator outlet . . . . . . . . . .
oC
0 ÷ 15
Maximum capacity of electric centrifugal fan I, II, III speed
87666787A - 11 - 2007
m3/min
3.0 ÷ 6.5
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 OPERATING PRINCIPLES The function of the air conditioning system is to create and maintain optimum working conditions inside the tractor cab. The climate inside the cab essentially depends on four factors: --
temperature;
--
humidity;
--
speed;
--
purity of the air in the cab.
Obviously ”ideal” conditions will vary from person to person, and so it is not possible to specify optimum values for the above factors; however, we can specify a range of values within which the majority of people will feel most comfortable. As regards temperature and humidity, we can define a zone, known as the ’comfort zone’, within which the temperature and humidity combination corresponds to satisfactory climatic conditions. From the diagram it can be seen that humidity should be within the range of 30% to 70%. Below 30% there is excessive dehydration of the mucous tissue of the nose and throat, whereas above 70% an uncomfortable sense of dampness may be perceived. The temperature may therefore vary between 18 and 28°C. The air flow speed must not be so high as to cause discomfort; speeds of 0.07 -- 0.25 m/s are normally acceptable.
5
As regards air purity, no precise limits have been defined; however, it is important to remember that the human organism gradually alters the composition of the air in the surrounding environment by breathing, increasing the amount of carbon dioxide and humidity, and decreasing the amount of oxygen, etc. These problems can be eliminated by allowing a small flow of external air to enter the cab. However, as agricultural tractors are often used in dusty conditions (dust from the earth, hay, etc.), the installation of dry filters on the external air inlets provides a simple solution. The use of air conditioning in tractors and agricultural machinery in general serves to neutralise unpleasant climatic conditions inside the cab; the air conditioning system controls the temperature and humidity of the air drawn into and already present in the cab so as to maintain a comfortable climate for the operator. The operating principle of the system is similar to that of a domestic refrigerator: heat is removed from the air by means of a physical process (the evaporation of a liquid) which draws heat from the surrounding environment. The liquid used in this process (refrigerant) is a product with a high refrigeration coefficient, low toxicity and mixes well with lubricating oils. The various components of the system are connected by pipes in which the refrigerant circulates. Relative humidity %
Simplified psychrometric diagram 1. Sensation of unbearable coldness. 2. Sensation of coldness. 3. Comfort zone. 4. Sensation of heat. 5. Sensation of unbearable heat.
25372
Temperature oC
1
87666787A - 11 - 2007
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
6
MAIN COMPONENTS OF CAB AIR CONDITIONING SYSTEM The air conditioning system comprises five main components: 1. Compressor; 2. Condenser; 3. Dryer filter; 4. Thermostatic expansion valve; 5. Evaporator. To understand the operating cycle of the system, follow the flow of the refrigerant starting from the compressor (1). The compressor draws in vaporised refrigerant at a pressure of 0.2÷ 2.5 bar compressing it to a pressure of 10 ÷ 22 bar. The refrigerant, heated by compression to 60÷120°C, is directed to the condenser coil (2) (still in vapour form) located in front of the engine radiator. The air flow, produced by the electric fan and the forward movement of the tractor, cools the refrigerant by means of heat exchange. This action cools the refrigerant to the point of condensation between 40÷60 °C depending on the outside temperature, changing the vapour into liquid.
The refrigerant, in liquid state at high pressure, is purified by passing through the filter/dryer (3) from where it flows to the expansion valve (4), which restricts the flow of refrigerant and thus reduces its pressure. As it passes through the expansion valve (4), part of the refrigerant is transformed into vapour and the low temperature mixture of vapour and liquid thus formed enters the evaporator (5). Here the electric fan causes a continuous circulation of the cab air over the fins of the evaporator (5), helping the refrigerant to absorb heat from the air and thus change completely from a liquid to vapour. The evaporation process removes heat from the air passing over the evaporator (5) and thus reduces the temperature inside the cab. The flow of air over the cold surface of the evaporator (5) also condenses some of the moisture in the air and therefore reduces the humidity in the cab. On leaving the evaporator (5) at 0÷15 °C the low pressure mixture is taken in by the compressor (1) to start a new cycle.
1
5
3
4
2
25372
2 Schematic diagram of the air conditioning system 1. 2. 3.
Compressor. Condenser. Dryer filter.
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4. 5.
Expansion valve with thermostatic sensor. Evaporator.
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 Compressor
1
2
3
4
7
5
The compressor serves to pressurise the refrigerant and force it through the system.
SANDEN SD 5H11 MODEL
Axial reciprocating piston type, driven by the engine crankshaft via a vee belt. 25375
The operation of the compressor can be summarised as follows: The swashplate (4), on which pivot the ball ends of the connecting rods of the pistons (2), rests on the cam rotor (5). As the cam rotor rotates it exerts a continuous thrust on the swashplate, which is prevented from rotating by the coupling with the fixed gear (3). The angle of the swashplate causes reciprocating movement of the pistons.
the
The reed valve (1) on the cylinder head with five lobes (one for each piston) controls the inlet and discharge stages of the cylinders. The valve opening and closing system is automatic, achieved by preloading of the shutter blades. The rotating parts of the compressor are lubricated by special oil, inserted during assembly, some of which circulates through the system mixed with the refrigerant.
COMPRESSOR OIL -- TYPE AND QUANTITY
3 Axial flow reciprocating piston compressor SANDEN SD 5H11 1. 2. 3. 4. 5.
Combined inlet and discharge valve. Piston with seal ring. Driving gear. Connecting rod disk. Cam rotor.
Also remember that:
Never leave the compressor oil container open, always make sure that it is tightly closed. If left exposed the oil will absorb humidity from the air and may, subsequently, damage the system. Do not transfer compressor oil from the original container to another container. Do not introduce any additives to the compressor oil. Any additional substances could contain elements which are incompatible with the chemical base of the refrigerant and thus alter its characteristics. Do not use engine oil of any type to lubricate the compressor and the system.
The tractor is equipped with a SANDEN SD 5H11 compressor for R134a refrigerant. After assembly, the compressor is filled with 185 cm3 of PAG SP20 lubricating oil. In case of top up or oil change, use only this type of oil. It is not necessary to check the compressor oil level unless the system develops significant gas leaks.
Warning -- If the system develops significant leaks of R134a refrigerant, there will also be a significant loss of PAG SP20 compressor oil. It is therefore necessary in these cases to check the level of oil in the compressor, taking account that of the total quantity of lubricating oil (185 cm3) on average the compressor contains 130 รท 135 cm3, while the remainder (50--55 cm3) circulates among the various system components. For problems of this type, we recommend that you seek assistance from an authorised NEW HOLLAND service centre.
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8
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
Condenser
The condenser (1) is the system component in which the refrigerant vapour condenses to form a liquid.
The condenser works in similar way to the engine cooling radiator, allowing the vapour to give up heat to the external air. 27664
4
It comprises a series of inner tubes through the refrigerant flows and a outer shell consisting of a series of thin aluminium fins which increase the surface area in contact with the cooling air flowing through the condenser.
The condenser radiator is fitted under the engine bonnet, in front of the engine radiator. This is the ideal position to take full advantage of the air flow from the radiator cooling fan, necessary for heat exchange.
Dryer filter
The filter/dryer (1) is fitted under the engine bonnet, positioned between the condenser and the expansion valve, performs two basic functions, acting as a filter to remove solid and liquid particles from the refrigerant and as a temporary storage container during variable charge stages.
It is important to eliminate water from the system to prevent corrosion and consequent damage to the components.
27663
5 The filter therefore contains substances capable of absorbing humidity.
Solid particles, such as grit, metal particles produced by the mechanical wear of the compressor, oxides, etc., can also damage the system and so the filter incorporates screens to retain them.
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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 Thermostatic expansion valve
9
2
1
3
This valve serves to reduce the pressure of the liquid refrigerant from the condenser so that the refrigerant entering the evaporator can evaporate and thus take heat from the air which is to be cooled.
4 7
The expansion valve has two main functions:
6
5
25389
--
--
metering: the calibrated bore (6, fig. 6) inside the valve body creates a difference in the pressure of the refrigerant between the inlet (4) (liquid state) and the outlet (7) (mixed liquid/vapour state); the calibrated bore (6) also serves to atomise the refrigerant to facilitate subsequent evaporation;
modulation: inside the valve body a thermostatic sensor controls the valve aperture so that the right quantity of refrigerant enters the evaporator to ensure complete evaporation.
6 1. 2. 3. 4. 5. 6. 7.
Expansion valve block. From the evaporator outlet. Thermostatic sensor. To compressor suction inlet. From filter/dryer. Spring. Calibrated bore and ball. To evaporator inlet.
NOTE: In the event of malfunction, replace the valve.
If the thermostatic sensor (2, fig. 6) detects an increase in the temperature of the refrigerant at the evaporator outlet, the flow of refrigerant is increased.
If the temperature in the cab drops or the compressor starts to operate at a higher capacity (due to an increase in engine speed), the flow rate into the evaporator is reduced.
The expansion valve is installed on the evaporator inlet fitting (7), and as the internal refrigerant flow control system is completely automatic, it requires no special maintenance.
To perform functional testing, with the system is fully charged, check that the system operating pressures are those indicated on page 4.
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10
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
Evaporator
Thermostatic switch (ANTI--FROST)
The cooling cycle is completed inside the evaporator. The refrigerant at the expansion valve outlet is a mixture of vapour liquid at low temperature and low pressure. As it passes through the evaporator it absorbs heat from the cab air, evaporates, and is then taken in by the compressor. 27769
The operation of the evaporator is controlled by the expansion valve which regulates the flow of refrigerant to obtain the required degree of air cooling. The evaporator performs the opposite function to the condenser, but it is constructed in a similar way; the only differences being the overall dimensions and the internal pipe layout. The evaporator also has dehumidification of the cab.
another
function:
The air passing over the evaporator contains a certain quantity of moisture, and this must be kept within certain limits for operator comfort. Some of the humidity in the air condenses on the fins of the evaporator. The centrifugal fan draws the ambient air through the fins of the evaporator (where it is cooled and dehumidified) and into the cab. The housing around the evaporator is equipped with a condensate trap from which the condensate is carried outside the vehicle through discharge tubes.
7 The thermostatic switch (thermostat) is a safety device, fitted with a sensor (1, fig. 7) inserted on the evaporator outlet pipes (2), where it constantly monitors the temperature. The sensor bulb is filled with a special gas which expands or contracts according to the temperature, acting on a membrane connected to a complex mechanism which opens or closes an electric circuit connected to the compressor electro--magnetic clutch, switching the compressor on or off as required. The thermostatic sensor (1) therefore prevents ice from forming on the evaporator, as a result of the treatment of extremely damp air, and obstructing the flow of air into the cab. For this reason, in the event of replacement or maintenance operations, it is important that the thermostatic sensor (1) is inserted on the evaporator outlet pipes (2). Tape the two components together with insulating tape in order to ensure efficient system operation.
NOTE: In the event of malfunction, replace the thermostatic switch (1).
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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
11
CAB HEATING AND VENTILATION CONTROLS
1
2
VENTILATION Turn on the cab ventilation by means of the selector switch (1, fig. 8) and direct the air flow by positioning the front vents (2). Air may be selected from inside or outside the cab by adjusting the rear side recirculation vents (1, fig. 9) which can be placed in two positions. -- vents closed: air is drawn from outside the cab through the lateral filters. -- vents open: the greater part of the air is drawn from inside the air through the vents. Fresh air drawn into the cab from outside is always filtered. With the fan in operation and doors, windows, and recirculation vents closed, the pressure inside the cab is greater than the external pressure. Consequently, air can only enter the cab through the lateral filters, after suitable filtering.
24023
8
NOTE: To increase cab pressure, air must only be taken from the outside (air re--circulation vents 1, fig. 9 closed). 26427
9
Electric Fan The fan control switch (1, fig. 8 and 10) is powered up when the ignition switch (1, fig. 12) is in position B.
A
B
C
A. Low speed. B. Medium speed. C. High speed. Air filter
DANGER Remember that the filters of the cab provide no protection against anti--parasitic chemicals in general. Protection against these products can only be obtained by taking the specific precautions required for each individual product. This applies to all types of filter, for which the prescriptions for use and maintenance must be followed scrupulously. Even the use of active carbon filters does not exempt the operator from adopting the personal safety precautions recommended for the product in question.
1 10
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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
12 HEATING
1
2
3
The heating control knob (1, fig. 11) allows the operator to regulate the air temperature, by increasing or decreasing the coolant circulation from the engine. The electric fan control switch (2) allows the operator to regulate the quantity of air entering the cab through the vents (3, fig. 11) and (1, fig. 9). 24026
11
Temperature control knob (1)
--
Turned fully to the left in an anticlockwise direction = minimum temperature (hot water circulation off).
--
Turned fully to the right in a clockwise direction = maximum temperature (hot water circulation fully open).
NOTE: The total capacity of the cooling system is 10 litres for models without cabs and 12 litres for models with cabs.
IGNITION SWITCH
To operate the three functions on the switch (1, fig. 12) turn the key to the following positions: A. No power supply to any of the circuits (key can be removed). Stopping the engine: automatic operation of fuel injection shut--off device. B. Standby for engine start up. Operation of panel lights and instruments. Power supplied to various circuits.
27179
12 C. Engine start: if released, the key returns automatically to position (B).
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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
1
A
3
B
13
C
2
24027
13
CAB AIR CONDITIONING AND TEMPERATURE CONTROLS
Air conditioning and temperature control button The system operates with the ignition key switched on. With the electric fan knob (1) in positions A--B or C, turn the knob (2) to switch on the air conditioning. Heater control knob For maximum temperature, turn the knob (3) clockwise (fully to the right). To shut off the water supply to the heater and switch off the heater, turn the knob (3) fully anticlockwise. 3--speed electric fan control knob Functions when the ignition switch is in the starting position (B, fig. 12) A. Low speed. B. Medium speed. C. High speed. NOTE: To pressurise the cab, see the Ventilation chapter on page 11 in this Section
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14
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
OP. 50 200 03 FUNCTION AND COOLING TESTING With the pressure gauges connected to the system in the manner described on page 22 and all cocks closed, proceed as follows: 1. Start the engine and bring it up to a speed of 1500 rpm. 2. Check that the knob (3) is turned fully to the left (maximum cold), so as to exclude the heating function. 3. Adjust the electric fan (1) to maximum speed. 4. Turn the knob (2) to turn on the air--conditioner.
After the system has been in operation for about 15 minutes, check the following values: 5. Pressure on the suction side of the compressor, as indicated by the low pressure gauge. 6. Pressure on the delivery side of the compressor, as indicated by the high pressure gauge. 7. Ambient air temperature. 8. Ambient relative humidity. 9. Temperature of air leaving vents inside the cab. The pressure values will depend on the external ambient conditions and the altitude. The system is to be considered as functioning correctly if the pressure and temperature readings are within the value ranges indicated on the table below.
1
A
3
B
C
2
24027
14 Gas HRC134a
Air Conditioner System Quantity of HFC--134a refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . g
800
System delivery side pressure . . . . . . . . . . . . . . . . . . . bar
(kg/cm2)
10 ÷ 22 (10.2 ÷ 22.4)
System suction side pressure bar . . . . . . . . . . . . . . . . . bar
(kg/cm2)
0.2 ÷ 2.5 (0.2 ÷ 2.5)
Pressure switch setting (high pressure) . . . . . . . . . . . . bar (kg/cm2)
25 (25,5)
Pressure switch setting (low pressure) . . . . . . . . . . . . bar (kg/cm2)
2 (2)
Temperature of refrigerant fluid at compressor outlet . . . . . . . . . oC
60 ÷ 120
Temperature of refrigerant fluid at condenser outlet . . . . . . . . . .
oC
40 ÷ 60
Temperature of refrigerant fluid at evaporator outlet . . . . . . . . . .
oC
0 ÷ 15
Maximum capacity of electric centrifugal fan I, II, III speed .
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m3/min
3.0 ÷ 6.5
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 PRESSURE VARIATIONS AT DIFFERENT ALTITUDES Altitude (m) above sea level
Absolute atmospheric pressure (kg/cm2)
Correction (kg/cm2)
0
1,029
0
300
0.994
-- 0.035
600
0.959
-- 0.070
900
0.924
-- 0.105
1200
0.889
-- 0.140
1500
0.854
-- 0.175
1800
0.819
-- 0.210
2100
0.791
-- 0.238
2400
0.763
-- 0.268
15
Checking the temperature of the air coming out of the vents inside the cab
If the temperature of the air measured at the vents inside the cab is within the value range indicated in the following table for the external ambient air temperatures specified, the system is functioning efficiently.
If the temperature of the air at the vents exceeds the maximum value indicated in the table, refer to the FAULT DIAGNOSIS GUIDE, on the following pages.
It should be remembered that altitude affects pressure, as indicated in the table above. In order to obtain the pressure value in the various sections of the system, the relative correction value must be subtracted from the pressure gauge reading.
CAB VENTS TEMPERATURE TABLE
External ambient temperature
20°C
Temperature of air at vent outlets (inside cab)
27°C
4 ÷ 8°C
28°C
35°C
6 ÷ 12°C
36°C
43°C
12 ÷ 20°C
10. Carry out temperature checks on the high and low pressure parts of the system:
--
--
11. The compressor should not be excessively noisy, there should be an audible click when the drive is engaged.
all high pressure parts -- from the compressor delivery fitting to the condenser, expansion valve installed on the evaporator unit -- should be uniformly hot to touch.
all low pressure parts, -- from the expansion valve outlet to the suction fitting on compressor -- should be uniformly cold to touch. There should not be excessive condensation on the suction pipe and the low pressure pipe connector on the compressor.
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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
16
MAINTENANCE OF THE AIR CONDITIONING SYSTEM
1) COMPRESSOR: check the mountings, the tension of the drive belt and the oil level.
At the start of the season in which it will be used, check the efficiency and operation of the system. If the system has been out of use and charged for a prolonged period, oil may have flowed out of the compressor to other parts of the system and consequently this oil must be returned to the compressor. To carry out this operation, proceed as follows: 1. Start the engine and bring it up to a speed of 1500 rpm. 2. Check that the knob (3, fig. 14) is turned fully to the left, in order to turn off the heating function and provide maximum cooling. 3. Adjust the electric fan (1) to maximum speed. 4. Press the push button (2) to switch on the air conditioning. After the system has been in operation for about 15 minutes, check the following values: Check that the relative temperatures of the external ambient air and the air flowing out of the vents inside the cab correspond to the values indicated in the table on page 15. If the temperature values are correct, the system is perfectly efficient and only requires a visual inspection of the main components:
2) CONDENSER: check mounting and that the fins are free of excessive deposits. Straighten any bent fins using the comb tool 380000312.
2
1
NOTE: Carry out the same checks on the EVAPORATOR (9) and the CONDENSER (5). 3) FILTER/DRYER: the sight glass on the receiver--drier can provide useful information about system operation, as described below. Replace the receiver--dryer after the system has been repaired on two occasions. 4) EXPANSION VALVE: this valve does not require maintenance; in the event of malfunction contact specialised personnel of the NEW HOLLAND service network. If the temperature of the air at the vent outlets does not conform to the indications given in the table on page 15, proceed with the system troubleshooting operations described on the following pages.
3
4
10
9
8
7
6
5
25374
15 1. 2. 3. 4. 5.
Compressor. Inlet pipe (low pressure). Outlet pipe (high pressure). Warm air. Condenser.
87666787A - 11 - 2007
Schematic diagram of the air conditioning system. 6. Filter/dryer. 7. Sight glass. 8. Expansion valve with thermostatic sensor. 9. Evaporator. 10. Cool, dehumidified air.
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
17
Also remember that: When disconnecting the hoses, close the ends with plastic caps to prevent foreign matter and humidity from getting inside the hoses. Handle the thermostatic sensor carefully during removal operations to avoid damage. Always use two spanners to unscrew the hose fittings to avoid twisting the fitting.
25380
16 The sight glass on the receiver--drier can provide useful information about system operation. The 4 possible conditions of the sight glass are shown in the figure 16. A. Clear glass. This could indicate that the system is correctly charged, or that there is no refrigerant in the system (in the latter of these cases the cooling action of the evaporator would be absent). In other cases the system might have been charged with an excessive quantity of refrigerant (in this case the system pressure must be checked. B. Bubbles in the glass. The formation of vapour or foam bubbles indicates that the system contains an insufficient quantity of refrigerant or the presence of air in the system. Bubbles may also be occasionally seen on switching on the system and on disengagement of the electro--magnetic clutch. C. Threads of oil in glass. Indicates a lack of refrigerant and that the compressor oil is circulating in the system. D. Non--uniform (streaky) fluid in glass. Indicates that the drying agent in the filter has leaked into the circulating system (as a result of the containment disks breaking).
WARNINGS FOR AIR CONDITIONING SYSTEM REPAIR OPERATIONS Warning -- If any of the system components need to be replaced, follow the safety instructions noted in Section 50 and always follow the recovery, recycling and charging operations described in op. 50 200 04.
AIR CONDITIONING SYSTEM FAULT DIAGNOSIS SUMMARY There are three main ways in which the system can malfunction: -- the system does not work at all; -- the system does not provide sufficient cooling; -- the compressor operates irregularly. Bearing in mind that insufficient cooling may also be due to external causes, generally a mechanical and visual inspection will provide information on how the system is operating. This information can then be supplemented by electrical testing. If the cause of the problem has still not been identified, it will be necessary to carry out a more thorough investigation and test the pressure in the various sections of the system, as specified previously. Visual inspection of components All visual inspection should be carried out with the engine stopped and the cab heating and air conditioning system switched off. -- Check that the cab external air intakes are clean. -- Look for visible leaks of liquid refrigerant on hoses or system fittings. -- Check that the engine, condenser and evaporator radiators are clean. -- Check that the thermostatic sensor makes contact with the evaporator outlet hoses, using the special thermal tape, to ensure efficient system operation. Follow the troubleshooting operations described on the following pages.
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18
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 AIR CONDITIONING SYSTEM TROUBLESHOOTING THE SYSTEM DOES NOT WORK
87666787A - 11 - 2007
1.
Check fuses.
2.
Check compressor drive belt tension.
3.
Check if the clutch coil is receiving power.
4.
Check that the ground contact is efficient
5.
Check the system control devices -- the relays, wiring, thermostat, etc.
6.
Visually check the condition of all fittings, unions and pipes.
7.
Check the clearance between the front disk and pulley of the electro--magnetic clutch.
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
19
AIR CONDITIONING SYSTEM TROUBLESHOOTING (CONT.) INSUFFICIENT COOLING
HIGH DISCHARGE PRESSURE AND/OR HIGH SUCTION PRESSURE
DISCHARGE PRESSURE LOW AND/OR SUCTION PRESSURE LOW
CHECK THE SIGHT GLASS (7, fig. 15)
CHECK THE SIGHT GLASS (7, fig. 15)
EXCESS REFRIGERANT IN SYSTEM Note: bubbles could be visible in the sight glass. Evacuate refrigerant until a large number of bubbles appear in the sight glass, then add refrigerant to the system until the bubbles disappear
BUBBLES IN SIGHT GLASS Insufficient refrigerant. Possibly due to small leaks. 1. Check the system for leaks and eliminate them. 2. Add refrigerant until the bubbles disappear and both pressure gauges show normal readings.
DISCHARGE PRESSURE NORMAL AND/OR SUCTION PRESSURE NORMAL
Note: during testing, the low pressure gauge reading could fall to negative values or remain normal. HUMIDITY IN THE SYSTEM 1. Evacuate the refrigerant from the system. 2. Replace the filter--dryer. 3. Remove all air from the system then proceed with re--charging.
CONDENSER 1. The condenser could be clogged or it might not be receiving an adequate air flow. Clean condenser fins.
EXPANSION VALVE Check the valve as described on page 9. 1. If the valve fails to pass the test, renew it.
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20
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 AIR CONDITIONING SYSTEM TROUBLESHOOTING (CONT.) INSUFFICIENT COOLING
DISCHARGE PRESSURE NORMAL AND/OR SUCTION PRESSURE NORMAL
DISCHARGE PRESSURE LOW AND/OR SUCTION PRESSURE LOW
DISCHARGE PRESSURE NORMAL AND/OR SUCTION PRESSURE NORMAL--HIGH
Note: the high pressure gauge reading should be constant and should not fall.
RESTRICTION Water or ice forms downstream of the restriction (on receiver--drier or on the pipe between the condenser outlet and the expansion valve). 1. Remove the relevant component and eliminate the restriction or replace the component.
ANTI--FROST SWITCH With the outside temperature below 30_ the electro--magnetic clutch is permanently engaged. 1. Check as described on page 10.
AIR IN THE SYSTEM 1. Recover--recycle the refrigerant in the system. 2. Replace the filter--dryer. 3. Evacuate the system and then re--charge.
87666787A - 11 - 2007
2. Renew the antifrost switch if it does not work properly, taking care not to crush the capillary coil tube, and install it in the same position as the previous one on the evaporator outlet pipe.
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
21
AIR CONDITIONING SYSTEM TROUBLESHOOTING (CONT.) COMPRESSOR AND ELECTROMAGNETIC CLUTCH
UNUSUAL NOISE WITH CLUTCH ENGAGED
INSUFFICIENT COOLING
1. Check all compressor mountings. 2. Check engine components in the vicinity of the compressor. 3. Check if the electromagnetic clutch operates intermittently or slips.
The compressor runs noisily or does not run.
4. Check the clutch bearing. 5. Check that the clutch pulley runs freely. 6. Check the oil level in the compressor.
UNUSUAL NOISE WITH CLUTCH DISENGAGED OR VIBRATION
1. Check the electric power supply. 2. Check the clearance between the front disk and the pulley.
1. Check the condition, pulley alignment and tension of the compressor drive belt. 2. Check the clearance between the front disc and pulley of the electromagnetic clutch. 3. Check the clutch power supply, the current absorbed, the power supply wire, and the ground connection.
4. Check that the clutch pulley runs freely. 5. Check that there is sufficient refrigerant in the system. 6. Check the compressor for leaks. 7. Check the system for leaks.
87666787A - 11 - 2007
22
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 ATTENTION
During these operations, follow the safety instructions and instructions for use described at the start of Section 50. Handle all parts carefully, wear the prescribed safety clothing, including goggles, gloves and safety footwear.
REFRIGERANT RECOVERY--RECYCLING AND EVACUATION--CHARGING STATIONS
ATTENTION Do not use recovery/recycling and system emptying/charging machines which are designed for use with a refrigerant type other than that used in the system. Different types of refrigerant have different chemical compositions and are incompatible. Connecting the piping to the stations When connecting the stations to the system service valves, always connect the low pressure blue pipes (11, fig. 17, or 17, fig. 18), to the service valve on the suction side of the compressor (S--Suction), and the high pressure red pipes (12, fig. 17, or 15, fig. 18), to the service valve on the discharge side of the compressor (D--Discharge). Important: check the seals in the pipe unions (11, 12, 16, fig. 17), or (15, 17, 24, fig. 18) and replace if faulty. Remember that pipe fittings with seals must be hand--tightened only without forcing, otherwise the seal may be damaged. RECOVERY AND RECYCLING STATION (294048) Description (Refer to figure 17) The machine is designed to recover and recycle the refrigerant used in air conditioning systems. Recovered refrigerant is first subjected to an evaporation process in a special chamber to remove any oil. In the filter section, the acidity is neutralised, moisture is absorbed and solid particles are screened out. The decontaminated refrigerant is then stored in the metering cylinder.
TECHNICAL CHARACTERISTICS Recovery compressor equipped with oil level indicator, discharge valve and service connection. Anti--acid decontaminating filter (3), with high moisture absorption capacity.
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Refrigerant/oil distillation cylinder (4) with heating element, automatic device for return of oil to the recovery station compressor and automatic flow control valve for refrigerant entering the station. Graduated cylinder (19) for recovered refrigerant, 2.2 kg capacity, with heater and a safety valve. 2--way pressure gauge unit, with refrigerant flow indicator and pressure gauges (1 and 2) controlling the pressure in the cylinder and at the inlet. Humidity indicator (15) for checking the decontaminated refrigerant. Low pressure switch for automatic cycling of the compressor. Graduated container for discharge of recovered contaminated oil. Switch (5) 1--0--2 for recovery and cylinder heating. Operation indicator lights. Flexible service pipes (11, 12 and 16) with safety cocks. Recovery capacity: 200 grams/minute. Power supply: 220V (50 Hz). Service Replacement of refrigerant decontamination filter (3) Refer to figure 18, proceed as follows: Warning -- Replace the filter (3) every 12 months, or earlier if the humidity indicator (15) becomes yellow (and remains this colour) during the recovery/recirculation phase. 1. Close all the valves including the yellow service valve (9) installed below the distillation cylinder (4). 2. If refrigerant is present in the circuit set push button (5) to position â&#x20AC;?1â&#x20AC;? and carry out the refrigerant recovery operation. The compressor will stop automatically when the pressure gauge (2) drops to --0.3 bar. 3. Remove and replace the contaminated filter (3). 4. Carry out a normal evacuation operation for approx. 30 minutes, using the recycling, evacuation and charging system (380000315) proceeding as follows: connect the pipe (17, fig. 18) to the service valve (14, fig. 17), open the cock on the pipe and cocks (4, 9 and 10, fig. 18). On completion of the evacuation operation, close cocks (4, 9 and 10), the cock fitted on the pipe (17) and disconnect pipe (17).
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 Check filter connections for leaks (3)
23
RECYCLING, EVACUATION AND CHARGING STATION (380000315)
Refer to figure 17, proceed as follows: 5. To check for leaks at the connections of the previously replaced filter (3) open the yellow service cock (9) on the distillation cylinder (4). 6. Carry out a brief recycling operation on the refrigerant contained in the cylinder (19), proceeding as described in operations 18รท21, and, using a leak detector, check for leaks at the connections of the new filter. 7. Record the operation on the appropriate service report card. Changing the compressor oil in the recovery/recycling station
Description (Refer to figure 18) The machine is designed for emptying and charging air conditioning systems with refrigerant. The emptying stage is necessary to remove any moisture and impurities from the system. The refrigerant drawn from the system is transferred to a graduated cylinder, from which it subsequently pumped into the air conditioning system.
Refer to figure 17, proceed as follows:
Technical characteristics
Warning -- The oil in the recovery/recycling station compressor should be replaced with new oil every 12 months, in order to maintain station refrigerant treatment capacity and to protect the compressor.
Double--acting, ballasted, rotary vacuum pump (21) in oil bath.
1. Open cock (13), and drain the oil into a container to be disposed of in accordance with local regulations for waste oil disposal.
Charging cylinder (31) with maximum level indicator and graduated scale for measurement of quantity of refrigerant.
2. Close cock (13).
5--way pressure gauge manifold with 2 pressure gauges (5 and 6) and 1 vacuum meter (8).
3. Remove the caps from the service valves (14) on the side of the compressor and (13) on the sight glass.
Flexible service pipes (15, 17 and 24) with safety cocks: Power supply: 220V (50 Hz).
4. Connect the service pipe of the evacuation station to valve (14) and connect a suction pipe to valve (13) on the sight glass.
Service
5. Perform the evacuation operation with the pump in operation. The new oil can be aspirated from an external container by means of the suction pipe. 6. Once the compressor has been filled with correct quantity of oil (half--way up the sight glass) close valve (13), disconnect the pick--up pipe, and replace the cap on service valve (13). Continue the evacuation for approx. 30 minutes. 7. On conclusion, close the cocks, switch off the pump, disconnect the service pipe and replace the cap on service valve (14).
Check level and change oil in pump of evacuation/charging station (periodic check) Refer to figure, 18 proceeding as follows: Periodically check the level and condition of the oil. Drain off the old oil, if necessary, through plug (18). Used oil must always be disposed of in accordance with the applicable regulations. Remove cap (13) and fill the vacuum pump (21) with new oil of the type indicated by the pump manufacturer up to the half--way line on the sight glass (14).
8. Record the operation on the appropriate service report card.
87666787A - 11 - 2007
24
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
OP. 50 200 04 DRYING, RECHARGING AND REFRIGERATION CHECK Recovery of refrigerant from the cab air conditioning system using the recovery/recycling station 294048
ATTENTION During operation 5020004, follow the safety instructions and instructions for use described at the start of Section 50. Handle all parts carefully, wear the prescribed safety clothing, including goggles, gloves and safety footwear.
NOTE: The recovery operation can be performed quicker and more completely if the system is previously heated. The heat will help the refrigerant to evaporate, facilitating evacuation from the system. Refer to figure 17 and proceed as follows: 1. If possible, operate the air conditioning system for a few minutes with the tractor engine running and the hood down, so that the heat produced is gradually transferred to the various components in the system, thus allowing any pockets of very cold fluid in the system to evaporate. 2. Stop the engine.
DANGER The recovery operation must only be performed with the tractor engine stopped. 3. If the charging cylinder (19) already contains refrigerant, check that there is still sufficient free volume to contain all the refrigerant in the system (maximum cylinder capacity is 2 kg); if not, transfer the excess refrigerant to an external cylinder in the manner described on page 26. 4. Connect the station’s supply lead to a power outlet. 5. Make sure that all cocks are closed except the service cock (9). 6. Remove the caps from the service valves installed on the suction and discharge lines of the compressor. 7. Connect the blue service pipe (11) to the valve on the suction (low pressure) side of the compressor (marked ”S”).
87666787A - 11 - 2007
8. Connect the red service pipe (12) to the valve on the discharge (high pressure) side of the compressor (marked ”D”). 9. Switch on the cab ventilation fan at maximum speed to assist the transfer of heat between the ambient air and the evaporator coil. 10. Open the cocks (10) fitted on pipes (11 and 12). 11. Slowly open cock (6--LOW) on the pressure gauge manifold. Pressure gauge (2) will indicate the pressure of the refrigerant in the system; if the needle is near the ”0”, the system is empty. 12. Set switch (5) to position ”1” (RECOVERY) -green indicator light will illuminate. The recovery unit compressor will start. During the recovery operation the refrigerant passes through the distillation chamber (where the oil is separated out), the purification filter (where most of the impurities are filtered out), and then finally arrives at the graduated cylinder. The compressor stops automatically when the pressure gauge (2) shows --0.3 bar. 13. Wait a few minutes to allow any pockets of liquid refrigerant left in the system to evaporate and be evacuated. 14. Check the pressure (2): if the pressure rises above the previous absolute value of --0.3 bar, the station will automatically start a second recovery operation. If, on the other hand, the pressure has remained near the value obtained during the first recovery operation, this indicates that all of the refrigerant has been recovered and the operation is completed.
NOTE: If after 10 minutes of operation the station has not recovered more than 1 kg of refrigerant, check the pressure gauge (1). If the pressure reading is over 10 bar open cock (21) and discharge air, then check that pressure gauge (1) does not exceed a maximum of 10 bar throughout the entire recovery operation. 15. Close all the cocks except cock (9), disconnect the service pipes (11 and 12) from the air conditioning system compressor and switch off the station. 16. Switch off the cab ventilation fan.
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
25
19. Connect the 2 ends of the yellow (16) and blue (11) pipes with the connector supplied.
Recycling of recovered refrigerant On completion of the recovery operation, the refrigerant must completely purified.
ATTENTION Recovered refrigerant must be completely purified before it can be re--used.
Proceed as follows: 17. All cocks must be closed, with the exception of cock (9, fig. 17) and the station must be switched off -- switch (5) in position ”0” and the green indicator light off. 18. Connect the end of the yellow service pipe (16) to the free connector (17) located on the left--hand side of the pressure gauge manifold.
1
20. Slowly open the cock (18--REF) and the blue cock (6--LOW) on the pressure gauge manifold, and the cocks on the two previously connected service pipes (16 and 11). 21. Set switch (5) in position ”1” (RECOVERY), green indicator light on. The recovery compressor will start to operate and the refrigerant will pass from the graduated cylinder to the recovery circuit (distillation cylinder, filter and compressor) and then return to the graduated cylinder. 22. Continue the operation until the circular sector of the humidity indicator (15) becomes green. If, after 15 minutes, the circular sector of the indicator (15) still has not turned green, replace the filter (3), as described on page 22.
3
2
21
4
20
5
19
6
18
7 8 9
17 25378
16
15
14
13
12
11
10 17
Refrigerant recovery and recycling station 12. Red service pipe for connection to compressor 1. Cylinder pressure gauge. (discharge side). 2. Recovery control pressure gauge. 13. Recovery compressor oil discharge cock. 3. Anti--acid and decontamination filter. 14. Recovery compressor service valve (suction). 4. Recovered refrigerant/oil distillation cylinder. 15. Humidity indicator. 5. Switch. 16. Yellow service pipe for refrigerant transfer. 6. Refrigerant inlet control cock (LOW). 17. Fitting for refrigerant transfer. 7. Recovered oil discharge cock (yellow). 18. Cock (REF) for refrigerant transfer. 8. Recovered oil discharge pipe. 19. Refrigerant cylinder 9. Oil return to compressor control cock (yellow). 20. Safety valve. 10. Quick--fit connectors. 21. Yellow cylinder discharge cock (gaseous stage). 11. Blue service pipe for connection to compressor (suction side).
87666787A - 11 - 2007
26
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
NOTE: The circular sector of the humidity indicator (15, fig. 17) must remain green throughout the recycling operation. If the colour of the sector tends to vary between yellow and green, or turns completely yellow, this means that the filter is saturated with moisture and therefore must be replaced. 23. On completion of the decontamination operation, close the yellow cock (18--REF) and continue to recover the refrigerant. The compressor will stop automatically when the pressure gauge (2) indicates a pressure of --0.3 bar. 24. Close the cock (6--LOW), the two cocks on the ends of the yellow (16) and blue (11) service pipes, disconnect pipes (16 and 11) and switch off the station, turning switch (5) to position ”0”. Discharge of recovered oil On completion of the recovery operation, any contaminated oil will be visible in the distillation chamber (4). This oil must be discharged and disposed of (in accordance with applicable regulations on the disposal of used oil). Proceed as follows: 25. Slowly open the yellow cock (7) and discharge the recovered oil in the graduated container. 26. If no refrigerant leaks, whether major or minor, have ever been detected in the system, on recharging, replace the contaminated oil with same quantity of new oil (see page28). Transfer of decontaminated refrigerant from cylinder (19) to an external cylinder If for any reason the decontaminated refrigerant is not to be put back into the air conditioning system immediately, for reasons of safety it must be transferred from cylinder (19) to a homologated refillable gas container. Proceed as follows: 27. Check that all the cocks are closed with the exception of cock (9) and that the station is switched off. Check that the container (cylinder) is large enough to contain all the refrigerant to be transferred without exceeding the permitted safety level. 28. Connect the end of the yellow service pipe (16) without the cock to the free connector (17) on the
87666787A - 11 - 2007
left--hand side of the pressure gauge manifold, and connect the other end (with the cock) to the red connector of the external cylinder. 29. Set switch (5) to position ”2” HEATING CYLINDER to switch on the refrigerant heater fitted to the cylinder (19) so as to facilitate the transfer of the refrigerant from the cylinder to the external cylinder. 30. Open the yellow cock (18--REF), the yellow cock on the service pipe and red cock on the external cylinder. 31. On completion of the transfer, close all cocks and switch off the station by turning switch (5) to position 0. Evacuation and charging the cab air conditioning system using the recycling, evacuation and charging station 380000315. NOTE: Operations 32 ÷ 34 must only be carried out if there is no refrigerant in the graduated cylinder (31, fig. 18).
Evacuation of the graduated cylinder (31) of the evacuation/charging station Refer to figure 18, proceed as follows: 32. Close cocks (4, 22 and 27). 33. Open cocks (3, 9 and 10). 34. Start the pump by turning switch (19) to position ”1” to evacuate the cylinder (31). After 5 minutes close cocks (3, 9 and 10) and switch off the pump. Charging the graduated cylinder (31) of the evacuation/charging station If the decontaminated refrigerant in the recovery/recycling station is to be immediately put back into the tractor air conditioning system, it must be transferred from cylinder (19, fig. 17) to cylinder (31, fig. 18) of the evacuation/charging station, proceeding as follows: 35. Using figure 18, connect the end of the yellow service pipe (24) without the cock to the free connector (28) on the left--hand side of the evacuation/charging pressure gauge.
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 36. Connect the other end (with the cock) to the free connector (17, fig. 17) on the left--hand side of the recovery/recycling station pressure gauge manifold. 37. Using figure 18 for reference, check that all the cocks of the recovery/recycling station are closed, apart from cocks (9 and 17) and the cock fitted on the pipe (16). 38. Check that all the evacuation/charging station cocks are closed, apart from cock (27, fig. 18). 39. Check that the stations are switched off with switches (5 and 18) in position ”0”. 40. Using figure 18 for reference, turn switch (5) to position ”2” HEATING CYLINDER to switch on the refrigerant heater installed on the cylinder (19), to facilitate the transfer of refrigerant to cylinder (31, fig. 18) of the evacuation/charging station.
2
1
41. On completion of the refrigerant transfer operation, close all of the cocks, apart from cock (9, fig. 17) and switch off the recovery/recycling station by turning the switch (5) to position ”0”. 42. Check the quantity of refrigerant in the graduated cylinder (31, fig. 18). 43. From the total quantity of refrigerant required in the air conditioning system indicated in the note on the following page, calculate the quantity of refrigerant that must be added to the cylinder (31) to make up the total amount required. 44. Transfer refrigerant from the external cylinder to the graduated cylinder (31) proceeding as follows. 45. Connect the yellow pipe (24) to connector (28) and to the external cylinder containing the refrigerant (upside down if not equipped with an outlet valve. 46. Open the cock on the external cylinder, the cock on the charging pipe (24) and cock (27).
3
4
5
6
7
8 9
31
10
30
11
29
12
28
13
27
14
26
15
25 24 25378
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
27
23 22 21 20 19 18 17
16
Evacuation/charging station. 17. Blue service pipe for connection to suction side of Safety valve. compressor. Cylinder pressure gauge. 18. Oil drain plug. Refrigerant charging cock. 19. On/Off switch (I), heater (II). Low pressure side cock (LOW). 20. Oil meter connector. Low pressure gauge. 21. Vacuum pump. High pressure gauge (red). 22. High pressure side cock (HIGH). 5--way pressure gauge manifold. 23. Sight glass. Vacuum meter. 24. Yellow service pipe. Vacuum test cock (VAC). 25. Cylinder heater. Vacuum meter test cock. 26. External ring. Vacuum meter safety valve. 27. Refrigerant transfer cock (REF). Oil charging cock. 28. Refrigerant transfer connector. Oil filler cap. 29. Glass rod. Sight glass. 30. Outer casing (Plexiglass). Red service pipe for connection to discharge side of 31. Refrigerant charging cylinder. compressor. Quick--fit connectors.
18
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28
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
47. Rotate the outer casing (30) so that pressure value indicated on the graduated scale corresponds with the value shown on pressure gauge (2). 48. When the refrigerant in the cylinder has reached the required level, as indicated on the glass rod (29), close the cock of the external cylinder, the cock on the charging pipe (24) and cock (27). NOTE: If excessive time is required to transfer refrigerant from the external cylinder to cylinder (31), slightly open valve (1) and discharge air from the cylinder (31); the pressure reading on pressure gauge (2) should not exceed 5 bar. Evacuation of the cab air conditioning system (previously discharged using the recovery/recycling station) 49. Remove the caps from the service valves on the suction and discharge lines of the compressor. Refer to figure 18, proceed as follows: 50. Connect the blue service pipe (17) to the valve on the low pressure side of the compressor marked ”S”. 51. Connect the red service pipe (15) to the valve on the high pressure side of the compressor marked ”D”. 52. Open the quick--fit cocks (16). 53. Open cocks (4 -- 9 -- 10 -- 22). 54. Start the pump by turning switch (19) to position ”I” and evacuate the system for at least thirty minutes; pressure gauges (5 -- 6 -- 8) should show a negative reading. If the evacuation operation is not performed correctly, check all connections. 55. Close cock (9), switch off the pump by turning switch (19) to position ”0” and check the vacuum seal for at least five minutes using vacuum meter (8). Then close all cocks. Charging the cab air conditioning system (after evacuation) with new oil If no refrigerant leaks, whether major or minor, have ever been found in the system, on recharging, replace the contaminated oil previously recovered in operations (25 and 26) with new oil. If, on the contrary, significant leaks have occurred in the past, proceed with the compressor oil level check procedure described on page 7.
87666787A - 11 - 2007
Refer to figure 18, proceed as follows. 56. 57. 58. 59.
Pour the oil into the graduated oil meter. Connect the oil meter to the oil meter (20). Close cocks (4 and 10). Set switch (19) to position ”2” to switch on the refrigerant heater on cylinder (31). 60. Open cock (12) and the cock on the graduated oil meter. 61. Check the quantity of oil flowing from the oil meter, and once the required quantity has been reached, close cocks (12) and the cock on the oil meter, and remove the graduated meter. Charging the cab air conditioning system with refrigerant (after evacuation) NOTE: The quantity of refrigerant required to be introduced into the system is 800 grams (R134a refrigerant). Refer to figure 18, proceed as follows: 62. Keep switch (19) in position 2, with the refrigerant heater in cylinder (31) on, and heat the refrigerant for approx. 10 ÷ 15 minutes to facilitate transfer from the cylinder to the tractor air conditioning system. 63. According to the refrigerant type, rotate the outer casing (30) so that the graduated scale and the pressure values correspond with the pressure reading on gauge (2). 64. Move the external ring (26) along the cylinder glass to mark the quantity of refrigerant to be charged. 65. Open cock (22) and charge from the high pressure side. 66. Open cock (3), charge approx. 300 grams of refrigerant, close cock (3) and check for leaks. 67. If there are no leaks, continue charging up to the prescribed quantity. 68. On completion of charging operations, turn switch (19) to position ”0”, close cocks (3 and 22), disconnect pipes (15 and 17) and replace the caps on the service valves. Carry out functional tests with the system set to maximum performance levels, as described below.
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
29
SUMMARY OF THE AIR CONDITIONING SYSTEM CHARGING OPERATIONS NOTE: The pressure readings noted below are valid for an ambient temperature of 25°C --
Pressure gauge readings on completion of refrigerant recovery and recycling operation.
25381
19 --
Pressure gauge readings with cocks (4 -- 9 -- 10 and 22, fig. 18) open, cylinder (31) with 1100 grams of refrigerant, red and blue service pipes connected to the tractor system, cocks (16) closed and compressor cut off.
25382
20 --
Pressure gauge readings with cocks (4 -- 9 -- 10 and 22, fig. 18) open, cylinder (31) with 1100 grams of refrigerant, red and blue service pipes connected to the tractor system, cocks (16) open and compressor on (initial evacuation stage).
25383
21 --
Pressure gauge readings with cocks (4 -- 9 -- 10 and 22, fig. 18) open, cylinder (31) with 1100 grams of refrigerant, red and blue service pipes connected to the tractor system, cocks (16) open and compressor on (final stage of evacuation after 30 minutes).
25384
22 87666787A - 11 - 2007
30 --
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 Pressure gauge readings with cocks (4 -- 10 -- 22, fig. 18) open, cylinder (31) with 1100 grams of refrigerant, red and blue service pipes connected to the tractor system, cocks (16) open, compressor off and cock (9) closed (check on vacuum meter (8) that no pressure drops occur over a period of five minutes).
25385
23 --
Pressure gauge readings (start of charging -- end of charging). All previously opened cocks are to be closed, apart from cocks (3 and 4, fig. 18), compressor off. The level of refrigerant in the charging cylinder can be seen to drop; proceed until only 300 grams of refrigerant remain in the charging cylinder (800 transferred). The reading on vacuum meter (8) remains the same from the beginning to the end of the charging operation.
25386
24
87666787A - 11 - 2007
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
1
A
3
B
31
C
2
24027
25
OP. 50 200 06 CHECKING FOR AND REMOVING GAS LEAKS
Testing for leaks with leak detector 380000314
With the system charged and the pressure gauges connected, proceed as follows:
6. Switch on the electronic leak detector.
7. Move the probe around all pipe connections and all possible points of leakage:
--
the presence of refrigerant (i.e.: the leak), is signalled by an increase in the frequency of the audible signal.
1. Start the engine.
2. Check that the knob (3) is turned fully to the left (maximum cold), so as to turn off the heating function.
3. Set the cab ventilation fan (1) to maximum speed.
NOTE: The refrigerant is heavier than air, therefore it will be easier to detect the leak point from below rather than from above. 8. If leaks are found in the pipe connections, tighten the fittings in order to eliminate the leak.
4. Turn the knob (2) to turn on the air--conditioner.
5. Bring the engine up to a speed of 1500 rpm.
Warning -- If any of the system components need to be replaced, always follow the recovery, recycling and charging operations described in operation 50 200 04.
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32
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
CHECKING FOR REFRIGERANT LEAKS USING AN ELECTRONIC LEAK DETECTOR
Refrigerant gas leak test
Leak detector (380000314)
The detector automatically adjusts its sensitivity in accordance with the quantity of gas present in air around the sensor tip when switched on and off.
The leak detector 380000314 is supplied in its own carrying case which also contains the two power supply batteries, the sensitivity test phial and an ear plug connection for audible leak indication.
In ventilated areas it can be extremely difficult to locate the source of a gas leak, as the leaking gas does not remain near the leakage point; in this case, it will be necessary to screen off the area in which the leak is suspected to obtain more accurate readings.
The instrument comprises the main unit and the flexible probe which contain the sensor at the tip. To correctly position the flexible probe, slacken off (counter--clockwise) the thumbscrew located on the bottom left--hand corner of the case.
In cases where the presence of large leaks masks smaller leaks, first locate and repair the large leaks before attempting to locate the smaller leaks; this will facilitate the location of the smaller leaks. Service
Mounted on the front of the instrument are the on/off switch, the red on/off LED and the acoustic gas detection indicator.
Always make sure that the detector is switched off before replacing the sensor element. To replace, rotate the probe counter--clockwise, install a new element and new felt pad rotating it clockwise on the flexible probe.
The socket for the headset connection is on the rear of the instrument. The battery compartment also houses the sensor element and a number of replacement felts.
Do not switch on the detector until the new sensor is screwed firmly on to the end of the flexible probe. Be careful to avoid getting grease or grit in the hole connecting the probe with the sensor element.
Use
1
2
3
4
Set the switch to ON: start looking for leaks; the frequency and the amplitude of the audible signal will increase if gas is detected. In the area around the leak, switch the instrument on and off again; the instrument will automatically switch to a new acoustic level. Carry out the following test each time you use the detector. Hold the sensor element close to the open sensitivity test phial; when the detector starts to emit an audible signal, switch it on and off. If the amplitude signal continues to increase, switch the instrument on and off again.
87666787A - 11 - 2007
25388
26 Leak detector probe 1. Flexible probe. 2. Sensing tip. 3. Felt pad. 4. Protective shield.
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 OP. 50 200 10
33
Checking compressor drive belt tension
COMPRESSOR DRIVE BELT TENSION ADJUSTMENT
Only check the tension when the belt is cold (below 40 °C).
12÷13mm
Check the tension by applying a load of 78÷98 N (8÷10 kg), to the centre of the belt run, indicated in the figure, the belt should deflect by ≅ 12÷13 mm. Periodic checking of drive belt When checking the tension, also check the amount of drive belt wear. The following cases may occur:
23927
27 The condition of the belt transmitting drive from the engine to the compressor is particularly important as regards the correct operation of the air conditioning system. This drive belt therefore requires careful attention, proceed as follows: 1) Fit the belt correctly. 2) Check the belt tension. 3) Check the condition of the belt.
Fitting the compressor drive belt When first fitted, the belt must not be forced, pulled with a screwdriver, or rolled over the edge of the pulley: this would cause overstretching of the low deformation fabric and subsequent breakage of the other fabrics. New belts must be fitted at a higher tension than normal so as to compensate for the initial stretching as the belt is run in; This means that the belt must be re--checked after 50 hours of operation and adjusted to the normal tension. This check is very important as if the belt is left too taut, it could damage the pulley bearings and cause the premature deterioration of the belt itself. If, on the other hand, the belt is too slack, it will start to slip and overheat and thus very rapidly deteriorate.
A. Belt shiny: belt sides worn to a smooth shine, can cause slippage. B. Belt cracked: may break suddenly due to splits on the inner surface caused by excessive flexure. C. Worn sides: with the sides worn or the inner part cracked the belt could break at any moment. D. Belt impregnated with grease: grease will cause the belt to wear rapidly. Take the following action: A. If the belt is too slack, tension it correctly; if excessively hot, replace the belt. B. If the cracks are deep, extending to half the thickness of the belt, replace the belt. C. Replace the belt. D. If the belt is excessively hot, replace the belt.
If the belt squeaks when running, check the tension and adjust if necessary. If the noise continues, replace the belt.
If the belt has been over--stretched and can no longer be tensioned correctly, replace the belt.
87666787A - 11 - 2007
34
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
OP. 50 206 14 CAB AIR INFEED VENTS DISASSEMBLY--ASSEMBLY Removal
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
Proceed as follows. 1. Remove the four retaining bolts and the RH side air infeed vent.
2. Remove the five retaining bolts (1) and the LH side air infeed vent (2).
Installation
27685
Proceed as follows.
3. Refit the LH side air infeed vent (2) the five retaining bolts (1).
4. Refit the RH side air infeed vent and the four retaining bolts.
87666787A - 11 - 2007
28
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
35
OP. 50 206 51 CAB HEATING/AIR CONDITIONING SYSTEM Removal--Installation
Removal
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
Proceed as follows.
1. Using operation 50 200 04 (Recovery--filter/drying, recharging and cooling control), carry out only operations 1รท31 regarding system refrigerant recovery, using control centre 380000315. 2. Carry out operation 90 160 60--Cab ceiling fittings R.I. (Only removal). 3. Disconnect the heater--air conditioner electrical connections (1).
27688
29
4. Remove the four condensate drainage pipes (1).
27689
30
87666787A - 11 - 2007
36
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
5. Remove the two air conditioning system pipes (1) from the compressor, that are connected to the expansion unit radiator.
27690
31 6. Remove the four retaining bolts (1) on the heater radiator support of the conditioning unit expansion device (2).
27691
32 7. Remove the clamps (2) and the pipes (1) connected to the heater radiator, then remove the support containing the radiators of the heater and of the air--conditioning unit expansion device (3). Installation (Op. 50 206 51)
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Proceed as follows.
--
Fit the two pipes connected to the heater radiator and the two securing clamps.
--
Fit the support, containing the heater radiator and conditioning unit expansion device, to the cab ceiling by means of the four screws.
--
Connect the two air conditioning pipes from the compressor to the expansion unit radiator.
--
Connect the four condensate drainage pipes.
--
Connect the heater--air conditioner unit electrical connections.
--
Carry out operation 90 160 60--Cab ceiling fittings R.I. (Only installation).
87666787A - 11 - 2007
27692
--
----
33 Using operation 50 200 04 (Filter/drying, recharging and cooling control), only carry out operations 32รท68 with regard to system emptying and charging, using control centre 380000315. Reconnect the battery negative cable. Carry out operation 50 200 03 -- Air conditioning system functional testing. (If necessary), carry out operation 5020006 -Air conditioning system checks and eventual elimination of gas leaks.
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
37
OP. 50 206 54 CAB HEATING UNIT Disassembly--Assembly Disassembly
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 27693
With the unit on the work bench, proceed as follows. 1. Remove the heater -- conditioning half--casing (1) retaining screws (2).
34
unit
2. Remove the half--casing (1).
27694
35 3. Remove the heater radiator (1).
Assembly Procedure
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
27695
36 --
Proceed as follows.
4. Fit the heater radiator. 5. Fit the heater -- conditioning unit half--casing. 6. Tighten the heater -- conditioning half--casing, using the screws.
unit
87666787A - 11 - 2007
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
38
OP. 50 206 56 CAB AIR CONDITIONING SYSTEM EVAPORATOR UNIT
Disassembly--Assembly Disassembly
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 27693
With the unit on the work bench, proceed as follows. 1. Remove the heater -- conditioning unit half--casing (1) retaining screws (2).
37
2. Remove the half--casing (1).
27694
38 3. Remove the conditioning system evaporator (1).
Assembly Procedure
ATTENTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
27696
39 --
Proceed as follows.
4. Fit the conditioning system evaporator. 5. Fit the heater -- conditioning unit half--casing. 6. Tighten the heater -- conditioning half--casing, using the screws.
87666787A - 11 - 2007
unit
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
39
OP. 50 206 66 CAB FAN UNIT Disassembly--Assembly Disassembly
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. With the unit on the work bench, proceed as follows. 1. Remove the heater -- conditioning half--casing (1) retaining screws (2).
unit
27693
40
2. Remove the half--casing (1).
27694
41 3. Remove the securing clamp (1) and electric fan (2) on the heater -- conditioning unit.
Assembly Procedure
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
27697
42 --
Proceed as follows.
4. Fit the heater --conditioner unit electric fan, securing in position with the clamps. 5. Fit the heater -- conditioning unit half--casing. 6. Tighten the heater -- conditioning half--casing, using the screws.
unit
87666787A - 11 - 2007
40
SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
1
SECTION 55 -- ELECTRICAL SYSTEM Chapter 1 -- Instrument panel CONTENT Section 55100
Description
Page
Analog instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Digital instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Senders, sensors & switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ANALOG INSTRUMENTS
MPF0492A
1 Analog control panel 1. Tachometer. 2. Fuel gauge.
3. Engine coolant temperature gauge. 4. Hours worked counter. 5. LED indicators to signal machine service status.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
2
2 Analog control panel indicators The indicator lights on the control panel inform you of the operational condition of the machine. There are 26 indicator lights of various colours. Some of them signal trouble, act promptly when they light up in order to resolve the problem and prevent serious problems with your machine.
INDICATOR AND WARNING LIGHTS
3. Battery cut--off (amber)
1. Side lights (green)
Lights up when the sidelights are switched on 2. Full--beam headlights (blue)
It stays on for 30 seconds with the ignition key on STOP unless the battery is cut off. It switches off within 30 second when the battery is cut off by pressing the specific button. 4. Work lights (amber)
The light illuminates when the headlights are on main beam.
87666787A - 11 - 2007
Lights up when the working lights are switched on (cab models only)
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 5. First trailer direction indicator (green) Flashes at the same time as the tractor turn indicators, if connected. 6. Engine oil pressure (red)
The light should go out a few seconds after the engine is started. If it stays on when the engine is running, switch it off and look for the cause of the problem. When the engine is warmed up and running at minimum revs, with the tractor stationary, the light may illuminate, even if no faults are present. 7. Brake fluid level (amber)
Comes on when the fluid drops below â&#x20AC;?MINâ&#x20AC;? level. Periodically check that the light is working properly. With the ignition key on the first position, by pressing the pushbutton on the lid of the brake fluid reservoir, the light should come on. 8. Trailer brake (red)
Comes on, with the engine running, when the brakes are applied with the tractor brakes coupled together for road driving. The light comes on whenever the handbrake is on or when the brake fluid pressure is low. 9. Fuel level (amber)
The light comes on when the fuel filter is clogged. 10. Engine air filter (amber)
3
11. Differential lock (amber)
Lights up when the differential lock is ON. 12. Right direction (green)
indicator
Flashes at the same time as the right--hand turn lamps. 13. Automatic four--wheel drive (green) Lights up when four--wheel drive is engaged automatically by means of the relevant push--button. 14. Four--wheel drive (green)
Lights up when front--wheel drive is engaged automatically. 15. Front power take--off (amber)
Lights up when the power take--off is engaged (if fitted). 16. Rear power take--off (amber)
Lights up when the engine is running and the power take--off is engaged. 17. Fuel level (amber) indicator
The light comes on when the tractor needs refuelling. See Section 00 for the fuel tank capacity. 18. Indicator not active
The light comes on when the engine air filter cartridge is totally or partially clogged and needs servicing.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
4
19. Handbrake (red)
22. Second trailer indicator (green)
Indicates that the handbrake is on (with starter key inserted). It blinks with the ignition key on STOP and the handbrake disengaged
Flashes at the same time as the tractor turn indicators, if connected.
20. Grid Heater (amber)
The indicator lights up when the grid heater is turned on by the ignition key. 21. Power steering oil pressure (red)
The light should go out a few seconds after the engine is started. With the engine running at minimum revs and the tractor stationary, the light may come on without indicating a problem.
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direction
23. Left direction indicator (green)
Flashes at the same time as the left--hand turn indicators. 24. Abnormal battery charging system operation (red)
It should go out once the engine starts. If the light stays on when the engine is running, stop and find the cause of the problem. May light up when the engine is idling, but does not necessarily indicate a fault.
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
5
DIGITAL INSTRUMENT CLUSTER
3 Digital instrument control panel 1. Commands for setting the front electronic lift for T4040 Supersteer and T4050 Supersteer models.
5. Angular headlight switch.
2. Front PTO control for T4040 Supersteer and T4050 Supersteer models.
7. Control panel.
3. Front lift up and down switch. 4. Bonnet/cab lights switch.
NOTE: The switch (4) on models with roll bar is replaced by the switch (A) of the electrohydraulic four--wheel drive control:
6. Lights switch.
8. Power Shuttle control lever. 9. Hazard warning lights control switch. 10. Switch with dual function (UP DOWN) scrolling forwards or backwards in the menu. 11. Switch with dual function for navigating through the menu.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
6
4 Digital instrument panel
CAUTION If any trouble occurs during operation, it will be detected by the control system. The display in the centre of the instrument will show a numerical code associated with the symbol of the damaged component. 1. Left--hand digital display -- The display shows the tractor speed in km/h--MPH. 2. Information display -- The display shows information on the operational condition of the machine in the form of symbols or code numbers.
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3. Right--hand digital display -- The display shows the following information: -- rpm of the front PTO, where applicable, or of the rear one; -- Clock function; -- position of the front lift, where applicable, or of the rear one. 4. Fuel level bar gauge. 5. Warning and indicator lights. 6. Speedometer/tachometer. 7. Engine coolant temperature bar gauge.
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
7
5 Digital control panel indicators 1.
Stop warning light (red)
If the red â&#x20AC;?Stopâ&#x20AC;? warning light comes on, switch off the tractor immediately and look for the cause. A warning symbol will appear on the display confirming the location of the fault.
3. Abnormal battery charging system operation (red)
It should go out once the engine starts. If the light stays on when the engine is running, stop and find the cause of the problem.
2. Indicator lamp (amber)
Indicator lamp (amber) -- This indicator light comes on and the display shows a warning symbol. The light blinks for 4 seconds, after which the symbol on the display disappears and the indicator light stays on steady. To display the fault, you need to go to the menu. Stop the tractor and investigate the cause of the trouble.
4. Fuel level (amber) indicator
The light comes on when the tractor needs refuelling. See Section 00 for the fuel tank capacity.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
8
5. Four--wheel drive (green)
Lights up when front--wheel drive is engaged automatically. 6. Automatic four--wheel drive (green) Lights up when four--wheel drive is engaged automatically by means of the relevant push--button. 7. Power take--off (amber)
Lights up when the engine is running and the power take--off is engaged. 8. High (HI) ranges (green)
Lights up when the high gear range is selected (transmission with Power--Shuttle/Dual Command (2 Speed Power Shift) only). 9. Front lift (amber)
Lights up when the front lift unit is disabled, or lights up briefly when the engine is started (even if the tractor is not fitted with a front lift). 10. Front power take--off (amber)
Lights up with the engine running when the front power take--off is engaged (if fitted). 11. Differential lock (amber)
13. Left direction indicator (green)
Flashes at the same time as the left--hand turn indicators. 14. Engine oil pressure (red)
The light should go out a few seconds after the engine is started. If the light stays on when the engine is running, stop and find the cause of the problem. When the engine is warmed up and running at minimum revs, with the tractor stationary, the light may illuminate, even if no faults are present. 15. Trailer brake (red)
Comes on, with the engine running, when the brakes are applied with the tractor brakes coupled together for road driving. The light comes on whenever the handbrake is on or when the brake fluid pressure is low. 16. Indicator not active
17. Handbrake (red)
Indicates that the handbrake is on (with starter key inserted). It blinks with the ignition key on STOP and the handbrake disengaged. 18. Battery cut--off (amber)
Lights up when the differential lock is ON. 12. Right direction (green)
indicator
Flashes at the same time as the right--hand turn lamps.
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It stays on for 30 seconds with the ignition key on STOP unless the battery is cut off. It switches off within 30 second when the battery is cut off by pressing the specific button.
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 19. Thermostarter (Grid Heater) indicator (amber) The indicator lights up when the grid thermostarter is turned on by the ignition key. 20. Full--beam headlights (blue)
The light comes on when the headlights are on full beam.
9
22. Second trailer indicator (green)
direction
Flashes at the same time as the tractor turn indicators, if connected. 23. First trailer direction indicator (green) Flashes at the same time as the tractor turn indicators, if connected. 24. Work lights (amber)
21. Side lights (green)
Lights up when the sidelights are switched on.
Lights up when the working lights are switched on (cab models only).
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10
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
TRANSMITTERS, SENSORS & SWITCHES
MPH1936A
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
11
TRANSMITTERS, SENSORS & SWITCHES
28006
MPH1937A
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
12
TRANSMITTERS, SENSORS & SWITCHES
28006
MPH1938A
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
13
TRANSMITTERS, SENSORS & SWITCHES
28006
MPH1939A
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
14
TRANSMITTERS, SENSORS & SWITCHES
28006
MPH1940A
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
15
TRANSMITTERS, SENSORS & SWITCHES
28006
MPH1941A
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
16
TRANSMITTERS, SENSORS & SWITCHES A. TRAILER BRAKE SAFETY PRESSURE SWITCH. Activates when the trailer brake pressure circuit drops below 3 bar. The warning lamp lights up. B. ENGINE OIL PRESSURE SWITCH. Activates when the engine oil pressure drops below 0.68 bar. The warning lamp lights up. C. DIESEL SEDIMENT UNIT FILTER SENSOR. Activates when the sensor detects water; switches on the instrument’s warning light. D. BRAKE LIGHTS SWITCHES. Activates when the brakes are applied. E. REAR POWER TAKE--OFF REVS SENSOR. This sensor is positioned on the rear PTO casing and reads the PTO revs at the different engine rotation speeds. F. GEARS IN NEUTRAL SWITCH. Indicates when the gears are in neutral. G. PARKING BRAKE SWITCH. The switch closes when the parking brake is applied. H. CREEPER SWITCH. Indicates the Creeper position (on/off). I.
DIFFERENTIAL LOCK SWITCH. Activates when the differential lock is engaged. The warning lamp lights up. Switch normally off.
J. ELECTRONIC LIFT PULL SENSOR. Indicates the drawbar pull to the lift. K. AIR FILTER CLOGGED SENSOR. Activates when the vacuum in the air intake system exceeds a pre--stabilised value. The warning lamp lights up. L. TRAILER BRAKE INDICATOR SWITCH. Activates when the trailer brakes are applied. The warning lamp lights up. M. LIFT ARMS POSITION SENSOR. Indicates the position and height of the lift arms. N. STEERING SENSOR. Indicates the steering angle on the front axle right--hand wheel. O. FUEL LEVEL TRANSMITTER. The signal emitted by the transmitter potentiometer determines the fuel level shown on the instrument. When the tank is empty the resistance is approximately 250 Ω; when half--full, the value is 140 Ω; when full, the value is approx. 30 Ω. P. FRONT AND REAR AXLE SPEED SENSORS. Respectively indicates front and rear wheel slip. Q. ENGINE COOLANT TEMPERATURE SENSOR. The temperature transmitter resistance varies in proportion to the coolant temperature, generating a modulated voltage signal that is measured by the instrument. With the temperature at ∼ 65 ˚C, the resistance of the value is between 481 and 337 Ω; with the temperature at 110 ˚C, the resistance of the value is between 90 and 112 Ω. R. DUAL COMMAND (2 SPEED POWER SHIFT) MODE POSITION SENSOR. Indicates the Dual Command (2 Speed Power Shift) hydraulic splitting operation. S. SHUTTLE MODE SENSOR POSITION. Indicates forward or reverse movement. 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
17
T. 4 WD INDICATOR SWITCH. Activates when there is no oil pressure in the 4 WD control lines. The warning lamp lights up. U. ALTERNATOR. Provides a square wave signal and recharges the battery. The alternator also provides power for the electrical devices on the tractor. V. TILT SENSOR. Indicates the tractor tilt. W. G1 GEAR SWITCH. Indicates the range position. X. C GEAR SWITCH. Indicates the gear engaged (located in front of the G1 switch). Y. BRAKE OIL LEVEL SWITCH. Activates when the brake fluid drops below the minimum level. The warning lamp lights up. Z. SPEED SENSOR. Indicates the theoretical tractor ground speed. Aa. TRANSMISSION OIL TEMPERATURE SENSOR. Indicates the oil temperature in the transmission unit. Bb. STARTING ADVANCE THERMOMETRIC CUT--OUT SWITCH.
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18
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
1
SECTION 55 -- ELECTRICAL SYSTEM Chapter 2 -- Components
CONTENT Section
Description
Page
55 40440
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Control panel with analog instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Control panel with digital instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INTRODUCTION The components described in this section are grouped in controls located inside the cab (in the specific locations listed below) and in controls positioned on the outside of the tractor: 1. Instrument panel controls (central control panel with analog or digital instruments). 2. Cab controls. 3. Right--hand side controls. 4. Electronic lift controls. 5. Central console controls.
DESCRIPTION OF COMPONENTS CENTRAL CONSOLE PANEL The controls on the central console panel (with either an analog or digital control panel) are as follows:
--
function select push--button (only with digital control panel);
--
hazard warning light switch;
--
four--wheel drive switch.
--
clock adjustment push--button (only with digital control panel);
--
function select push--button (only with digital control panel);
For the location of the controls listed above (according to the different types of instrument), refer to fig. 1 (analog instruments) or fig. 5 (digital instruments).
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ANALOG CONTROL PANEL
MPF0492A
1 Analog control panel 1. Tachometer.
4. Hours worked counter.
2. Fuel gauge.
5. Hours worked counter.
3. Engine coolant temperature gauge.
6. LED indicators to signal machine service status.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
3
SPEEDOMETER/TACHOMETER Engine rev counter and six--figure hour meter: the figures on the black background count the hours of work and that on the red background (last figure on the right) show the tenths of an hour. The green and blue sectors show the number of engine rpm required to reach standard power take--off speed, respectively 540, 540 E and 1000 rpm. --
Green mark = PTO at 540 rpm.
--
Blue mark = PTO at 540E and 1000 rpm. 2
Engine coolant temperature gauge --
Green area = normal temperature.
--
White area = temperature too low.
--
Red area = engine overheating.
In this case, slow the engine to idling speed (without stopping the engine) and, if the light stays on, have the cooling system checked.
3 Fuel gauge. Shows fuel level in the tank. When the tank is full, the pointer moves completely to the right. When the fuel level falls below 1/4, the needle moves into the red area
4
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4
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
DIGITAL INSTRUMENT CONTROL PANEL
5 Digital instrument control panel 1. Commands for setting the front electronic lift for T4040 Supersteer and T4050 Supersteer models.
5. Angular headlight switch.
2. Front PTO control for T4040 Supersteer and T4050 Supersteer models.
7. Control panel.
3. Front lift up and down switch. 4. Bonnet/cab lights switch.
NOTE: The switch (4) on models with roll bar is replaced by the switch (A) of the electrohydraulic four--wheel drive control.
87666787A - 11 - 2007
6. Lights switch.
8. Power Shuttle control lever. 9. Hazard warning lights control switch. 10. Switch with dual function (UP DOWN) scrolling forwards or backwards in the menu. 11. Switch with dual function for navigating through the menu.
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
5
Rev counter/hourmeter (1) The engine rev counter. To obtain the engine rpm, multiply the number indicated by the pointer by 100.
Digital display (2) On switching on the engine, the digital display automatically goes into tractor speed mode in km/h or in MPH depending on the setting made.
Digital display (3) The digital display can give the operator different information:
6
1. rear PTO speed (displayed automatically on starting the engine); 2. front PTO speed (if fitted); 3. clock; 4. rear lift position; 5. front lift position (if fitted).
Engine coolant temperature gauge. 1. Red area = engine overheating (the temperature exceeds 100 0C). In this case, slow the engine to idling speed (without stopping the engine) and, if the light stays on, have the cooling system checked. 2. Green area = normal temperature (temperatures between 60 0C and 100 0C). 3. Blue area = temperature too low (temperatures between 40 0C and 60 0C). 7 Fuel gauge. Shows fuel level in the tank. When the tank is full, all the sectors are illuminated. Whereas, when the last two sectors at the bottom (1) remain illuminated, the fuel level is less than 1/4.
8
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
6
MULTIFUNCTION DISPLAY The multifunction liquid crystal display (1) can show useful and necessary information when driving and a menu for making the following adjustments: 1. 2. 3. 4. 5. 6.
tractor speed calibration; instrument brightness control; sound level on/off on pressing the buttons; unit of measurement in km/h or MPH; setting the clock and 12/24 hour format; fault codes display.
9
The menu is navigated through by using the toggle switches (1 and 2). Each button provides two controls, depending on the position where it is pressed To enter the SETUP MENU you need to turn the ignition key page 12 onto position (B) or (C), and hold down switch (1) in position (B) for more than three seconds.
10
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
7
CONTROLS ON RIGHT--HAND CAB UPRIGHT The following controls are located on the right--hand cab upright: -- Rotating beacon switch (1). -- Work lights switch (2). -- Windscreen wiper switch (3). -- Front windscreen washer switch (4). -- Rear windscreen wiper/washer switch (5). NOTE: All controls are operational when the starter key is in position (B, fig. 12). 11 Key--start ignition switch To obtain the three starter key--switch (1) functions, turn the key to the following positions: -- position A = no power to circuits (key can be removed). Stopping the engine; automatic operation of fuel injection shut--off device. -- position B = engine start standby. Operation of panel lights and instruments. Power supplied to various circuits. -- position C = engine start: if released, the key returns automatically to position (B). 26083
12
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
8 MAINTENANCE
Front work lights lamp bulb replacement
CAUTION When handling halogen bulbs, only touch the metal parts, never the bulb. If the bulb comes into contact with your fingers, the intensity of the light emitted will be reduced, adversely affecting its service life. In the event of contact, clean the bulb with a cloth soaked in alcohol and leave to dry. To change the bulbs of the front lights, proceed as follows: 1. Pull the lever (1) to open the bonnet. 2. Lift the bonnet from the front and let it rise up.
13
3. Extract the connection (2). 4. Remove the rubber guard (1) to get to the halogen lamp; then change it with a new one of the same power (55/60 W).
14 Changing swivel work light bulbs To change the lamp bulbs, proceed as follows: 1. Extract the connection (1). 2. Turn the lamp (2) clockwise. 3. Extract it and change it with a new one of the same power (60 W).
15
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 REPLACING THE FRONT SIDE, AND INDICATOR LIGHT BULBS
9
1
Remove transparent cover (1), press the bulb in, twist anti--clockwise and unscrew. Replace it with a small bulb of the same power: --
indicator light bulbs (1) 21W;
--
brake lights and side lights (2) -- double filament 21W/5W.
NOTE: The transparent orange cover must be fitted facing the outside of the mudguard.
3
2
27637
16
TAIL LIGHTS, BRAKE LIGHTS AND DIRECTION INDICATOR LAMP BULB REPLACEMENT (VERSION WITHOUT CAB, NORTH AMERICAN VERSION) To change the bulbs, proceed as follows: 1. Unscrew the four bolts (1) securing the transparent cover of the tail light.
1
MPF0510A
17 2. To extract the lamp bulbs (1), press them inwards and turn them anticlockwise. 3. Change the blown bulb with a new one of the same power, bearing in mind that: -- side light (5 W) (top) -- direction indicator light (21 W) (middle) -- brake light (21 W) (bottom).
1
MPF0509A
18
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
NUMBER PLATE LIGHT BULB REPLACEMENT Proceed as follows: 1. Pull the black rubber cover (1) outwards to access the lamp. 2. Take out the bulb (2) and change it with a new one of the same power (5 W).
1 2
MPF0511A
19
LAMP BULB REPLACEMENT CAB FRONT AND REAR WORK LIGHTS
Turn the light, rotate the cover (1) and extract it from its seat. Extract the bulb by pulling outwards. NOTE: Never touch the new bulbs with your hands, hold the bulb with a cloth or through its wrapping.
20
REAR SIDELIGHTS, BRAKE AND DIRECTION INDICATOR LIGHT BULBS. Replacement Remove transparent cover (1), press the bulb in, twist anti--clockwise and unscrew. Replace it with a bulb of the same power: -- indicator light bulbs (1) 21W; -- brake lights and side lights (2) -- double filament 21W/5W. NOTE: The transparent orange cover must be fitted facing the outside of the mudguard. 21
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
11
REPLACING THE COURTESY LIGHT AND ADJUSTABLE READING LIGHT To access the two bulbs, proceed as follows: -- use a screwdriver to prise open the transparent cover (1) and remove. Courtesy light -- pull the lamp (2) downwards (pressure fitted) and replace it with a new bulb of the same power (10 W). 26611
22 Adjustable reading lamp -- detach the ground lead from the battery to switch off power to the lamp holder; -- loosen the screw (1); -- using a screwdriver, turn the retaining bracket (2) and remove; -- replace the bulb (3) with a new bulb of the same power (5 W).
26212
26613
23 WORK LIGHT BULB REPLACEMENT To replace the bulb, proceed as follows: 1. Pull back the rubber guard (2). 2. Remove the transparent cover (1). 3. Press the bulb (3) in and twist anticlockwise to remove. 4. Replace the bulb with a new one of the same power (35 W).
24
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
REPLACING ELECTRONIC LIFT UNIT CONTROL INDICATOR LIGHTS To replace faulty indicator lights, first remove the support plate as described below: 1. Unscrew the retaining bolts (1) (fig. 25 and 26). 2. Lift the control support plates. 3. Rotate the faulty indicator anticlockwise by 1/4 of a turn (fig. 27); extract and replace with a new indicator bulb of the same power (1.2 W) (fig. 28).
25
26
26618
27
26619
28 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
1
SECTION 55 -- ELECTRICAL SYSTEM Chapter 3 -- Starting System CONTENT Section
Description
Page
55 000
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 System testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
55 201 50
Starter motor. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
55 201 54
Starter motor. Disassembly--Assembly
.......................................... 8
Bench testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TECHNICAL DATA CHARACTERISTICS Starter motor Power (kW)
TYPE OF STARTER MOTOR Iskra AZF 4591 4.2
Direction of rotation (pinion side view)
clockwise
Maximum armature shaft end float (mm)
0.1 รท 0.4
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
2
DESCRIPTION AND OPERATION The type of starting system installed depends on the type of gearbox fitted on the tractor. All systems consist of an ignition key--switch, heavy--duty wiring, a starter motor with an electromagnet, a starter relay and gear, range gear and PTO control lever switches. These are the basic circuit components used on versions with mechanical gearbox. More sophisticated systems include other components, which ensure the engine can be started only under the proper conditions. A 2.5 kW starter motor is series installed. This motor has four poles, four brushes with integrated electromagnet and positive mesh engagement control. The electromagnet consists of two parallel--connected windings. The low resistance intake winding is grounded via the engine, whilst the high resistance hold winding is grounded via the electromagnet body. When the key--switch contact is closed (with the gear and range gear in neutral and the PTO disengaged) the coils are energised and the plunger is magnetically drawn into the electromagnet. This movement, transmitted by an adjustable joint mechanism, makes the driving pinion engage the flywheel rim gear. When the pinion makes contact
MPH1928A
with the rim gear, the plunger closes a series of contacts in order to directly power--up all four field coils, thereby supplying full power to the starter motor. At this stage, one end of the intake coil is connected to the positive battery pole through the starter switch, whilst the other end is connected to the positive battery pole through the solenoid valve contacts. In this manner the intake coil is bypassed, without absorbing power, and the hold coil exclusively maintains the electromagnet plunger in position. The starter motor includes a series of contacts and a two--part electromagnet plunger that totally closes the contacts, even if the pinion teeth are not perfectly in line with those of the crown wheel. When this happens, a clutch spring compresses the pinion, forcing it to engage completely as soon as the starter motor begins to turn over. When the key--switch is released, power to the electromagnet and motor is cut off. The electromagnet return spring, acting on the adjustable joint mechanism, frees the driving pinion from the gear and re--opens the solenoid valve contacts. A roller--type clutch mechanism is incorporated in the driving pinion unit. This prevents the pinion from overspeeding if it remains engaged in the flywheel crown wheel after the engine has started.
MPH1927A
Fuses and relay control unit
87666787A - 11 - 2007
1
Starter motor
2
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
3
TROUBLESHOOTING The engine does not turn over when the starter key is turned, with gears and range gears in neutral and PTO disengaged.
Is the battery fully charged?
Charge or replace battery. Is the engine rotating correctly?
NO
YES
NO
Check the starting circuit wiring. Are all connections tightened, is the battery correctly grounded, are there any broken or frayed wires present, which could cause a short circuit?
YES
Repair the wiring accordingly.
NO
Is the engine seized?
YES
NO
Find the cause of engine failure.
Turn the starter key: is a value of +12V measured on the starter solenoid valve input wire (red and black striped wire)?
Has the solenoid valve triggered?
YES
YES
NO
NO
The coils or brushes are probably faulty, or mechanically damaged.
The solenoid valve is probably faulty, remove the motor and check. Check the starter relay: does the relay work when the starter key is turned?
Replace the relay
NO
YES
Remove the connector from the relay: is a value of +12V measured at pin 5 (red and black striped wire) when the starter key is turned?
Replace the relay
YES
NO
Check the inverter lever, gear and range gear switches and PTO lever wires: are the wires connected?
NO
Reconnect the wire to the switch
YES
Check the operation and condition of all switches.
Replace the switch
NO
YES
Does the instrument panel display light up when the starter key is turned? YES
NO
Check that the battery main power supplies the key--switch (pin 30).
Check the starter key--switch: if the wire is connected and in good condition, replace the switch.
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
4 SYSTEM TESTS
Starting system test on tractor. To troubleshoot the starting system simply and rapidly with conclusive results, use a battery/starter tester (high discharge rate tester) with incorporated 0 20 V voltmeter and 0 500 A ammeter. When using testing devices, follow test procedures recommended by the manufacturer. If testing devices are not available, carry out the following procedure using a standard 0 20 V voltmeter and a 0 500 A ammeter to check correct starter motor operation, without removing it from the engine. Before the test: â&#x20AC;˘
Check that the battery is fully charged
â&#x20AC;˘
Check the condition of all the starting system wiring (no damaged or frayed wires, no loose connections).
â&#x20AC;˘
Check that the engine is not seized.
Current absorbed on the starter motor circuit.
5
1
1. Disconnect the battery (3) ground cable (negative). 2. Disconnect the positive battery cable from the starter electromagnet (5). Connect the positive lead of an ammeter (1) to the positive battery terminal and the negative lead to the electromagnet input terminal (5).
4
3. Reconnect the ground wire (negative) to the battery negative terminal (3).
3
2
26630
4. Connect the positive voltmeter point (2) to the positive battery terminal clamp and the negative to the negative battery terminal clamp.
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3
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
5
5. Disconnect the injection pump closing solenoid valve wire. 6. Run the engine and note voltmeter and ammeter readings. Voltage must remain constantly around 12 V with an absorption value of 250 300 A. •
If the absorption value corresponds with the technical data, the starter motor (4) is working correctly. If voltage drops during the test, carry out the ”Starting system circuit resistance” test (see the relative heading).
•
If the absorption value exceeds that of the technical data, check the circuit as described below. If the starting system circuit tests are satisfactory, then the starter motor is faulty and will need to be removed in order to identify the cause.
•
If the current absorption value is lower than that of the technical data, then the starter motor is faulty and will need to be removed in order to identify the cause.
Starting system circuit resistance (voltage drop).
2
1
If the voltage absorption value is too high, check the individual circuit components to find the cause of the voltage drop.
V
IMPORTANT: Disconnect the injection pump shut--off solenoid valve wire.
3
Battery positive cable. 1. Connect the positive voltmeter point (1) to the positive battery terminal clamp (2). 2. Connect the negative lead on the voltmeter to the starter motor electromagnet terminal (3).
26631
4
3. Run the engine and check the voltmeter readings. If voltage exceeds 0.2 V, check and tighten the cable connections. Re--check the voltage and, if the value is still too high, replace the cable.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
Starter motor ground connections.
1
2
1. Connect the positive lead on the voltmeter (1) to the starter motor casing (2). 2. Connect the negative lead on the voltmeter to the engine block (3). 3. Run the engine and check the voltmeter readings. If the value exceeds 0.2 V, check the ground connections between the starter motor flange and the engine rear cover.
3
26632
5 Battery ground lead
1
2
1. Connect the positive lead on the voltmeter (1) to the engine block (2).
V
2. Connect the negative lead on the voltmeter to the negative terminal on the battery (3). 3. Run the engine and check the voltmeter readings. If voltage exceeds 0.2 V, check and tighten the ground cable connections. Re--check the voltage and, if the value is still too high, replace the ground cable.
26633
3 6
Operation 55 201 50 STARTER MOTOR Removal--Installation 1. Disconnect the battery negative cable. 2. Remove the plastic guard (3) on the terminals. 3. Unscrew the nut and remove the power and emergency switch terminal (4). 4. Extract the three retaining bolts (2) on the starter motor (1). 5. To reassemble the starter motor, carry out the removal operations in reverse.
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26633
7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
7
26635
8 Starter motor components 1. 2.
Electromagnet Electromagnet nuts
7. 8.
Field coils and casing Brush holder
3. 4. 5. 6.
Bolt and stud assembly Control side support Lever Reduction unit
9. Brush plate 10. Armature 11. Coupling
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8
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
OVERHAUL
7. Extract the motor casing from the armature and the bracket on the control side.
Operation 55 201 54 STARTER MOTOR REMOVED Disassembly--Assembly
8. Extract the control lever knuckle pin from the control side of the casing
Refer to figure 9. 1. Position the starter motor in a vice with padded jaws.
9. Remove the circlip that holds the control unit and the inner plate to the armature shaft, by first removing the circlip retaining collar perpendicularly using a suitably sized piece of piping. Then lever the circlip from the groove.
2. Disconnect the biggest braided cable that connects the field coils casing with the electromagnet.
10. Extract the armature and control unit.
3. Remove the three screws from the front casing and extract the electromagnet. Remember that the plunger remains connected to the control lever.
REASSEMBLY
4. Remove the electromagnet plunger by raising and releasing it from the control lever. 5. Remove the two nuts from the rear casing and the two screws that secure the rear cover and the brush plate to the casing. Remove the â&#x20AC;?Câ&#x20AC;? clamp and the armature shaft end--float adjustment shims, leaving the brush gear on the switch. Remove the fine metal washer from the switch side of the armature. 6. At this stage of the procedure, check the brushes and the switch. Check that the brushes are not stuck together and, if necessary, clean both the brushes and the respective channels with a cloth soaked in kerosene. Also check that the brushes are not worn. If the minimum length is less than that shown in the technical data, the starter motor will need to be replaced.
NOTE: The brushes cannot be serviced separately. They are welded to their support and do not require replacement during the entire operating life of the starter motor.
87666787A - 11 - 2007
1. To reassemble the starter motor, carry out the disassembly operations in reverse order. Before reassembly, check the armature axial end--float and test the starter motor (without load). CHECKING ARMATURE END FLOAT 1. Position the starter motor in a vice with padded jaws and connect a dial gauge to the flange on the control side of the casing. Position the dial gauge pointer on the end of the armature shaft. 2. Push the armature fully forward and zero--set the dial gauge. Push the armature fully back and note the reading on the instrument. 3. Readings must fall within the limits specified in the technical information table. If the value is higher, check the armature and brush plate are not worn. Replace worn parts and, if necessary, check the end float again.
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 Starter motor test (without load) NOTE: a fully charged battery and a battery/starting tester (high discharge rate tester) with a carbon battery (variable load resistance) are required to carry out this test. 1. Position the starter motor in a vice with padded jaws. 2. Connect the battery negative cable (4) to the starting motor mounting flange. 3. Using a short cable, make a bridge (7) between the electromagnet contacts (6). 4. Connect the positive lead on a voltmeter (3) to the positive terminal on the battery (4) and the negative lead to the negative terminal on the battery. Connect the positive lead on the ammeter(1) to the positive terminal on the battery (4) and the negative lead to the battery or the starter motor terminal. 5. Position a manual tachometer (5) on the end of the armature shaft. The maximum power absorption, which is a specific value for each starter motor, must be within the range of values shown on the TECHNICAL DATA table. Adjust the carbon battery voltage (2) and the armature rpm to the values shown on the table. 6. If the starter motor does not work according to the technical data specifications, check to see if the field coils are grounded, the armature scrapes or if the armature shaft is deformed.
6
9
7 1
5
2
3
4 26636
9
BENCH TESTS
1
ARMATURE 1. The switch surface must be clean and not burnt. If necessary, remove the burn stains with fine sandpaper -- not emery cloth. Finally, clean the switch with a cloth soaked in kerosene. 2. If the switch needs re--facing, make sure that the diameter is not below the minimum value prescribed in the TECHNICAL DATA table. After re--facing, the switch must be polished with fine sandpaper and cleaned with a cloth soaked in kerosene.
26637
10
NOTE: do not cut the armature metal when making insulation slots.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
3. Armature insulation can be checked by connecting an ohmmeter (1) between switch segments and the armature shaft. This reading should show infinity, i.e.: there should be no continuity. 4. To test for short circuits in the armature, use a suitable test instrument or, as the only alternative, try replacing the armature. 5. If the armature circumference has obviously made contact with the pole pieces, the pole bearings are probably too worn. First check that the pole pieces are fixed and that the armature rotates correctly in a lathe. If necessary, replace the armature bearings. Field coils. 1. To test the field coils insulation, connect an ohmmeter to each of the coil brushes in turn and to a clean and unpainted area of the casing. There should be no readings, that is, there should be no continuity. 2. To test the field coils continuity, connect an ohmmeter to each of the coil brushes in turn and to the main power terminal (the biggest braided cable). The reading should be 1 â&#x201E;Ś. 3. If there is a fault in the field coils, replace the entire box and field coils system.
26638
1 11
Bearing Bushes. 1. Check if the bushing on the brush plate and the box on the drive pinion side are worn. Assemble the armature shaft and observe the end--float. Replace the bushings if end float is excessive. Check the field poles to see if there are any signs of scraping against the casing. This could also be caused by worn bushings. Pinion. 1. Check roller clutch operation. The pinion must spin clockwise only. If the pinion is either locked or spins in both directions, or if the pinion teeth are damaged, assemble a new control unit. If there is clear evidence of damage to pinion teeth, check flywheel rim gear, as described in Section 10.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
1
SECTION 55 -- ELECTRICAL SYSTEM Chapter 4 -- Charging system CONTENT Section
Description
Page
55 000
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 System testing and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
55 301 10
Alternator. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
55 301 12
Alternator. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TECHNICAL DATA TYPE OF ALTERNATOR
CHARACTERISTICS
ISKRA
Polarity
Grounded negative
Direction of rotation (pulley side)
Clockwise
Rated voltage (V)
14
Maximum rotation speed (rpm)
12.000
Maximum output (A)
120
Regulator controlled voltage (V)
14.25 ÷ 14.75
Inductor coil resistance (Ω) at 25°C
2.5 ÷ 2.7
BOLT TORQUES PARTS TO BE TIGHTENED Pulley retaining nut
Nm 75÷80
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
2
DESCRIPTION AND OPERATION Description of the alternator Bosch alternators, in the 120 A version, are installed on all models. Stator winding is ventilated with an air conducting diaphragm in the support on the rectifier bridge side and peripheral openings in the support on the control side. The alternator, installed on the right--hand side of the engine, is operated by a pulley and a V--type driving belt. Alternators are fitted with a built--in regulator. 120 Amp Alternator 1. 2. 3.
Socket W Battery connection (B+ terminal) Alternator charge indicator connection (D+ terminal)
87666787A - 11 - 2007
1 2
3 MPH1933A
1
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
3
1 5 2
3
4
26640
2 Alternator charging circuit 1. 2. 3. 4.
Starter Switch Alternator charging indicator light Battery Alternator electronic voltage regulation circuit
Alternator Operation Refer to figure 2. When the starter key is turned, low current passes from the battery through the rotor field wiring. The circuit closes, powering the charge warning light, the alternator D+ terminal, the rotor field winding, the alternator regulator and ground. At this point the warning light illuminates and the rotor is partially magnetised. When the engine starts and the rotor, which is partially magnetised, rotates inside the stator windings, three--phase alternating current is generated. A constant quantity of this current is transformed into direct current by three field diodes incorporated in the rectifier unit.
5. Alternator B+ : Battery connection D+ : Alternator Charge Indicator
The direct current is then reintroduced into the circuit to increase current flow through the rotor field winding. This action causes a constant increase in the rotor magnetic field, together with a rapid increase of current and voltage output. As the generated voltage output (reflected by D+ terminal) increases, the warning light intensity decreases and when the voltage at the D+ terminal equals that on the battery side of the warning light, the light goes out. Voltage continues to increase until it reaches the pre--stabilised regulated voltage level. If the driving belt breaks, there will be no voltage accumulation in the alternator. The charge warning light will remain on -- indicating the presence of a fault.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
4
1
2
3
MPH1934A
2
MPH1935A
1
3 Fan belt tensioner Fig. 3. Belt for models without air conditioning 1. 2.
Belt Alternator
4
Fig. 4. Belt for versions with air conditioning 1. 2. 3.
Air conditioner compressor Alternator belt Compressor belt
SYSTEM TESTING AND TROUBLESHOOTING Precautions during the operation To avoid damage to the components of the alternator charging system, the following precautions must be observed: •
NEVER MAKE OR BREAK any charging circuit connection, including the battery, when the engine is running.
•
NEVER SHORT CIRCUIT the alternator positive terminal to check if it is working.
•
ALWAYS DISCONNECT battery cables when re--charging the battery on the tractor with a battery charger.
•
ALWAYS CHECK battery polarity when installing a battery or using a supplementary battery to start the engine.
•
DO NOT SHORT CIRCUIT regulator input/output terminals whilst the alternator is working.
•
CONNECT POSITIVE TO POSITIVE AND NEGATIVE TO NEGATIVE.
Preliminary checks Before carrying out these electrical tests, carefully inspect the charging system and the electrical system in general. Check continuity in all conductors and connections, making sure they are correctly tightened.
87666787A - 11 - 2007
1. Battery check Check all battery elements with a densimeter. The battery must be at least 70% charged and efficient. 2. Driving belt check Inspect the alternator driving belt and pulley, making sure that they are both clean and in good condition, with no traces of oil or grease. Check the alternator driving belt tension regularly. If the belt tension is insufficient, check the tension following the instructions of section 10, chapter 1, page 109. 3. Check the Warning Lamp Turn the starter key and check that the warning light is fully illuminated. If the warning light does not illuminate completely, check the light bulb. If the light bulb is in working order, carry out the alternator wire connection tests, as described under the heading ”PRELIMINARY TESTS” in this section. If the warning light is on, start the engine and run at a speed above the idling speed. The warning light should switch off. If the warning light does not go out, stop the engine and disconnect the D+ terminal wire. If the warning light goes out now, one of the alternator components is malfunctioning.
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 Carry out the ”ALTERNATOR COMPONENTS TEST”, as described in this section. If the warning light remains on, check that there are no grounded short circuits between the D+ wire endings and the warning light. Preliminary tests The preliminary tests can be carried out without removing any components from the tractor charging circuit. The tests check: • the alternator wiring connections • the alternator charging current and controlled voltage • voltage drops in the alternator charging circuit • maximum alternator output
5
The following testing devices are required: • • • •
0 to 30 V mobile coil voltmeter 0 to 1 V millivoltmeter 0 to 110 A mobile coil ammeter 1.5 Ohm 110 A variable load resistance.
NOTE: Most commercially available testing devices include several devices in the same case. Use these devices according to the manufacturer’s instructions.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
1. Alternator wire connection tests See figure 5. 1. Disconnect battery. 2. Disconnect terminals B+ (2) and D+ (3) on the alternator. 3. Reconnect the battery and turn the starter key to ON, without starting the engine. Connect a voltmeter (4) between each terminal and earth (ground) (1). Voltage must be present at the battery. If there is no voltage at the battery, find and repair the continuity failure in the external wire circuit. See the circuit diagram in figure 2. 4. Connect D+ terminal, warning light wire (red) and earth (ground). The warning light should switch on. 5. Disconnect the battery and reconnect the previously disconnected connectors to the alternator.
26643
5
NOTE: If the warning light does not switch on when the wire is reconnected to the alternator, there is a fault either in the alternator regulator or the rotor circuit. Check D+ terminal is clean and then test the alternator components as described in this section.
2. Charging current and regulated voltage tests See figure 6. 1. Make sure that all tractor electrical devices are switched off and that the starter key is in the OFF position. 2. Disconnect the battery negative terminal and the B+ alternator terminal (3). 3. Connect an ammeter (1) between the disconnected wire (red) (4) and the alternator B+ terminal. 4. Connect a voltmeter (2) between the alternator B+ terminal and earth (ground). 5. Reconnect the battery. Start the engine and run it at 2000 rpm. Note the readings on the voltmeter and ammeter. The voltmeter readings should be higher than the battery voltage and, when the ammeter value falls below 10 A, the voltmeter reading should stabilise at 13.6 รท 14 V.
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26644
6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
7
If the voltmeter reading is higher than 14 V, the alternator regulator must be replaced, as described in this section. (After installing a new regulator, carry out tests 4 and 5). If the voltmeter reading is lower than 13.6 V, there is either a faulty component on the alternator or a failure due to excessive resistance in external charging system connections. If the ammeter indicates zero A, one of the alternator components is faulty. Switch off the engine and carry out alternator components test, as described in this chapter. 3. Charging circuit voltage drop tests (a) Insulated side voltage drop tests Refer to figure 7. Make sure that the starter key is in the OFF position. 1. Disconnect the negative battery cable and the B+ alternator wire (1). 2. Connect a millivoltmeter (5) between the positive battery terminal clamp and D+ wire (3) (positive side of the wire. 3. Connect an ammeter (2) between the B+ alternator terminal and the D+ wire (negative side of the wire).
26645
7
4. Reconnect the negative battery cable and connect a variable load resistance (4) with the cursor in the minimum current absorption position (maximum resistance) through the battery terminals. 5. Start the engine and increase speed to 2000 rev/min. 6. Gradually increase the resistance charging load (decreasing the resistance) until the ammeter indicates 45 or 65 A, according to the type of alternator. 7. Note the reading on the millivoltmeter, which should not exceed 400 millivolt. Readings higher than 400 millivolt indicates a fault due to excessive resistance on the external circuits. If the alternator does not output required power and the millivoltmeter reading is less than 400 millivolts, there is a malfunctioning component in the alternator. Carry out the alternator component tests as described in this section. 8. Stop the engine.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
(b) Ground side voltage drop test Refer to figure 8. 1. Make sure that the starter key is in the OFF position. 2. The circuit is the same as that described in the previous test, except that the millivoltmeter (4) is now connected between the negative battery terminal and the alternator casing (negative side of the casing).
NOTE: Make sure that the variable load resistance (3) is in the minimum current absorption position (maximum resistance).
26646
8
3. Start the engine and increase speed to 2000 rev/min. 4. Gradually increase the resistance charging load (decreasing the resistance) until the ammeter (2) indicates 45 or 65 A, according to the type of alternator. 5. Note the reading on the millivoltmeter, which should not exceed 200 millivolt. Readings higher than 200 millivolt indicates a fault due to excessive resistance on the external circuits. If the alternator cannot produce the requested output and the reading on the millivoltmeter is lower than 200 millivolt, there is a faulty component in the alternator. Carry out the alternator component tests as described in this section. 6. Stop the engine. 4. Maximum alternator output test Refer to figure 9. 1. Make sure that the starter key is in the OFF position. 2. Disconnect the negative battery cable and the alternator B+ wire (4). 3. Connect an ammeter (5) between the B+ alternator terminal (4) and the D+ wire (1) (negative side of the wire). 4. Connect a voltmeter (3) between the alternator B+ terminal (4) and earth (ground). 5. Reconnect the battery, start the engine and increase speed to 2000 rpm.
87666787A - 11 - 2007
26647
9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
9
6. Gradually increase the resistance charging load (2) (decreasing the resistance) until the ammeter indicates 45 or 65 A, according to the type of alternator. 7. Note that the voltmeter reading does not fall below 13.6 V. Readings of less than 13.6 V indicate the presence of a faulty alternator component. Carry out the alternator component tests as described in this section. Alternator component tests The alternator component tests must only be carried out if the INITIAL CHECKS have shown the presence of a faulty alternator component, allowing the following checks to be performed: • the regulator, • rotor field winding continuity, • rotor brushes, springs and contact rings. NOTE: The previously described component tests can be carried out with the alternator installed on the tractor. In order to carry out the other alternator component tests, remove the alternator from the tractor. See the section REMOVAL, INSTALLATION AND OVERHAUL in this chapter.
OP. 55 301 10 ALTERNATOR. Removal -- Installation IMPORTANT: Before disconnecting the alternator wires, make sure that the starter key is in the OFF position -- alternator removal. 1. Raise the bonnet. 2. Carry out operation 90 100 80 Protective mesh, only removal of right--hand guard (see section 90). 3. Disconnect the two wires B+ (1, fig. 11) and D+ (2, fig. 11) from the alternator. 4. Loosen and remove the nut and bolt (3, fig. 11) fastening the alternator to the belt tensioner (4, fig. 11). 5. Move the alternator so as to slacken the tension in the belt (1, fig. 13), then remove it from the pulley (2, fig. 13) from the alternator.
26648
10
11
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
10
1
2
3
4
5
6
7
8
10
9
26650
12 Alternator components 1. 2. 3. 4. 5.
Pulley retaining nut Pulley Cooling fan Front support plate Rotor
1. 2. 3.
Alternator pivoting Belt Pulley Alternator retaining bolt
6. 7. 8. 9. 10.
Stator Rear support plate Rectifier bridge Guard Electric voltage regulator with incorporated brushes
2
1 3 28011
13 Secure the alternator horizontally to a suitable support, with the inner contact surfaces protected by padding. Remove the guard (1) after having unscrewed the alternator retaining nuts. Before dismantling the alternator completely, carry out the operations and tests described on the following pages.
26651
14
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
11
Rotor and regulator field circuit test The following testing devices are required: • 12 V battery • multitester • 2 watt test lamp. Refer to figure 15. 1. Disconnect all alternator wires. 2. Connect a 12 V battery and a 2.2 watt test lamp (2) in series between D+ (1) and the alternator casing (negative side of casing). 3. The test lamp should light up. If the test lamp does not light up, then the rotor circuit is faulty. Check brushes, contact rings and rotor field winding continuity. If the test shows these components are satisfactory, then the regulator may be faulty.
26652
15
Checking the continuity of three stator windings
Ω
Position the points of an ohmmeter (adjusted to the Ω x1 scale) so that they touch the stator phase ends (a -- b -- c) in the three possible ways shown in Fig. 16 -- 17 -- 18. For each measurement the instrument must give a certain resistance reading that must be the same for all three measurements. If resistance is infinite or zero, the measured phase is either interrupted or short--circuited, therefore the stator will need to be replaced.
26653
16
Ω
26654
17
87666787A - 11 - 2007
12
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
â&#x201E;Ś
26655
18 Checking the diodes Disconnect the excitation diode terminal wire connector (1) from the pin connected to the positive brush.
26656
19 Unweld stator winding terminals (2) from the rectifier bridge.
26657
20 Energizing diode test Insert an ohmmeter point in the connector (1) mentioned above (Fig. 19). The second point must be placed in contact with each of the three terminals (A--B--C). Repeat the three measurements after inverting the instrument points.
26658
21 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
13
Positive power diode tests Place an ohmmeter point in contact with the positive (X) alternator terminal and the other successively with each of the three terminals (A--B--C). Repeat the three measurements after inverting the instrument point connections.
26659
22 Negative power diode tests Place an ohmmeter point in contact with negative (Y) diode plate and the other successively with each of the three terminals (A--B--C). Repeat the three measurements after inverting the instrument point connections.
26660
23 In the three tests described above, the instrument should show resistance at each terminal (A--B--C). Inverting the instrument points, there should be no resistance (Fig. 23). If there is resistance in both cases, then the diodes are short--circuited. Otherwise, with an R=0 value (interrupted diode), replace the entire rectifier bridge.
ROTOR Check on rotor winding resistance measured between pins connected to brushes Disconnect the excitation diode terminal wire connector (1) from the pin connected to the positive brush. Place both points of an ohmmeter (regulated on a â&#x201E;Ś x1) in contact with the two voltage regulator--brush holder pins. If the resistance reading is different from the prescribed value, or if it is infinite (interrupted circuit), check and replace the rotor if necessary.
26661
24
87666787A - 11 - 2007
14
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
OP. 55 301 12 ALTERNATOR, REMOVED Disassembly -- Assembly Fit a suitable Allen wrench in the hexagonal hole on the alternator shaft to prevent it from moving. With another wrench unscrew the fan and rotor pulley. Extract these parts, together with the spacers and alternator shaft washers.
26662
25 Disconnect the energizing diode terminal wire connector (2) from the pin connected to the positive brush. Unscrew the screws (3) securing the electronic voltage regulator (4), complete with brushes, to the rear alternator support. Unscrew the nuts (5) and extract the screws that fasten the alternator main external parts.
26663
26 Electronic voltage regulator A. Brushes B. Plate pins
26664
27 Separate the parts (as illustrated) bearing in mind that a considerable degree of pressure on the rotor shaft is required to free the front support plate (6) and the rotor (7). If a press is not available, use a brass drift to avoid damaging the thread.
26665
28 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
15
Unscrew the screws (9) securing the rectifier bridge (10) to the rear support plate (8). The rectifier bridge must not be disassembled: it is supplied as a whole spare part.
26666
29 Separate the rectifier bridge (10) from the rear support plate and unweld the stator winding terminals (11).
26667
30 Separate the stator (12) and the terminals (11) from the rear support plate (8).
26668
31 Inductor winding insulation test Place both points of an ohmmeter (regulated on a â&#x201E;Ś x1 scale) in contact respectively with a slip ring and the rotor casing (see arrows). The instrument should show infinite resistance. If this is not the case, replace the rotor.
26669
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
Check on inductor (rotor) resistance on slip rings Place both points of an ohmmeter (regulated on a â&#x201E;Ś x1 scale) in contact respectively with the rotor slip rings (see arrows): the instrument should show a certain degree of resistance. If the resistance reading is different from the prescribed value, or if it is infinite (interrupted circuit), replace the rotor. Check that the bearing rotates freely, without sticking or making noise. Check that the brushes have not dented the rings. If this is the case, replace the whole rotor.
26670
33 Assembly Procedure To assemble, reverse the order of the disassembly operations.
4 2
OVERHAUL 1. Check that the rotor and stator poles are not worn. If this is the case, either the bearings are worn, the boxes are not aligned or the rotor shaft is deformed. NOTE: The alternator bearings cannot be serviced separately, therefore they must both be changed when necessary.
1 3 26671
34
2. Remove the screws (1) securing the plate (2) locking the bearing (3), then remove it from the front support plate (4) (Fig. 34). Check for wear and damage and: if necessary, replace. Before installing the ball bearing, check the front support plate holder and clean it carefully. 3. Installation of bearing (5) on the support plate side is different from the previous operation. A new rotor and bearing assembly must be fitted.
26672
35 INSTALLATION 1. Refit the alternator by following the removal procedure in reverse order. During installation, remember to: â&#x20AC;˘ make sure that the negative (ground) battery cable is disconnected from the battery during alternator installation. â&#x20AC;˘ regulate the alternator driving belt as previously described in this chapter.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
1
SECTION 55 -- ELECTRICAL SYSTEM Chapter 5 -- Battery CONTENT Section
Description
Page
55 000
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
55 301 40
Battery removal -- installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Battery checking and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Battery charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Battery problems -- frequent causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TECHNICAL DATA CHARACTERISTICS Voltage (V)
TYPE OF BATTERY All models 12
Cold start amperage (C.C.A)
6800
Capacity (Ah)
100
Number of elements Weight (kg) Grounding terminal
6 ~ 20 Negative
DESCRIPTION AND OPERATION A ”sealed”, maintenance--free battery is installed in all models, located in front of the radiator. NOTE: ”Maintenance--free ” means that the battery does not leak electrolyte in normal conditions of use. Water loss may occur if the battery is charged over 14.4 V. This causes the liquid to boil as a result of the gas formed whilst the battery is fully charging. This event may be caused by a charging system fault, quick recharging or topping up. The four main functions of a battery are: • to supply a source of electric energy for starting, switching on and running the instruments. • controlling the electrical system. • to supply electricity when the power required is higher than that produced by the alternator. • to support inactive loads from the radio and the microprocessor memory.
Each element of the battery consists of positive and negative plates, positioned alternatively one next to the other. Each positive plate is separated from the adjacent negative plate by means of a porous insulating spacer. If one of the positive plates comes into contact with the negative plates in the element, the element will short circuit and be irreparably damaged. All of the positive plates are welded to a bar and form a positive terminal, whereas all of the negative plates are welded to a similar bar and form a negative terminal. Each positive plate consists of a lead grid with lead peroxide pasted to the grid holes. The negative plates consist of a lead grid with lead sponge pasted to the grid holes. The plates are covered by electrolyte formed by a diluted sulphuric acid solution. The battery casing is made of polypropylene.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
OP. 55 301 40 BATTERY Removal -- Installation REMOVAL 100 Ah Battery installed in front of the engine radiator 1. Raise the bonnet. 2. Loosen the bolts on both terminals and disconnect the negative (2) and positive (1) cables from the battery, making sure that they do not touch the battery. 3. Unscrew the retaining bolts (3) and remove the battery.
INSTALLATION Applicable to all types of battery 1. To re--install the battery, reverse the removal procedure, with the following precautions: • Make sure that the battery is clean and there are no traces of electrolyte leakage, also check that the breather covers are correctly installed. Spread petrolatum (e.g.: vaseline) on the terminals; do not use traditional grease lubricants, as these products may favour electrolytic corrosion. • Make sure that the battery housing and support are clean without objects (stones, etc.) which could pierce the battery casing. • Make sure that the battery terminal polarity is correct and that the terminal connections are not too tight. • If a radio is installed, all data stored in the memory will be lost and it will need to be reprogrammed. Electronic control units and microprocessors -- when installed -- will not lose stored data, as electronic stress and transmission control calibration are not involved in this operation.
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1
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 BATTERY CHECKING AND MAINTENANCE RELATIVE DENSITY The relative density of the battery electrolyte shows the charge level of the battery. When the battery is fully charged, the relative density of the electrolyte is at least 1.280 at 25°C. Alternatively, the approximate charge status can be measured by using a digital voltmeter (± 0.01V) as follows: Less than 10.5 V battery unusable* Less than 11.8V battery flat Less than 12.3V battery half--charged More than 12.6V battery fully charged * See the notes under the ”TESTS” heading, for instructions on how to recuperate a slightly sulphated battery. The battery voltage must be measured on a flat battery, considering the following: A. The battery must have been flat for at least four hours. B. If the vehicle has been used recently, switch the headlamps on for two minutes. When a battery is flat, the sulphuric acid in the electrolyte combines chemically with the plates and this decreases the relative density of the solution. A battery densimeter will determine the relative density of the electrolyte in an element, and the quantity of sulphuric acid not used in the solution indicates the degree of charge of that element. Low temperatures require a higher battery charge to operate. For example: a battery with a relative density of 1.225 at 27°C (80°F) can activate the starter motor at ambient temperatures, but will fail to do so if the temperature drops as a result of poor battery performance levels. Table 1 shows the effect of temperature on battery performance. Table 1 Temperature
Efficiency of a Fully Charged Battery
25.0°C --4.5°C --24.0°C --27.5°C --31.0°C --34.5°C --37.5°C
100% 82% 64% 58% 50% 40% 33%
3
Maximum battery life can be obtained by paying the right attention and by carrying out regular checks. The energy capacity output must not be exceeded by a constant/excessive overload and charging requirements must be respected. BATTERY SERVICE
ATTENTION Batteries contain sulphuric acid and generate a highly explosive hydrogen and oxygen mix during charging. Never use devices that produce flames or sparks whilst checking the electrolyte level • Always protect hands and eyes before removing the battery caps. During battery maintenance, observe the steps noted below: 1. Keep the electrolyte at the recommended level of 17 mm over the plates. If this level is not respected, the acid concentration will increase, which could cause damage to the separators and diminish plate performance. 2. Only use distilled or demineralized water, never overfill or use tap/rain water or other sources of water. 3. Keep the battery 75% charged (at least) to avoid plate sulphation, performance loss and possible freezing at low temperatures. 4. Avoid overcharging the battery, as excessive charge will generate high internal heat, causing grid deterioration water leaks. 5. During rapid recharging, make sure that the battery temperature does not exceed 50°C. 6. Do not add sulphuric acid to an element unless electrolyte has been spilled. Before topping up, make sure that the solution has the correct relative density. Slow recharging is the only way to fully recharge the battery. Use a high amperage battery charger to charge the battery with high current intensity for short periods of time, but this must be followed by a slow charge to achieve full capacity battery performance. •
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
DRY CHARGED BATTERIES Dry charged batteries must be prepared as followed: 1. Remove the breather caps from the battery element. 2. Fill each element to the recommended level with electrolyte, at the relative density of 1.260. NOTE: The electrolyte is formed with sulphuric acid, diluted at a temperature of 21° 32°C. 3. After filling, leave the battery to rest for 15 minutes, then check the electrolyte level and top up if required. 4. Charge the battery for 4 hours at 5 8 A, making sure that all of the elements are freely producing gas. 5. Refit the breather caps on the battery element.
CHARGING THE BATTERY Before charging a battery: 1. Thoroughly clean the battery casing, the covers on the elements and the terminals with diluted ammonia or warm water. 2. Check the level of the electrolyte in each element and, if found to be under the plate level, top up with distilled water to cover the plates. NORMAL CHARGING (TOP UP) 1. Fully charge the battery using a slow battery charger at 3 to 6 A for the required time. This operation could take 36 hours or more if the battery is extremely flat. A severely sulphated battery may not charge. When the battery is fully charged, the elements produce gas freely and the relative density will remain constant. Disconnect the battery charger after three consecutive densimeter readings taken each hour, to show that the relative density has stopped increasing. 2. When using a rapid or fast ampere charge, follow the manufacturer’s instructions carefully. High charging amperage increases the electrolyte temperature and, if the battery charger is not fitted with an automatic timer or thermostat, this temperature may exceed 50°C, which can lead to violent boiling in the battery, thereby damaging the internal components.
87666787A - 11 - 2007
3. Re--check the level of the electrolyte in each element and add distilled water as needed.
ATTENTION Explosive gas is formed when a battery is charged. Do not smoke or use naked flames when checking the electrolyte level and make sure that the battery charger is switched off before connecting or disconnecting, to avoid sparks that may ignite the gas. CHARGING EXTREMELY FLAT BATTERIES To recharge a Pb--Ca maintenance--free battery we recommend using a constant voltage battery charger. For extremely flat batteries, charge for 48 hours at 16 V, with current limitation (50A for 100Ah). This method is self--regulating: high current is provided at the beginning (when the battery voltage is very low), whilst current decreases progressively when the battery is fully charged (and the voltage is high). If only constant voltage battery chargers are available, we recommend using voltage levels and times shown in table 2. The figures refer to very flat batteries. If the battery is only 50% discharged, use half the time shown (slow charging programme). For other conditions, reduce charging time proportionally. When feasible, use the slowest charging programme for increased battery life. Table 2 Type of battery 100Ah (800 cca) Slow Charge Programs
25hrs at 5A 12.5hrs at 10A
Fast charge Program (emergencies only)
7 hours at 10A
If violent boiling occurs during recharging, due to gas formation or electrolyte leakage (50°C or more), temporarily reduce or stop battery charging to avoid damaging the battery.
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 TESTS Before beginning battery tests, check that the breathers are not blocked, there is no rust, the breather caps are not open and the casing is not cracked. Equipment required for testing: • Densimeter • Battery starter tester (high amperage multi--tester) • Thermometer • Battery charger Relative density: This test shows the charge level of the battery. 1. With the float in the vertical position, note the reading. 2. Adjust the densimeter reading for battery electrolyte temperature variations, subtracting 4 points (relative density 0.004) for every 5.5°C below the calibrated temperature of the densimeter and adding 4 points (relative density 0.004) for every 5.5°C above this temperature. The following examples have been calculated with a densimeter calibrated at 30°C. Example 1: Temperature lower than 30°C Battery electrolyte temperature 19°C Densimeter reading 1.270 Subtract 11.0 x 0.004 5.5 1.262 Correct relative density = Example 2: Temperature above 30°C Battery electrolyte temperature 40°C Densimeter reading 1.220 0.007 Add 10.0 x 0.004 5.5 1.227 Correct relative density = 3. Use the following table to determine the charge level. Charge level
Corrected Specific Gravity at 15°C
Corrected Specific Gravity at 25°C
Average battery voltage
100% 75% 50% 25% Discharged
1.295 1.253 1.217 1.177 1.137
1.287 1.246 1.210 1.170 1.130
12.66 12.45 12.30 12.00 11.84
NOTE: The relative density should not vary more than 0.025 points between cells.
5
5. If the relative density is less than 1.280, charge the battery and check the charging system to determine the cause of the low charge. NOTE: If distilled water has been added recently, recharge the battery for a short time, otherwise the densimeter will not provide precise readings. If the battery has been charged under static conditions, a thicker electrolyte will accumulate at the bottom of the elements. The battery must be shaken at regular intervals in order to mix the electrolyte: this will improve the charging amperage and provide more precise densimeter readings during the tests. Performance test The performance test helps us to understand if the battery can adequately start the engine. Voltage readings show the battery condition. Before carrying out the test, check the battery electrolyte level is correct and the open circuit voltage is 12.5V or more. The battery can be tested in the tractor or removed. 1. Switch the battery start tester current control to OFF (high amperage discharge tester). Calibrate the voltage selection switch to the rated battery voltage, or slightly higher. Connect the positive tester conductors to the positive terminal on the battery and the negative conductors to the negative battery terminal. 2. Turn the current control knob until the ammeter reading reaches half the cold start battery amperage and note the voltage reading. • If the reading shows 9.6 V or more after 15 seconds, the battery has adequate power output and can be easily charged following the normal procedure. • If the reading is below 9.6 V, the battery is not satisfactory for use and must be tested as described below. CAUTION: Do not leave high discharge on the battery for more than 15 seconds. Test charge: This test is only for batteries that failed to pass the previously described performance test. 1. Connect the positive battery charger tester conductors (high amperage discharge tester) to the positive battery terminal and the negative conductors to the negative battery terminal. 2. Connect the positive battery charger conductor to the positive terminal on the battery and the negative conductor to the negative battery terminal.
4. If the relative density is 1.280 or more, the battery is fully charged and in good working condition.
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6
3. Turn the battery charger timer to more than the ”3 minute” charge, and then back to the ”3 minute” charge. 4. Set the charging amperage as close as possible to 40 A. 5. After 3 minutes of rapid charging, read the voltmeter. • If the total voltage exceeds 15.5 V, the battery is not satisfactory and is probably sulphated or worn and must be replaced. NOTE: A slightly sulphated battery can be renewed using a multiple type battery charger, with upper open circuit voltage limit of 50 V. A sulphated battery has high resistance and will require high initial voltage to overcome resistance due to sulphation. There may be no visible signs of charging at the beginning. After a few minutes of inactivity a low charge will be shown, followed by a rapid amperage rise. Amperage must not exceed 14.0 A or the temperature of the electrolyte must not exceed 50°C. When the amperage has stabilised, reset the voltage until the amperage remains fixed at 5 A. Continue at this level until the relative density of the electrolyte stops increasing (approx. 1.275 1.280 at 20°C; This may take 48 hours. Let the battery rest for 24 hours and then carry out the previously described performance test. •
If the total voltage is below 15.5 V, check the relative density of each element and recharge the battery according to the following scale: Relative density
Rapid charge up to:
1.150 or less from 1.151 to 1.175 from 1.176 to 1.200 from 1.200 to 1.225
60 minutes 45 minutes 30 minutes 15 minutes (slow charge only)
BATTERY PROBLEMS -- FREQUENT CAUSES 1. Internal circuit open. 2. Internal short. 3. Electrolyte leak.
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4. Grid active material separation. 5. Accumulation of sulphate crystals too big to be dispersed. These faults are normally caused by: 1. Component failure inside the element. 2. Excessive crystal growth leading to perforated separators and possibly short circuits. 3. Excessive overload (inefficient charging system, high voltage rapid charging, operation at high temperatures). 4. Battery electrolyte freezing. A fully charged battery freezes at --65°C. A 50% charged battery freezes between --17°C and --27°C. Completely flat electrolyte freezes at --3°C to --11°C. Excessively rapid recharging and boiling caused by gas formation leads to separation of the active material from the grids. Separation destroys the battery chemical function. 5. Crystals are formed when batteries are left flat. High temperature and long periods with the battery flat increase this condition. If a battery is left at ambient temperature for a week, it will be difficult to recharge on the tractor. Recharging will require a higher constant voltage. After 3 weeks, the battery will be permanently damaged and it will be necessary to follow the procedure described for extremely flat batteries. Fully charged batteries last for longer. A lead--calcium battery discharges 3% every month. This means that in 16 months the charge will drop by 50%. The inactive load on the tractor is approx. 50mA. An approximate discharge on an unused vehicle is valued at 8Ah per week. It is worth noting that if a battery is weak during engine start--up, it is best to let the battery rest for two minutes. This rest time should increase as the temperature decreases. When two batteries are installed, do not use an old battery with a new one. One battery will always stop before the other one. If the battery has lasted as forecasted, charge both batteries. If a battery stops before the prescribed time, due to a manufacturing fault, then only replace one of the batteries.
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
1
SECTION 55 − ELECTRICAL SYSTEM Chapter 6 − ELECTRIC CIRCUITS TRACTORS FITTED WITH CAB CONTENT Section
Description
Page
55 100
Electrical circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical circuit components (numerical order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuses and relays layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fuse and relay layout on cab right−hand upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Power sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Ground location points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 How to use the wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Connector code reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Wire colour coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Symbols used in electrical circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Wiring diagram components (functional order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Version index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 VERSION 1 2WD models, electrohydraulic differential lock, rear mechanical lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 VERSION 2 Electrohydraulic four−wheel drive, electrohydraulic differential lock, mechanical rear lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 VERSION 3 Electrohydraulic four−wheel drive, electrohydraulic differential lock and electronic rear lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 VERSION 4 Permanent four−wheel drive, electrohydraulic differential lock, mechanical rear lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 VERSION 5 Permanent four−wheel drive, electrohydraulic differential lock, electronic rear lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 Input/output wiring diagram for the electronic control unit of the Power Shuttle (16 + 16) . . . . 394 Input/output wiring diagram for the electronic control unit of the Dual Command (2 Speed Power Shift) Power Shuttle (32 + 16/44 + 16) . . . . . . . . . . . . . . . . . . . . . . . . . . 396 Front lift and front PTO and 4WD control unit input/output wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398 Input/output wiring diagram for the control unit of the rear lift . . . . . . . . . . . . . . . . . . . . . . 400 Input/output wiring diagram for the control unit of the instrument panel . . . . . . . . . . . . . 402 87666787A2 − 06 − 2009
2
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
3
ELECTRICAL CIRCUIT COMPONENTS This section lists a description of the electrical components forming the tractors system. There are two lists, divided in the following order: 1. Numerical order (increasing) page 4;
DESCRIPTION
SUFFIX ALT
Alternator
AUD
Audio devices
BAT
Battery
CB
Battery cut--out
C CAP
2. Functional order (divided by type of components) page 27. Below is an explanation of the suffixes related to each component.
Connections Capacitor
D
Diode
F
Fuse
GND
Ground
LMP
Lamps
LED
LEDs
MOD
Control units
M
Engine
RLY
Relays
RES
resistor
SEN
Sensor
SOL
Solenoid valve
SW
Switch
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
4
ELECTRICAL CIRCUIT COMPONENTS (NUMERICAL order) C--1 C--2 C--3 C--4 C--5 C--6 GND--7 C--8 C--9 SW--10 MOD--11 SW--12 C--13 C--14 C--14A C--14B C--15 C--16 SW--17 C--18 SW--19 LMP--20 C--21 LMP--22 MOD--23 C--24 MOD--25 F--26 MOD--27 C--28 C--29 SW--30 C--31 CB--31 SW--32 SEN--33 SW--34 SW--35 SW--36 SW--37 GND--38 SW--39 MOD--40 C--41 M--42 MOD--43
Front side connection -- engine (24 PIN) Cab system connection (20 PIN) Trailer brake circuit intermediate connection (4 PIN) 25A and 40A power socket connection Front lights connection Transmission system connection (24 PIN) Dashboard ground Trailer brake circuit main connection (4 PIN) Power--shuttle system connection (24 PIN) Hazard lights switch Instrument Front PTO switch Front lift and PTO system connection (13 PIN) 7--pin socket connection ISO seven--pin socket North American seven--pin socket Gearbox neutral connection Electronic thermostarter connection (6 PIN) Front grille work lights switch Rear electronic lift connection (8 PIN) Starter switch RH front direction indicator and side light Power--Shuttle system connection (6 PIN) LH front direction indicator and side light Electronic flasher Digital instrument connection Fuse box and main relay 30A maxi--fuse (40A for North America) Rear lift electronic control unit Diagnostics connection Rotating beacon socket Battery cut--out circuit switch Connection for battery cut--out circuit on engine Battery cut--out circuit jumper Operator present switch Tilt sensor Rear electronic lift up/down switch 4WD control switch Differential lock switch LH rear external electronic lift up/down switch Rear ground Parking brake switch Rear electronic lift indicator lights and working depth adjustment control panel Seat connection Front and rear window washer pump Rear electronic lift control panel
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
5
ELECTRICAL CIRCUIT COMPONENTS (Continued) SW--44 LMP--45 C--46 C--47 LMP--48 C--49 SW--52 SW--53 M--54 SW--55 M--56 GND--57 MOD--58 AUD--60 AUD--61 C--62 SW--63 MOD--64 RES66 SW--67 M--68 LMP--69 RLY--70 SEN--71 SW--72 C--73 SW--74 MOD--75 LMP--76 LMP--77 LMP--78 LMP--79 LMP--80 LMP--81 LMP--82 BAT--83 ALT--84 M--85 SEN--86 SEN--87 C--88 SEN--89 M--90 SEN--91 SEN--92 SEN--93
RH rear external electronic lift up/down switch RH tail light 8A two--pin socket 40 A four--pin socket (North America) LH tail light 25A two--pin socket Windscreen washer switch Windscreen wiper switch Wiper motor Rear window wiper/washer switch Rear wiper motor Cab ground Radio RH speaker LH speaker Fan unit connection Rotating beacon control switch Permanent 4WD control unit Fan speed resistor unit Ventilation and air--conditioning system electric fan switch Ventilation and air--conditioning system electric fan Fan control unit lamp Conditioner relay Electronic thermostat for air conditioner Air conditioner switch Front work lights connection Work lights switch Fuse box and cab relay Cab RH front work light Cab LH front work light Cab RH rear work light Cab LH rear work light RH cab SMV light LH cab SMV light Cab overhead lighting Battery Alternator Starter motor Brake fluid level sensor Air filter clogged sensor Cigar lighter Sediment unit filter sensor Conditioner compressor Filter/dryer sensor Engine oil pressure sensor Coolant temperature sensor
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
6
ELECTRICAL CIRCUIT COMPONENTS (Continued) SOL--94 SOL--95 SW--96 SW--97 SOL--99 SOL--100 SEN--101 MOD--102 SW--103 SW--104 SW--105 GND--106 SEN--107 SEN--108 SOL--109 RLY--110 SW--111 SEN--112 SW--113 SW--114 SW--115 SW--116 SOL--117 AUD--118 LMP--119 LMP--120 LMP--121 LMP--122 SEN--123 SEN--124 SW--125 SEN--126 SEN--127 SEN--128 SEN--129 SEN--130 SEN--131 SEN--132 SOL--133 SOL--134 SOL--135 SW--136 SOL--138 SOL--139 SOL--140 SW--141
Engine cut--out electromagnet Solenoid valve to cut out starting advance, depending on temperature Starting advance thermometric cut--out switch External lights control switch Front lift UP solenoid valve Front lift DOWN solenoid valve Front lift arms position sensor Front electronic lift control panel Front lift up/down switch Front PTO switch Front electronic lift block switch 4WD indicator ground Trailer brake indicator light pressure switch Trailer brake circuit safety pressure switch Trailer brake solenoid valves Trailer brake circuit relay Rear PTO switch Power steering indicator light pressure switch Lights switch Gearbox neutral switch Splitter switch Differential lock indicator switch Differential lock solenoid valve Horn Grille LH front work light Front LH headlamp Front RH headlamp Grille RH front work light Fuel level transmitter 4WD indicator pressure switch Shuttle lever switch Steering sensor Rear axle speed sensor Front axle speed sensor Ground speed sensor PTO rpm sensor Draft sensor Arms position sensor Rear electronic lift DOWN solenoid valve Rear electronic lift UP solenoid valve 4WD solenoid valve Stoplamp switch Dual Command (2 Speed Power Shift) mode solenoid valve Shuttle mode solenoid valve Dump solenoid valve G1 ranges switch
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
7
ELECTRICAL CIRCUIT COMPONENTS (Continued) SW--142 SW--143 SOL--146 SOL--147 SEN--148 MOD--150 SW--151 SW--152 SEN--153 GND--155 MOD--156 RLY--157 RLY--158 RES--159 F--160 SW--161 SW--162 C--166 C--167 F--168 F--169 C--170 SW--171 C--175 SEN--176 MOD--177 LMP--178 C--179 C--180 GND--181 SEN--182 SW--183 C--184 C--185 SEN--203 MOD--204 SW--205 SW--206 SEN--208 LMP--210 SW--211 LMP--212 LMP--213 LMP--214 GND--215
C1 gears switch Creeper switch Lo clutch solenoid valve Hi clutch solenoid valve Transmission oil temperature sensor Power Shuttle control unit Clutch pedal switch Power Shuttle control lever Clutch pedal sensor Dashboard Power Shuttle ground Grid heater electronic module Grid heater relay (coil) Grid heater relay (contact) Grid heater 125A maxi--fuse ”Up/Down” control button ”Enter” control button Brake lights signal test connection Connection for CAN line (4 PIN) 50A mega--fuse 50A mega--fuse Front lift system connection (8 PIN) Front lift main switch Four--wheel drive system connection (4 PIN) Engine rpm sensor Digital instrument Work light Rear lights connection (2 PIN) Rear lights connection (6 PIN) Trailer brake circuit ground Transmission oil pressure sensor Dual Command (2 Speed Power Shift) and Dump Clutch buttons LH cab SMV light connection RH cab SMV light connection Shuttle position sensor Four--wheel drive control unit Front lift UP external control switch Front lift DOWN external control switch Front PTO sensor Number plate light 4WD indicator switch Number plate light RH two--faced headlight LH two--faced headlight Power sockets ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
8
LOCATION OF FUSES AND RELAYS DANGER If electrical system relays need to be changed, check that correct spare parts are used and that they are fitted in the correct positions. The use of structurally or functionally different relays -- even if interchangeable -- could seriously compromise tractor control with dangerous results
VERSION 1 Fig. 1
--
Electrohydraulic differential lock.
--
Power Shuttle unit.
--
Digital instrument.
--
30/40A power socket.
--
North America circuit.
--
Trailer Brake.
List of relay functions I.
Brake lights circuit.
II.
Differential lock circuit
III.
Not used.
IV.
Differential lock circuit
V.
Full beam headlight circuit.
VI.
Dipped beam headlight circuit.
VII.
Not used.
VIII.
Front headlight switchover circuit.
IX.
Front headlight switchover circuit.
X.
Side lights circuit
XI.
Front power take--off indicator light circuit.
XII.
Not used.
XIII.
Engine starter circuit maxi--relay.
87666787A - 11 - 2007
RADIO
Two/four--wheel drive models with: mechanical four--wheel drive and mechanical lift, fitted for:
1
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
9
Main fusebox Version 1 tractors, page 8 Valves
Amps.
PROTECTED CIRCUITS
1
5
Front right--hand and rear left--hand side lights, side lights indicator.
2
5
Front left--hand and rear right--hand side lights, control instrument panel light.
3
15
ISO side lights, or 7--pin work light (North America).
4
15
Full beam headlights.
5
15
Dipped beam headlights.
6
5
+Instrument common.
7
10
Differential lock circuit.
8
10
8A power socket, digital instrument.
9
15
Direction indicator and hazard lights.
10
10
Horn, full beam flasher.
11
5
Starter safety circuit.
12
5
Engine cut--out electromagnet
13
10
Power Shuttle circuit.
14
10
Power Shuttle circuit.
15
15
Swivel position lights, seat, cab users relay.
16
10
Trailer brake and hydraulic adjustment circuit.
17
--
Not used.
18
--
Not used.
19
10
Stop Lights.
20
7.5
Grid--heater circuit
21
--
Not used.
22
--
Not used.
23
--
Not used.
24
--
Not used.
25
5
Electronic control unit power supply, +battery, seat safety circuit.
26
--
Not used.
27
--
Not used.
28
--
Not used.
29
--
Not used.
30
7.5
Radio.
Maxi fuses 30A ISO power socket
40A North America power socket
50A Cab circuit
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
10 VERSION 2 Fig. 2
--
Power Shuttle unit.
--
Digital instrument.
--
30/40A power socket.
--
North America circuit.
--
Trailer Brake.
--
Grid--heater circuit.
RADIO
Four wheel drive models with: electrohydraulic four--wheel drive, electrohydraulic differential lock and mechanical lift, fitted for:
List of relay functions I.
Brake lights circuit.
II.
Differential lock circuit
III.
Differential lock circuit
IV.
Differential lock circuit
V.
Full beam headlight circuit.
VI.
Dipped beam headlight circuit.
VII.
4WD and brake lights circuit.
VIII.
Bonnet/cab dipped beam switchover circuit
IX.
Bonnet/cab dipped beam switchover circuit
X.
Side lights circuit
XI.
Not used.
XII.
Not used.
XIII.
Engine starter circuit maxi--relay.
87666787A - 11 - 2007
2
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
11
Main fusebox Version 2 tractors, page 10 Valves
Amps.
PROTECTED CIRCUITS
1
5
Front right--hand and rear left--hand side lights, side lights indicator.
2
5
Front left--hand and rear right--hand side lights, control instrument panel light.
3
15
ISO side lights, or 7--pin work light (North America).
4
15
Full beam headlights.
5
15
Dipped beam headlights.
6
5
+Instrument common.
7
10
Differential lock circuit, four--wheel drive circuit.
8
10
8A power socket, digital instrument.
9
15
Direction indicator and hazard lights.
10
10
Horn, full beam flasher, seat safety circuit.
11
5
Starter safety circuit.
12
5
Engine cut--out electromagnet
13
10
Power Shuttle circuit.
14
10
Power Shuttle circuit.
15
15
Swivel position lights, seat, cab users relay.
16
10
Trailer brake and hydraulic adjustment circuit.
17
--
Not used.
18
--
Not used.
19
10
Stop Lights.
20
7.5
GRID--HEATER control unit circuit.
21
--
Not used.
22
--
Not used.
23
--
Not used.
24
--
Not used.
25
5
Electronic control unit power supply, (+battery), seat safety circuit.
26
--
Not used.
27
--
Not used.
28
--
Not used.
29
--
Not used.
30
7.5
Radio.
Maxi fuses 30A ISO power socket
40A North America power socket
50A Cab circuit
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
12 VERSION 3 Fig. 3
--
Power Shuttle unit.
--
Digital instrument.
--
40 A power socket.
--
North America circuit.
--
Trailer Brake.
--
GRID--HEATER circuit.
RADIO
Four wheel drive models with: electrohydraulic four--wheel drive, electrohydraulic differential lock and electronic lift, fitted for:
List of relay functions I.
Brake lights circuit.
II.
Differential lock circuit
III.
Differential lock circuit
IV.
Differential lock circuit
V.
Full beam headlight circuit.
VI.
Dipped beam headlight circuit.
VII.
4WD and brake lights circuit.
VIII.
Front headlight switchover circuit.
IX.
Bonnet/cab dipped beam switchover circuit
X.
Side lights circuit
XI.
Not used.
XII.
Not used.
XIII.
Engine starter circuit maxi--relay.
87666787A - 11 - 2007
3
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
13
Main fusebox Version 3 tractors, page 12 Valves
Amps.
PROTECTED CIRCUITS
1
5
Front right--hand and rear left--hand side lights, side lights indicator.
2
5
Front left--hand and rear right--hand side lights, control instrument panel light.
3
15
ISO side lights, or 7--pin work light (North America).
4
15
Full beam headlights.
5
15
Dipped beam headlights.
6
5
+instrument common, +external push--buttons, electronic lift indicator lights.
7
10
Differential lock circuit, 4WD.
8
10
8A power socket, digital instrument.
9
15
Direction indicator and hazard lights.
10
10
Horn, full beam flasher
11
5
Starter safety circuit.
12
5
Engine cut--out electromagnet
13
10
Power Shuttle circuit.
14
10
Power Shuttle circuit.
15
15
Swivel position lights, seat, cab users relay.
16
10
Trailer brake and hydraulic adjustment circuit.
17
10
Electronic lift circuit
18
--
19
10
Stop Lights.
20
7.5
GRID--HEATER control unit circuit.
21
7.5
Front lift circuit.
22
7.5
Front lift circuit.
23
7.5
Front lift circuit.
24
20
Front lift circuit.
25
5
Electronic control unit power supply, (+battery), seat safety circuit.
26
--
Not used.
27
--
Not used.
28
--
Not used.
29
--
Not used.
30
7.5
Not used.
Radio.
Maxi--fuses 30A ISO power socket
40A North America power socket
50A Cab circuit
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
14 VERSION 4 Fig. 4
--
GRID--HEATER circuit.
--
Power Shuttle unit.
--
Digital instrument.
--
30/40A power socket.
--
North America circuit.
--
Trailer Brake.
List of relay functions I.
Brake lights circuit.
II.
Differential lock circuit
III.
Differential lock circuit
IV.
Differential lock circuit
V.
Full beam headlight circuit.
VI.
Dipped beam headlight circuit.
VII.
Not used.
VIII.
Bonnet/cab dipped beam switchover circuit
IX.
Bonnet/cab dipped beam switchover circuit
X.
Side lights circuit
XI.
Not used.
XII.
Not used.
XIII.
Engine starter circuit maxi--relay.
87666787A - 11 - 2007
RADIO
Four wheel drive models with: permanent 4WD, electrohydraulic differential lock and mechanical lift, fitted for:
4
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
15
Main fusebox Version 4 tractors, page 14 Valves
Amps.
PROTECTED CIRCUITS
1
5
Front right--hand and rear left--hand side lights, side lights indicator.
2
5
Front left--hand and rear right--hand side lights, control instrument panel light.
3
15
ISO side lights, or 7--pin work light (North America).
4
15
Full beam headlights.
5
15
Dipped beam headlights.
6
5
+instrument common, +external push--buttons, electronic lift indicator lights.
7
10
Differential lock circuit and front lift circuit.
8
10
8A power socket, digital instrument.
9
15
Direction indicator and hazard lights.
10
10
Horn, full beam flasher.
11
5
Starter safety circuit.
12
5
Engine cut--out electromagnet
13
10
Power Shuttle circuit.
14
10
Power Shuttle circuit.
15
15
Swivel position lights, seat, cab users relay.
16
10
Trailer brake and hydraulic adjustment circuit.
17
10
Front lift circuit.
18
10
Permanent 4WD circuit.
19
10
Stop Lights.
20
7.5
GRID--HEATER control unit circuit.
21
--
Not used.
22
--
Not used.
23
--
Not used.
24
--
Not used.
25
5
Electronic control unit power supply, (+battery), seat safety circuit.
26
--
Not used.
27
--
Not used.
28
--
Not used.
29
--
Not used.
30
7.5
Radio.
Maxi--fuses 30A ISO power socket
40A North America power socket
50A Cab circuit
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
16 VERSION 5 Fig. 5
--
Power Shuttle unit.
--
Digital instrument.
--
Front Lift.
--
40 A power socket
--
North America circuit.
--
Trailer Brake.
--
GRID--HEATER circuit.
RADIO
Four wheel drive models with: permanent 4WD, electronic rear lift and electrohydraulic differential lock, fitted for:
List of relay functions I.
Brake lights circuit.
II.
Differential lock circuit.
III.
Differential lock circuit.
IV.
Differential lock circuit.
V.
Full beam headlight circuit.
VI.
Dipped beam headlight circuit.
VII.
Not used.
VIII.
Front headlight switchover circuit
IX.
Front headlight switchover circuit
X.
Side lights circuit
XI.
Not used.
XII.
Not used.
XIII.
Engine starter circuit maxi--relay.
87666787A - 11 - 2007
5
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
17
Main fusebox Version 5 tractors, page 16 Valves
Amps.
PROTECTED CIRCUITS
1
5
Front right--hand and rear left--hand side lights, side lights indicator.
2
5
Front left--hand and rear right--hand side lights, control instrument panel light.
3
15
ISO side lights, or 7--pin work light (North America).
4
15
Full beam headlights.
5
15
Dipped beam headlights.
6
5
+instrument common, +external push--buttons, electronic lift indicator lights.
7
10
Differential lock circuit, four--wheel drive circuit.
8
10
8A power socket, digital instrument.
9
15
Direction indicator and hazard lights.
10
10
Horn, full beam flasher.
11
5
Starter safety circuit.
12
5
Engine cut--out electromagnet
13
10
Power Shuttle circuit.
14
10
Power Shuttle circuit.
15
15
Swivel position lights, seat, cab users relay.
16
10
Trailer brake and hydraulic adjustment circuit.
17
10
Electronic lift circuit.
18
5
Permanent 4WD circuit.
19
10
Stop Lights.
20
7.5
GRID--HEATER control unit circuit
21
7.5
Front lift circuit
22
5
Front lift circuit
23
7.5
Front lift circuit
24
20
Front lift circuit
25
5
Electronic control unit power supply, (+battery), seat safety circuit.
26
--
Not used.
27
--
Not used.
28
--
Not used.
29
--
Not used.
30
7.5
Radio.
Maxi fuses 30A ISO power socket
40A North America power socket
50A Cab circuit
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
18
FUSE AND RELAY LAYOUT ON CAB RIGHT--HAND UPRIGHT Air conditioned cab relays (2) (Fig. 6) RLY--1
Rear work lights circuit.
RLY--2
Cab users key--locked circuit.
RLY--3
Air--conditioner compressor circuit.
RLY--4
Front work lights circuit.
1
Heated cab relays (2) (Fig. 6) RLY--1
Rear work lights circuit
RLY--2
Cab users key--locked circuit.
RLY--3
Not used.
RLY--4
Front work lights circuit. 2
MPM1018A
6
FUSE COLOUR CODING Colour code
Amps
Green
30
White
25
Amber
20
Light Blue
15
Red
10
Beige
5
4
7.5A
15A
1
5
10A
15A
2
6
30A
15A
3
MPE0373A
7
Fuse layout Fuse box (1) (cab circuit) fig. 7 Valves
PROTECTED CIRCUITS
Amps.
F1
Front worklamps.
15
F2
Rear work lamps.
15
F3
Rotating beacon, cigar lighter.
15
F4
Rear window wiper/washer.
7.5
F5
Front wiper.
10
F6
Air conditioning, fan unit
30
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
19
POWER SOCKETS (Fig. 8) The power sockets are located on the rear of the tractor, on the left--hand side. 1. Seven--pole socket. 2. 25 A two--pole power socket (ISO) 40 A four--pole power socket (North America)
MPE0204A
8 Seven--pole power socket (Fig. 9) The PTO contacts carry out the following functions: 1 -- L.
Left turn lamps.
2 -- 54G. Not used. 3 -- 31.
Ground.
4 -- R.
Right turn lamps.
5 -- 58R.
RH side lights.
6 -- 54.
Brake lights.
7 -- 58L.
LH side lights.
MPE0201A
9 25 A two--pole power socket (ISO version) (Fig. 10) Located under the seven--pole power socket and provided with two positive terminals and one ground, with the following positions: 82.
Key--controlled power.
54.
Direct power.
31.
Ground. MPE0200A
10 40 A power socket (North America version) (Fig. 11) Provides the following positions: 82.
Key--controlled power.
54.
Direct power.
31.
Ground.
58L.
Ground.
58R.
Direct power. MPE0202A
11 87666787A - 11 - 2007
20
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
GRID HEATER RELAY (Fig.. 12) The power relay for the starter pre--heating system (1) is located in the engine compartment in the area underneath the brake fluid reservoir. The relay is connected with two 16 mm2 power cables (2) and a connector (3) to power the coil.
1
3 MPH1931A
2 12
GRID HEATER CONTROL MODULE (Fig.. 13) The pre--heating control module (1) is located inside the panel and it controls the above--described power relay.
1
MPH1929A
13
ELECTRONIC FLASHER MODULE (Fig. 14) This module (1) is located inside the panel on the left--hand side near the fuse and relay control unit (2). This electronic device governs the operation of the direction indicators and hazard lights of the entire tractor.
1
2 MPH1930
14
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
21
GROUND LOCATION POINTS A.
Control panel ground.
B.
Engine compartment ground.
C. Cab roof ground. D. Seat ground. E.
Main rear ground (transmission)
F.
Chassis Ground.
G. Battery ground. H. Rear ground (power sockets, headlights)
87666787A - 11 - 2007
22
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 GROUND POINTS LAYOUT
MPM0994A
15 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
23
HOW TO USE THE WIRING DIAGRAMS The wiring diagrams are included in each version (type of transmission) and they have been drawn up in a functional manner. This means that the complete wiring diagram of a certain tractor version has been drawn over a number of pages, each one of which includes the
38
S E ZIONE 55 -- IMP IANT O ELE TT R ICO -- CAP IT O LO 6
S EZ IONE 55 -- IMP IANT O ELE T T R ICO -- CAP IT O LO 6
CIRCUITO DOPPIA TRAZIONE (S ch em a 1)
Connes
s ione
G N D -- 7
Ma ssa
cru sco tto
S E N -- 33
C -- 6
S ens or e inc linaz ione
im piant o tr a s m is s ione
S W -- 35
In te r r u t to r e c o m ando doppia
doppia
t ra z ione
39
CIRCUITO DOPPIA TRAZIONE -- S CHEMA 1
( 2 4 p in)
tr a z ione
M O D -- 6 4
C ent r a lina
G N D -- 106
M a s s a s egnalat
S E N -- 124
P res s o s tat o s egnalat
S E N -- 126
S ens or e d i s te rz o
S E N -- 127
S ens or e v eloc ità a s s a le pos te rior e
S E N -- 128
S ens or e v eloc ità a s s a le ant er ior e
S O L -- 135
E let tr ov alv o la doppia
or e doppia
portion of circuit related to one or more functions (e.g. ”Front and rear electronic lift”; ”Direction indicators and hazard lights”, etc.). All these pages, if joined together would make a complete diagram of the tractor for each version.
per m anent
e
tr a z ione
or e doppia
tr a z ione
tr a z ione
MPG1331A 87666786
-- 11 -- 2007
87666786
-- 11 - 2007
MPM0701A
16 There are a number of guides to help assist in reading and understanding the wiring diagrams. 1. The wiring diagrams (2) are located on the right--hand pages; the titles and keys (1) are on the left--hand pages. The title defines the function to which the diagram refers, the key indicates all the components on that specific page of the diagram.
2. The components and connectors are identified by an abbreviation composed of an alphabetical portion and a numerical portion: -- the alphabetical portion indicates the type of component (e.g. F indicates a fuse, C indicates a connector, MOD indicates a module, SW indicates a switch, etc.), -- the numerical portion is a progressive number.
87666787A - 11 - 2007
24
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
3. On each connecting wire there is an abbreviation indicating the colour and cross--section of the wire: the first letter (1) indicates the main colour of the wire, the second letter (2) indicates the colour of the striping along the wire, the number (3) indicates the cross--section of the wire in mm2.
MPM0708A
17 4. To be able to follow the circuit in its entirety, each wire continuing onto a different page of the diagram ends with an arrow and a reference to the page on which it continues or from which it comes. This reference is composed of an abbreviation made up of a number indicating the sheet of the diagram on which the wire continues and one or more letters to indicate the wire on the page being referred to. The following example gives a reference between diagram 1 (ref. 1), for the cab version and diagram 3 (ref. 2) (Fig. 18, 19)
MPM0699A
18
MPM0700A
19 5. The termination of the wire on a component is indicated with the symbol of the connection (see the key of symbols used on the diagrams) and the number of the pin on which the wire is connected (ref. 1) (Fig. 20).
MPM0699A
20 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
25
CONNECTOR CODE READING The connections on the wiring diagrams are indicated as in the following example. In this example the abbreviation (1) indicates the number of the key of the connection while the second abbreviation (2) indicates the number of the pin of the same connection.
MPM0727A
21
WIRE COLOUR CODING A
Light Blue
HV
Grey/green
AN
Light blue/black
HG
Grey/yellow
AG
Light blue/yellow
I
Blue
AB
Light blue/white
LB
Blue/white
AV
Light blue/green
LN
Blue/black
AR
Light blue/red
LR
Blue/red
B
White
M
Brown
BR
White/red
MB
Brown/white
BN
White/black
MN
Brown/black
BL
White/blue
N
Black
BG
White/yellow
NZ
Black/purple
C
Orange
NB
Black/white
CB
Orange/white
NR
Black/red
CN
Orange/black
R
Red
CL
Orange/blue
RG
Red/yellow
G
Amber
RN
Red/black
GV
Yellow/green
RV
Red/green
GN
Yellow/black
S
Pink
GR
Yellow/red
SN
Pink/black
GL
Yellow/blue
SG
Pink/yellow
H
Grey
V
Green
HM
Grey/brown
VN
Green/black
HR
Grey/red
VB
Green/white
HN
Grey/black
Z
Purple
HB
Grey/white
ZB
Purple/white
HL
Grey/blue
ZN
Purple/black
87666787A - 11 - 2007
26
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SYMBOLS USED IN ELECTRICAL CIRCUITS
Switch
Control switch
Sensor/Switch/Solenoid Valve
Sensor/Switch
Key--start Ignition Switch
Variable sensor
Motor
Diode
Light and warning indicator Ground Fuse
MPD2703A
87666787A - 11 - 2007
Connection
Rotating beacon power socket
Power fuse
Lamp
Relays
Battery
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
27
ELECTRICAL CIRCUIT COMPONENTS (FUNCTIONAL order)
COMPONENT
DESCRIPTION
ALTERNATOR ALT--84
Alternator
AUDIO DEVICES AUD--60
RH speaker
AUD--61
LH speaker
AUD--118
Horn
BATTERY BAT--83
Battery
CONNECTIONS C--1
Front side connection -- engine (24 PIN)
C--2
Cab system connection (20 PIN)
C--3
Trailer brake circuit intermediate connection (4 PIN)
C--4
25A / 40A socket connection
C--5
Front lights connection
C--6
Transmission system connection (24 PIN)
C--8
Trailer brake circuit main connection (4 PIN)
C--9
Power--Shuttle transmission system connection (24 PIN)
C--13
Front PTO and lift system connection (13 PIN)
C--14
Seven--pin socket connection
C--14A
ISO seven--pin socket
C--14B
North American seven--pin socket
C--15
Gearbox neutral connection
C--16
Electronic thermostarter connection (6 PIN)
C--18
Rear electronic lift connection (8 PIN)
C--21
Power--Shuttle system connection (6 PIN)
C--24
Digital instrument connection
C--28
Diagnostics connection
C--31
Connection for battery cut--out circuit on engine
C--41
Seat connection
C--62
Fan unit connection
C--73
Front work lights connection
C--166
Brake lights signal test connection
C--167
Connection for CAN line (4 PIN)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
28
COMPONENT
DESCRIPTION
C--170
Front lift system connection (8 PIN)
C--175
Four--wheel drive system connection (4 PIN)
C--179
Rear lights connection (2 PIN)
C--180
Rear lights connection (6 PIN)
C--184
LH cab SMV light connection
C--185
RH cab SMV light connection
JUMPERS CB--31
Battery cut--out circuit jumper
FUSES F--26
30A maxi--fuse (40A for North America)
F--160
125A Maxi--fuse
F--168
50A mega--fuse
F--169
50A mega--fuse
GROUND GND--7
Dashboard ground
GND--38
Rear ground
GND--57
Cab ground
GND--106
Four--wheel drive indicator ground
GND--155
Dashboard Power Shuttle ground
GND--181
Trailer brake circuit ground
GND--215
Power sockets ground
LAMPS LMP--20
RH front direction indicator and side light
LMP--22
LH front direction indicator and side light
LMP--45
RH tail light
LMP--48
LH tail light
LMP--69
Fan control unit lamp
LMP--76
Cab front RH work light
LMP--77
Cab front LH work light
LMP--78
Cab rear RH work light
LMP--79
Cab rear LH work light
LMP--80
RH cab SMV light
LMP--81
LH cab SMV light
LMP--82
Cab overhead lighting
LMP--119
Grille LH front work light
LMP--120
Front LH headlamp
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
COMPONENT
29
DESCRIPTION
LMP--121
Front RH headlamp
LMP--122
Grille RH front work light
LMP--178
Work light
LMP--210
Number plate light
LMP--212
Number plate light
LMP--213
RH two--faced headlight
LMP--214
LH two--faced headlight
MOTORS M--42
Front and rear window washer pumps
M--54
Wiper motor
M--56
Rear wiper motor
M--68
Ventilation and air--conditioning system electric fan
M--85
Starter motor
M--90
Air--conditioner compressor
ELECTRONIC MODULES - CONTROL UNITS MOD--11
Instrument
MOD--23
Electronic flasher
MOD--25
Fuse box and main relay
MOD--27
Rear lift electronic control unit
MOD--40
Working depth adjustment and rear electronic lift control panel
MOD--43
Rear electronic lift control panel
MOD--58
Radio
MOD--64
Permanent 4WD control unit
MOD--75
Fuse box and cab relays
MOD--102
Front electronic lift control panel
MOD--150
Power Shuttle control unit
MOD--156
Grid heater electronic module
MOD--177
Digital instrument
MOD--204
Four--wheel drive control unit
RESISTORS RES--66
Fan speed resistor unit
RES--159
Grid Heater
RELAYS RLY--70
Conditioner relay
RLY--110
Trailer brake circuit relay
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
30
COMPONENT
DESCRIPTION
RLY--157
Grid heater relay (coil)
RLY--158
Grid heater relay (contact)
SENSORS SEN--33
Tilt sensor
SEN--71
Air--conditioner electronic thermostat
SEN--86
Brake fluid level sensor
SEN--87
Air filter clogged sensor
SEN--89
Sediment unit filter sensor
SEN--91
Filter/dryer sensor
SEN--92
Engine oil pressure sensor
SEN--93
Coolant temperature sensor
SEN--101
Front lift arms position sensor
SEN--107
Trailer brake indicator light pressure switch
SEN--108
Trailer brake circuit safety pressure switch
SEN--112
Power steering indicator light pressure switch
SEN--123
Fuel level transmitter
SEN--124
Four--wheel drive indicator pressure switch
SEN--126
Steering sensor
SEN--127
Rear axle speed sensor
SEN--128
Front axle speed sensor
SEN--129
Advance speed sensor
SEN--130
Power take--off rpm sensor
SEN--131
Draft sensor
SEN--132
Arms position sensor
SEN--148
Transmission oil temperature sensor
SEN--153
Clutch pedal sensor
SEN--176
Engine rpm sensor
SEN--182
Transmission oil pressure sensor
SEN--203
Shuttle position sensor
SEN--208
Front PTO sensor
SOLENOID VALVES SOL--94
Engine cutout electromagnet
SOL--95
Solenoid valve to cut out starting advance, depending on temperature
SOL--99
Front lift UP solenoid valve
SOL--100
Front lift DOWN solenoid valve
SOL--109
Trailer brake solenoid valves
SOL--117
Differential lock solenoid valve
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
COMPONENT
31
DESCRIPTION
SOL--133
Rear electronic lift DOWN solenoid valve
SOL--134
Rear electronic lift UP solenoid valve
SOL--135
Four--wheel drive solenoid valve
SOL--138
HI--LO mode solenoid valve
SOL--139
Shuttle mode solenoid valve
SOL--140
Dump solenoid valve
SOL--146
Lo clutch solenoid valve
SOL--147
Hi clutch solenoid valve
CONTROL SWITCHES SW--10
Hazard lights switch
SW--12
Front PTO switch
SW--17
Front grille work lights switch
SW--19
Start switch
SW--30
Battery cut--out circuit switch
SW--32
Operator present switch
SW--34
Rear electronic lift up/down switch
SW--35
4WD control switch
SW--36
Differential lock switch
SW--37
LH rear external electronic lift up/down switch
SW--39
Parking brake switch
SW--44
RH rear external electronic lift up/down switch
SW--52
Front windscreen washer switch
SW--53
Windscreen wiper switch
SW--55
Rear window washer/wiper switch
SW--63
Rotating beacon control switch
SW--67
Ventilation and air--conditioning system electric fan switch
SW--72
Air conditioner control switch
SW--74
Work lights switch
SW--96
Starting advance thermometric cut--out switch
SW--97
External lights control switch
SW--103
Front lift up/down control switch
SW--104
Front PTO switch
SW--105
Front electronic lift block switch
SW--111
Rear PTO switch
SW--113
Lights switch
SW--114
Gearbox neutral switch
SW--115
Splitter switch
SW--116
Differential lock indicator switch
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
32
COMPONENT
DESCRIPTION
SW--125
Shuttle lever switch
SW--136
Stoplamp switch
SW--141
G1 ranges switch
SW--142
C1 gears switch
SW--143
Creeper switch
SW--151
Clutch pedal switch
SW--152
Power Shuttle control lever
SW--161
”Up/Down” control push--button
SW--162
”Enter” control push--button
SW--171
Front lift main switch
SW--183
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
SW--205
Front lift UP external control switch
SW--206
Front lift DOWN external control switch
SW--211
4WD indicator switch
POWER SOCKETS C--29
Rotating beacon power socket
C--46
8A two--pin socket
C--47
40 A four--pole power socket (North America)
C--49
25A two--pin socket
C--88
Cigar/Cigarette Lighter
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
33
VERSION INDEX The following pages contain the wiring diagrams for the five versions of the cab model, specifically:
VERSION
DESCRIPTION
PAGE
1
2WD VERSION, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR MECHANICAL LIFT
34 to 101
2
ELECTROHYDRAULIC FOUR--WHEEL DRIVE VERSION, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR MECHANICAL LIFT
102 to 172
3
ELECTROHYDRAULIC FOUR--WHEEL DRIVE VERSION, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR ELECTRONIC LIFT
173 to 248
4
PERMANENT FOUR--WHEEL DRIVE VERSION, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR MECHANICAL LIFT
249 to 320
5
PERMANENT FOUR--WHEEL DRIVE VERSION, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR ELECTRONIC LIFT
321 to 394
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
34
VERSION 1 2WD MODELS, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR MECHANICAL LIFT
Description
Wiring diagram circuits
Circuit 1
Battery cut--out circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Circuit 2
Power socket circuit, wiper/washer pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Circuit 3
Brakes, brake lights, differential lock circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Circuit 4
Direction indicator and hazard lights circuit (control switches and flasher) . . . . . . . . . . . . 46
Circuit 5
Grid--heater circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Circuit 6
Instrument and sensor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Circuit 7
Power take--off and safety device circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Circuit 8
Seven--pin socket and number plate light circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Circuit 9
External lights and horn circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Circuit 10
Power supplies 1 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Circuit 11
Power supplies 2 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Circuit 12
Trailer brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Circuit 13
Engine, sensors and transmitters circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Circuit 14
Safety and speed sensors circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Circuit 15
Intermediate connections circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Circuit 16
Cab ventilation and air--conditioning circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Circuit 17
Rotating beacon circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Circuit 18
Supplementary direction indicator lights and radio circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Circuit 19
Cab power supply circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Circuit 20
Windscreen and rear window washer/wiper circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Circuit 21
Work lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Circuit 22
Power Shuttle 8+8 / 16+16 circuit (dashboard side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Circuit 23
Power Shuttle circuit (transmission side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Circuit 24
Power Shuttle 32+16 / 44+16 circuit (dashboard side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Circuit 25
Power Shuttle circuit (transmission side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Circuit 26
Front PTO circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
87666787A - 11 - 2007
Page
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
35
ELECTRICAL CIRCUITS COMPONENTS VERSION 1
COMPONENT
NUMBER DIAGRAM
DESCRIPTION
C--1
6, 13
C--2
15, 17, 18, 19, 20, 21
C--3
12
Trailer brake circuit intermediate connection (4 PIN)
C--4
2
25A / 40A socket connection
C--5
9
Front lights connection
C--6
3, 6, 7, 14
GND--7
1, 4, 5, 6, 9, 11, 12, 13
C--8
12
C--9
22, 23, 24, 25
SW--10
4
Hazard lights switch
MOD--11
6
Instrument
SW--12
26
Front PTO switch
C--13
26
Front PTO and lift system connection (13 PIN)
C--14
8
Seven--pin socket connection
C--15
7
Gearbox neutral connection
C--16
5
Electronic thermostarter connection (6 PIN)
SW--17
4
Front grille work lights switch
SW--19
9, 10
LMP--20
9
RH front direction indicator and side light
C--21
15, 22, 24
Power--Shuttle system connection (6 PIN)
LMP--22
9
MOD--23
3, 4
C--24
6
MOD--25
9, 10, 11
F--26
9, 10
C--29
17
Rotating beacon power socket
SW--30
1
Battery cut--out circuit switch
C--31
1
Connection for battery cut--out circuit on engine
SW--32
14
Operator present switch
SW--36
3
Differential lock switch
GND--38
2, 3, 8, 9
SW--39
3
Parking brake switch
C--41
2
Seat connection
Front side connection -- engine (24 PIN) Cab system connection (20 PIN)
Transmission system connection (24 PIN) Dashboard ground Trailer brake circuit main connection (4 PIN) Power--Shuttle transmission system connection (24 PIN)
Start switch
LH front direction indicator and side light Electronic flasher Digital instrument connection Fuse box and main relay 30A maxi--fuse (40A for North America)
Rear ground
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
36 M--42
2
Front and rear window washer pumps
LMP--45
9
RH tail light
C--46
2
8A two--pin socket
C--47
2
40 A four--pole power socket (North America)
LMP--48
9
LH tail light
C--49
2
25A two--pin socket
SW--52
20
Front windscreen washer switch
SW--53
20
Windscreen wiper switch
M--54
20
Wiper motor
SW--55
20
Rear window washer/wiper switch
M--56
20
Rear wiper motor
GND--57
16, 17, 18, 19, 20, 21
MOD--58
18
Radio
AUD--60
18
RH speaker
AUD--61
18
LH speaker
C--62
16, 17
SW--63
17
Rotating beacon control switch
RES--66
16
Fan speed resistor unit
SW--67
16
Ventilation and air--conditioning system electric fan switch
M--68
16
Ventilation and air--conditioning system electric fan
LMP--69
16
Fan control unit lamp
RLY--70
16
Conditioner relay
SEN--71
16
Air--conditioner electronic thermostat
SW--72
16
Air conditioner control switch
C--73
21
Front work lights connection
SW--74
21
Work lights switch
MOD--75
19
Fuse box and cab relays
LMP--76
21
Cab front RH work light
LMP--77
21
Cab front LH work light
LMP--78
21
Cab rear RH work light
LMP--79
21
Cab rear LH work light
LMP--80
18
RH cab SMV light
LMP--81
18
LH cab SMV light
LMP--82
21
Cab overhead lighting
BAT--83
13
Battery
ALT--84
13
Alternator
M--85
13
Starter motor
SEN--86
13
Brake fluid level sensor
SEN--87
13
Air filter clogged sensor
C--88
17
Cigar/Cigarette Lighter
SEN--89
13
Sediment unit filter sensor
87666787A - 11 - 2007
Cab ground
Fan unit connection
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
37
M--90
13
Air--conditioner compressor
SEN--91
13
Filter/dryer sensor
SEN--92
13
Engine oil pressure sensor
SEN--93
13
Coolant temperature sensor
SOL--94
13
Engine cutout electromagnet
SOL--95
13
Solenoid valve to cut out starting advance, depending on temperature
SW--96
13
Starting advance thermometric cut--out switch
SW--97
4
External lights control switch
SOL--99
26
Front lift UP solenoid valve
SOL--100
26
Front lift DOWN solenoid valve
SEN--101
26
Front lift arms position sensor
MOD--102
26
Front electronic lift control panel
SW--103
26
Front lift up/down control switch
SW--104
7
Front PTO switch
GND--106
7
Four--wheel drive indicator ground
SEN--107
12
Trailer brake indicator light pressure switch
SEN--108
12
Trailer brake circuit safety pressure switch
SOL--109
12
Trailer brake solenoid valves
RLY--110
12
Trailer brake circuit relay
SW--111
7
Rear PTO switch
SEN--112
7
Power steering indicator light pressure switch
SW--114
7
Gearbox neutral switch
SW--115
7
Splitter switch
SW--116
3
Differential lock indicator switch
SOL--117
3
Differential lock solenoid valve
AUD--118
9
Horn
LMP--119
9
Grille LH front work light
LMP--120
9
Front LH headlamp
LMP--121
9
Front RH headlamp
LMP--122
9
Grille RH front work light
SEN--123
6
Fuel level transmitter
SEN--129
14
Advance speed sensor
SEN--130
6
Power take--off rpm sensor
SOL--135
7
Four--wheel drive solenoid valve
SW--136
3
Stoplamp switch
SOL--138
25
HI--LO mode solenoid valve
SOL--139
25
Shuttle mode solenoid valve
SOL--140
23, 25
Dump solenoid valve
SW--141
23, 25
G1 ranges switch
SW--142
23, 25
C1 gears switch
SW--143
25
Creeper switch
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
38 SOL--146
23, 25
Lo clutch solenoid valve
SOL--147
23, 25
Hi clutch solenoid valve
SEN--148
23, 25
Transmission oil temperature sensor
MOD--150
22, 24
Power Shuttle control unit
SW--151
22, 24
Clutch pedal switch
SW--152
22, 24
Power Shuttle control lever
SEN--153
22, 24
Clutch pedal sensor
GND--155
22, 24
Dashboard Power Shuttle ground
MOD--156
5
Grid heater electronic module
RLY--157
5
Grid heater relay (coil)
RLY--158
5
Grid heater relay (contact)
RES--159
5
Grid Heater
F--160
5
125A Maxi--fuse
C--166
3
Brake lights signal test connection
C--167
22, 24
F--168
13
50A mega--fuse
F--169
13
50A mega--fuse
C--175
7
Four--wheel drive system connection (4 PIN)
SEN--176
14
Engine rpm sensor
GND--181
12
Trailer brake circuit ground
SEN--182
23
Transmission oil pressure sensor
SW--183
25
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
C--184
18
LH cab SMV light connection
C--185
18
RH cab SMV light connection
SEN--203
25
Shuttle position sensor
MOD--204
26
Four--wheel drive control unit
SW--205
26
Front lift UP external control switch
SW--206
26
Front lift DOWN external control switch
SEN--208
26
Front PTO sensor
LMP--210
8
Number plate light
SW--211
7
4WD indicator switch
87666787A - 11 - 2007
Connection for CAN line (4 PIN)
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
39
WIRING DIAGRAMS 1--2--3--4
MPM0702A
22 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
40
BATTERY CUT--OUT CIRCUIT (Diagram 1)
GND--7
Dashboard ground
SW--30
Battery cut--out circuit switch
C--31 CB--31
Connection for battery cut--out circuit on engine Battery cut--out circuit jumper
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
41 BATTERY CUT--OUT CIRCUIT -- DIAGRAM 1
MPH2110A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
42
POWER SOCKETS, WIPER/WASHER PUMPS CIRCUIT (Diagram 2)
C--4 GND--38
25A and 40A power socket connection Rear ground
C--41
Seat connection
M--42
Front and rear window washer pumps
C--46
8A two--pin socket
C--47
40 A four--pole power socket (North America)
C--49
25A two--pin socket
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
43
POWER SOCKETS, WIPER/WASHER PUMPS CIRCUIT -- DIAGRAM 2
MPH2111A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
44
BRAKES, BRAKE LIGHTS, DIFFERENTIAL LOCK CIRCUIT (Diagram 3)
C--6 MOD--25
Transmission system connection (24 PIN) Fuse box and main relay RLY--1
Brake lights circuit
RLY--2
Differential lock circuit
RLY--6
Differential lock circuit
F--19 SW--36 GND--38
Stop Lights
Differential lock switch Rear ground
SW--39
Parking brake switch
SW--116
Differential lock indicator switch
SOL--117
Differential lock solenoid valve
SW--136
Stoplamp switch
C--166
Brake lights signal test connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
45
BRAKES, BRAKE LIGHTS, DIFFERENTIAL LOCK CIRCUIT -- DIAGRAM 3
MPH2105A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
46
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (control switches and flasher) (Diagram 4)
GND--7
Dashboard ground
SW--10
Hazard lights switch
SW--17
Front grille work lights switch
MOD--23 SW--97
Electronic flasher External lights control switch
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
47
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (control switches and flasher) -- DIAGRAM 4
MPH2112A
87666787A - 11 - 2007
48
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
49
WIRING DIAGRAMS 5--6--7
MPM0703A
23 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
50
GRID HEATER CIRCUIT (Diagram 5)
GND--7 C--16
Dashboard ground Electronic thermostarter connection (6 PIN)
MOD--156 Grid heater electronic module RLY--157
Grid heater relay (coil)
RLY--158
Grid heater relay (contact)
RES--159
Grid Heater
F--160
125A Maxi--fuse
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
51 GRID--HEATER CIRCUIT -- DIAGRAM 5
MPH2113A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
52
INSTRUMENT AND SENSOR CIRCUIT (Diagram 6)
C--1
Front side connection -- engine (24 PIN)
C--6
Transmission system connection (24 PIN)
GND--7 MOD--11
C--24
Dashboard ground Instrument A
Right turn signal indicator (green)
B
Handbrake indicator (red)
C
Work lights indicator (amber)
D
Full--beam indicator light (blue)
E
Left turn signal indicator (green)
F
Battery charging system malfunction light (red)
G
Engine oil pressure warning indicator (red)
H
Power steering oil pressure indicator (red)
I
Power Shuttle alarm
J
PTO indicator
K
4WD indicator (indicator)
L
High gear range engaged indicator (green)
M
Low gear range engaged indicator
N
Side lights indicator (green)
O
Clogged engine air filter indicator (amber)
P
Second trailer turn signal indicator (green)
Q
First trailer turn signal indicator (green)
R
Brake fluid level indicator (amber)
S
Grid heater indicator (amber)
T
4WD fault indicator
U
Front power take--off indicator
V
Trailer brake indicator (red)
W
Instrument lighting
X
Automatic four--wheel drive indicator (green)
Y
Front lift unit indicator
Z
Differential lock indicator (amber)
a
Fuel gauge
b
Engine coolant temperature gauge
Digital instrument connection
SEN--123
Fuel level transmitter
SEN--130
Power take--off rpm sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
53 INSTRUMENT AND SENSOR CIRCUIT -- DIAGRAM 6
MPH2106A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
54
POWER TAKE--OFF AND SAFETY DEVICE CIRCUIT (Diagram 7)
C--6
Transmission system connection (24 PIN)
C--15
Gearbox neutral connection
SW--104
Front PTO switch
GND--106 Four--wheel drive indicator ground SW--111
Rear PTO switch
SEN--112
Power steering indicator light pressure switch
SW--114
Gearbox neutral switch
SW--115
Splitter switch
SOL--135
Four--wheel drive solenoid valve
C--175 SW--211
* **
Four--wheel drive system connection (4 PIN) 4WD indicator switch
Standard version Splitter version
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
55
POWER TAKE--OFF AND SAFETY DEVICE CIRCUIT -- DIAGRAM 7
MPH2107A
87666787A - 11 - 2007
56
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
57
WIRING DIAGRAMS 8--9--10--11
MPM0704A
24 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
58
SEVEN--PIN SOCKET AND NUMBER PLATE LIGHT CIRCUIT (Diagram 8)
C--14
7--pin socket connection
C--14A
ISO seven--pin socket
C--14B
North American seven--pin socket
GND--38
Rear ground
LMP--210
Number plate light
* **
ISO version North America version
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
59
SEVEN--PIN SOCKET AND NUMBER PLATE LIGHT CIRCUIT -- DIAGRAM 8
MPH2114A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
60
EXTERNAL LIGHTS AND HORN CIRCUIT (Diagram 9)
C--5
Front lights connection
GND--7
Dashboard ground
LMP--20
RH front direction indicator and side light
LMP--22
LH front direction indicator and side light
MOD--25
Fuse box and main relay F--9
Direction indicator and hazard lights
F--10
Horn, full beam flasher
GND--38
Rear ground
LMP--45
RH tail light
LMP--48
LH tail light
AUD--118
Horn
LMP--119
Grille LH front work light
LMP--120
Front LH headlamp
LMP--121
Front RH headlamp
LMP--122
Grille RH front work light
* **
ISO version North America version
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
61 EXTERNAL LIGHTS AND HORN CIRCUIT -- DIAGRAM 9
MPH2115A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
62
POWER SUPPLIES 1 CIRCUIT (Diagram 10)
SW--19 MOD--25
F--26
Start switch Fuse box and main relay F--1
Front right--hand and rear left--hand side lights, side lights indicator
F--2
Front left--hand and rear right--hand side lights, control instrument panel light
F--3
ISO side lights, or 7--pin work light (North America)
F--4
Full beam headlights
F--5
Dipped beam headlights
F--6
+Instrument common
F--7
Differential lock circuit
F--11
Starter safety circuit
F--12
Engine cut--out electromagnet
F--13
Power Shuttle circuit
F--14
Power Shuttle circuit
F--15
Swivel position lights, seat, cab users relay
F--16
Trailer brake and hydraulic adjustment circuit
F--20
Grid--heater circuit
F--25
Electronic control unit power supply, +battery, seat safety circuit
F--30
Radio
30A maxi--fuse (40A for North America)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
63 POWER SUPPLIES 1 CIRCUIT -- DIAGRAM 10
MPH2108A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
64
POWER SUPPLIES 2 CIRCUIT (Diagram 11)
GND--7 MOD--25
Dashboard ground Fuse box and main relay RLY--2
Differential lock circuit
RLY--3
Differential lock circuit
RLY--4
Differential lock circuit
RLY--5
Full beam headlight circuit
RLY--10
Side lights circuit
RLY--13
Engine starter circuit maxi--relay
F--8
87666787A - 11 - 2007
8A power socket, digital instrument
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
65 POWER SUPPLIES 2 CIRCUIT -- DIAGRAM 11
MPH2116A
87666787A - 11 - 2007
66
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
67
WIRING DIAGRAMS 12--13--14--15
MPM0705A
25 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
68
TRAILER BRAKE CIRCUIT (Diagram 12)
C--3 GND--7
Trailer brake circuit intermediate connection (4 PIN) Dashboard ground
C--8
Trailer brake circuit main connection (4 PIN)
SEN--107
Trailer brake indicator light pressure switch
SEN--108
Trailer brake circuit safety pressure switch
SOL--109
Trailer brake solenoid valves
RLY--110
Trailer brake circuit relay RLY--9
Trailer brake circuit
RLY--10
Trailer brake circuit
RLY--13
Trailer brake circuit
GND--181 Trailer brake circuit ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
69 TRAILER BRAKE CIRCUIT -- DIAGRAM 12
MPH2117A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
70
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT (Diagram 13)
C--1
Front side connection -- engine (24 PIN)
GND--7
Dashboard ground
BAT--83
Battery
ALT--84
Alternator
M--85
Starter motor
SEN--86
Brake fluid level sensor
SEN--87
Air filter clogged sensor
SEN--89
Sediment unit filter sensor
M--90
Air--conditioner compressor
SEN--91
Filter/dryer sensor
SEN--92
Engine oil pressure sensor
SEN--93
Coolant temperature sensor
SOL--94
Engine cutout electromagnet
SOL--95
Solenoid valve to cut out starting advance, depending on temperature
SW--96
Starting advance thermometric cut--out switch
F--168
50A mega--fuse
F--169
50A mega--fuse
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
71
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT -- DIAGRAM 13
MPH2118A
87666787A - 11 - 2007
72
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 SAFETY AND SPEED SENSORS CIRCUIT (Diagram 14)
C--6
Transmission system connection (24 PIN)
SW--32
Operator present switch
SEN--129
Advance speed sensor
SEN--176 (NEF)
Engine rpm sensor (for engine on models 4040 and 4050)
SEN--176 (F5C)
Engine rpm sensor (for F5C engine)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
73 SAFETY AND SPEED SENSORS CIRCUIT-- DIAGRAM 14
MPH2109A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
74
INTERMEDIATE CONNECTIONS CIRCUIT (Diagram 15)
C--2
Cab system connection (20 PIN)
C--21
Power--Shuttle system connection (6 PIN)
NC = Not connected
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
75 INTERMEDIATE CONNECTIONS CIRCUIT -- DIAGRAM 15
MPH2119A
87666787A - 11 - 2007
76
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
77
WIRING DIAGRAMS 16--17--18--19--20--21
MPM0706A
26 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
78
CAB VENTILATION AND AIR--CONDITIONING CIRCUIT (Diagram 16)
GND--57 C--62
Cab ground Fan unit connection
RES--66
Fan speed resistor unit
SW--67
Ventilation and air--conditioning system electric fan switch
M--68
Ventilation and air--conditioning system electric fan
LMP--69
Fan control unit lamp
RLY--70
Conditioner relay
SEN--71
Air--conditioner electronic thermostat
SW--72
Air conditioner control switch
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
79
CAB VENTILATION AND AIR--CONDITIONING CIRCUIT -- DIAGRAM 16
MPH2124A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
80
ROTATING BEACON CIRCUIT (Diagram 17)
C--2
Cab system connection (20 PIN)
C--29
Rotating beacon power socket
GND--57 C--62 SW--63 C--88
Cab ground Fan unit connection Rotating beacon control switch Cigar/Cigarette Lighter
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
81 ROTATING BEACON CIRCUIT -- DIAGRAM 17
MPL0059A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
82
SUPPLEMENTARY DIRECTION INDICATOR LIGHTS AND RADIO CIRCUIT (Diagram 18)
C--2
Cab system connection (20 PIN)
GND--57
Cab ground
MOD--58
Radio
AUD--60
RH speaker
AUD--61
LH speaker
LMP--80
RH cab SMV light
LMP--81
LH cab SMV light
C--184
LH cab SMV light connection
C--185
RH cab SMV light connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
83
SUPPLEMENTARY DIRECTION INDICATOR LIGHTS AND RADIO CIRCUIT -- DIAGRAM 18
MPL0060A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
84
CAB POWER SUPPLIES CIRCUIT (Diagram 19)
C--2
Cab system connection (20 PIN)
GND--57
Cab ground
MOD--75
Fuse box and cab relays RLY--1
Rear work lights circuit
RLY--2
Ignition switch controlled cab users circuit
RLY--3
Air--conditioner compressor circuit
RLY--4
Front work lights circuit
F--1
Front work lights
F--2
Rear work lights
F--3
Rotating beacon, cigar lighter, overhead lighting, radio
F--4
Rear window wiper/washer
F--5
Windscreen wiper/washer
F--6
Air conditioning, fan unit
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
85 CAB POWER SUPPLIES CIRCUIT -- DIAGRAM 19
MPL0061A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
86
WINDSCREEN AND REAR WINDOW WASHER/WIPER CIRCUIT (Diagram 20)
C--2
Cab system connection (20 PIN)
SW--52
Front windscreen washer switch
SW--53
Windscreen wiper switch
M--54 SW--55 M--56 GND--57
Wiper motor Rear window washer/wiper switch Rear wiper motor Cab ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
87 WIPER/WASHER CIRCUIT -- DIAGRAM 20
MPL0062A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
88
WORK LIGHTS CIRCUIT (Diagram 21)
C--2 GND--57 C--73
Cab system connection (20 PIN) Cab ground Front work lights connection
SW--74
Work lights switch
LMP--76
Cab front RH work light
LMP--77
Cab front LH work light
LMP--78
Cab rear RH work light
LMP--79
Cab rear LH work light
LMP--82
Cab overhead lighting
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
89 WORK LIGHTS CIRCUIT -- DIAGRAM 21
MPL0063A
87666787A - 11 - 2007
90
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
91
WIRING DIAGRAMS 22--23--24--25--26
MPM0707A
27 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
92
POWER--SHUTTLE CIRCUIT 8+8 / 16+16 (dashboard side) (Diagram 22)
C--9
Power--Shuttle transmission system connection (24 PIN)
C--21
Power--Shuttle system connection (6 PIN)
MOD--150 Power Shuttle control unit SW--151
Clutch pedal switch
SW--152
Power Shuttle control lever
SEN--153
Clutch pedal sensor
GND--155 Dashboard Power Shuttle ground C--167
Connection for CAN line (4 PIN)
NC = Not connected
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
93
POWER SHUTTLE CIRCUIT 8+8 / 16+16 (dashboard side) -- DIAGRAM 22
MPH2122A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
94
POWER SHUTTLE CIRCUIT (transmission side) (Diagram 23)
C--9
Power--Shuttle transmission system connection (24 PIN)
SOL--140
Dump solenoid valve
SW--141
G1 ranges switch
SW--142
C1 gears switch
SOL--146
Lo clutch solenoid valve
SOL--147
Hi clutch solenoid valve
SEN--148
Transmission oil temperature sensor
SEN--182
Transmission oil pressure sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
95 POWER SHUTTLE CIRCUIT (transmission side) -- DIAGRAM 23
MPH2123A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
96
POWER--SHUTTLE CIRCUIT 32+16 / 44+16 (dashboard side) (Diagram 24)
C--9
Power--Shuttle transmission system connection (24 PIN)
C--21
Power--Shuttle system connection (6 PIN)
MOD--150 Power Shuttle control unit SW--151
Clutch pedal switch
SW--152
Power Shuttle control lever
SEN--153
Clutch pedal sensor
GND--155 Dashboard Power Shuttle ground C--167
Connection for CAN line (4 PIN)
NC = Not connected
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
97
POWER SHUTTLE CIRCUIT 32+16 / 44+16 (dashboard side) -- DIAGRAM 24
MPH2120A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
98
POWER SHUTTLE CIRCUIT (transmission side) (Diagram 25)
C--9
Power--Shuttle transmission system connection (24 PIN)
SOL--138
HI--LO mode solenoid valve
SOL--139
Shuttle mode solenoid valve
SOL--140
Dump solenoid valve
SW--141
G1 ranges switch
SW--142
C1 gears switch
SW--143
Creeper switch
SOL--146
Lo clutch solenoid valve
SOL--147
Hi clutch solenoid valve
SEN--148
Transmission oil temperature sensor
SW--183
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
SEN--203
Shuttle position sensor
* **
Version with Power Shuttle 44+16 e 32+16 with Dual Command (2 Speed Power Shift) function Version with Power Shuttle 44+16 e 32+16 with Dual Command (2 Speed Power Shift) function (paddy field version)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
99 POWER SHUTTLE CIRCUIT (transmission side) -- DIAGRAM 25
MPH2121A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
100
FRONT PTO CIRCUIT (Diagram 26)
SW--12 C--13
Front PTO switch Front PTO and lift system connection (13 PIN)
SOL--99
Front lift UP solenoid valve
SOL--100
Front lift DOWN solenoid valve
SEN--101
Front lift arms position sensor
MOD--102 Front electronic lift control panel SW--103
Front lift up/down control switch
MOD--204 Four--wheel drive control unit SW--205
Front lift UP external control switch
SW--206
Front lift DOWN external control switch
SEN--208
Front PTO sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
101 FRONT PTO CIRCUIT -- DIAGRAM 26
MPL0064A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
102
VERSION 2 ELECTROHYDRAULIC FOUR--WHEEL DRIVE, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR MECHANICAL LIFT
Description
Wiring diagram circuits
Circuit 1
Four--wheel drive circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Circuit 2
Battery cut--out circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Circuit 3
Power socket circuit, wiper/washer pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Circuit 4
Brakes, brake lights, differential lock circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Circuit 5
Direction indicator and hazard lights circuit (control switches and flasher) . . . . . . . . . . . . 118
Circuit 6
Grid--heater circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Circuit 7
Instrument and sensor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Circuit 8
Power take--off and safety device circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Circuit 9
Seven--pin socket and number plate light circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Circuit 10
External lights and horn circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Circuit 11
Power supplies 1 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Circuit 12
Power supplies 2 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Circuit 13
Engine, sensors and transmitters circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Circuit 14
Intermediate connections circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Circuit 15
Trailer brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Circuit 16
Cab ventilation and air--conditioning circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Circuit 17
Rotating beacon circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Circuit 18
Supplementary direction indicator lights and radio circuit . . . . . . . . . . . . . . . . . . . . . . . . . 150
Circuit 19
Cab power supply circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Circuit 20
Windscreen and rear window washer/wiper circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Circuit 21
Work lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Circuit 22
Power Shuttle 8+8 / 16+16 circuit (dashboard side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Circuit 23
Power Shuttle circuit (transmission side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Circuit 24
Power Shuttle 32+16 / 44+16 circuit (dashboard side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Circuit 25
Power Shuttle circuit (transmission side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Circuit 26
Front PTO circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Circuit 27
Digital instrument circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
87666787A - 11 - 2007
Page
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
103
ELECTRICAL CIRCUITS COMPONENTS VERSION 2
COMPONENT
NUMBER DIAGRAM
DESCRIPTION
C--1
7, 13
C--2
14, 17, 18, 19, 20, 21
C--3
15
Trailer brake circuit intermediate connection (4 PIN)
C--4
3
25A / 40A socket connection
C--5
10
Front lights connection
C--6
4, 7, 8, 15
GND--7
1, 2, 5, 6, 7, 10, 12, 13, 15
C--8
15
C--9
22, 23, 24, 25
SW--10
5
MOD--11
7, 27
SW--12
26
Front PTO switch
C--13
26
Front PTO and lift system connection (13 PIN)
C--14
9
Seven--pin socket connection
C--15
8
Gearbox neutral connection
C--16
6
Electronic thermostarter connection (6 PIN)
SW--17
5
Front grille work lights switch
SW--19
11
Start switch
LMP--20
10
RH front direction indicator and side light
C--21
14, 22, 24
Power--Shuttle system connection (6 PIN)
LMP--22
10
LH front direction indicator and side light
MOD--23
5
Electronic flasher
C--24
1, 7, 27
MOD--25
4, 10, 11, 12
F--26
11
30A maxi--fuse (40A for North America)
C--28
27
Diagnostics connection
C--29
17
Rotating beacon power socket
SW--30
2
Battery cut--out circuit switch
C--31
2
Connection for battery cut--out circuit on engine
SW--32
15
Operator present switch
SW--35
1
4WD control switch
SW--36
4
Differential lock switch
GND--38
1, 3, 9, 10
Front side connection -- engine (24 PIN) Cab system connection (20 PIN)
Transmission system connection (24 PIN) Dashboard ground Trailer brake circuit main connection (4 PIN) Power--Shuttle transmission system connection (24 PIN) Hazard lights switch Instrument
Digital instrument connection Fuse box and main relay
Rear ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
104 SW--39
4
Parking brake switch
C--41
3
Seat connection
M--42
3
Front and rear window washer pumps
LMP--45
10
RH tail light
C--46
3
8A two--pin socket
C--47
3
40 A four--pole power socket (North America)
LMP--48
10
LH tail light
C--49
3
25A two--pin socket
SW--52
20
Front windscreen washer switch
SW--53
20
Windscreen wiper switch
M--54
20
Wiper motor
SW--55
20
Rear window washer/wiper switch
M--56
20
Rear wiper motor
GND--57
16, 17, 18, 19, 20, 21
MOD--58
18
Radio
AUD--60
18
RH speaker
AUD--61
18
LH speaker
C--62
16, 17
SW--63
17
Rotating beacon control switch
RES--66
16
Fan speed resistor unit
SW--67
16
Ventilation and air--conditioning system electric fan switch
M--68
16
Ventilation and air--conditioning system electric fan
LMP--69
16
Fan control unit lamp
RLY--70
16
Conditioner relay
SEN--71
16
Air--conditioner electronic thermostat
SW--72
16
Air conditioner control switch
C--73
21
Front work lights connection
SW--74
21
Work lights switch
MOD--75
19
Fuse box and cab relays
LMP--76
21
Cab front RH work light
LMP--77
21
Cab front LH work light
LMP--78
21
Cab rear RH work light
LMP--79
21
Cab rear LH work light
LMP--80
18
RH cab SMV light
LMP--81
18
LH cab SMV light
LMP--82
21
Cab overhead lighting
BAT--83
13
Battery
ALT--84
13
Alternator
M--85
13
Starter motor
SEN--86
13
Brake fluid level sensor
SEN--87
13
Air filter clogged sensor
87666787A - 11 - 2007
Cab ground
Fan unit connection
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
105
C--88
17
Cigar/Cigarette Lighter
SEN--89
13
Sediment unit filter sensor
M--90
13
Air--conditioner compressor
SEN--91
13
Filter/dryer sensor
SEN--92
13
Engine oil pressure sensor
SEN--93
13
Coolant temperature sensor
SOL--94
13
Engine cutout electromagnet
SOL--95
13
Solenoid valve to cut out starting advance, depending on temperature
SW--96
13
Starting advance thermometric cut--out switch
SW--97
5
External lights control switch
SOL--99
26
Front lift UP solenoid valve
SOL--100
26
Front lift DOWN solenoid valve
SEN--101
26
Front lift arms position sensor
MOD--102
26
Front electronic lift control panel
SW--103
26
Front lift up/down control switch
SW--104
8
Front PTO switch
GND--106
8
Four--wheel drive indicator ground
SEN--107
15
Trailer brake indicator light pressure switch
SEN--108
15
Trailer brake circuit safety pressure switch
SOL--109
15
Trailer brake solenoid valves
RLY--110
15
Trailer brake circuit relay
SW--111
8
Rear PTO switch
SEN--112
8
Power steering indicator light pressure switch
SW--114
8
Gearbox neutral switch
SW--115
8
Splitter switch
SW--116
4
Differential lock indicator switch
SOL--117
4
Differential lock solenoid valve
AUD--118
10
Horn
LMP--119
10
Grille LH front work light
LMP--120
10
Front LH headlamp
LMP--121
10
Front RH headlamp
LMP--122
10
Grille RH front work light
SEN--123
7
Fuel level transmitter
SEN--124
8
Four--wheel drive indicator pressure switch
SEN--129
15
Advance speed sensor
SEN--130
7
Power take--off rpm sensor
SOL--135
8
Four--wheel drive solenoid valve
SW--136
4
Stoplamp switch
SOL--138
25
HI--LO mode solenoid valve
SOL--139
25
Shuttle mode solenoid valve
SOL--140
23, 25
Dump solenoid valve
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
106 SW--141
23, 25
G1 ranges switch
SW--142
23, 25
C1 gears switch
SW--143
25
Creeper switch
SOL--146
23, 25
Lo clutch solenoid valve
SOL--147
23, 25
Hi clutch solenoid valve
SEN--148
23, 25
Transmission oil temperature sensor
MOD--150
22, 24
Power Shuttle control unit
SW--151
22, 24
Clutch pedal switch
SW--152
22, 24
Power Shuttle control lever
SEN--153
22, 24
Clutch pedal sensor
GND--155
22, 24
Dashboard Power Shuttle ground
MOD--156
6
Grid heater electronic module
RLY--157
6
Grid heater relay (coil)
RLY--158
6
Grid heater relay (contact)
RES--159
6
Grid Heater
F--160
6
125A Maxi--fuse
SW--161
27
”Up/Down” control push--button
SW--162
27
”Enter” control push--button
C--166
4
Brake lights signal test connection
C--167
22, 24, 27
F--168
13
50A mega--fuse
F--169
13
50A mega--fuse
C--175
8
Four--wheel drive system connection (4 PIN)
SEN--176
15
Engine rpm sensor
GND--181
15
Trailer brake circuit ground
SEN--182
23
Transmission oil pressure sensor
SW--183
25
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
C--184
18
LH cab SMV light connection
C--185
18
RH cab SMV light connection
SEN--203
25
Shuttle position sensor
MOD--204
26
Four--wheel drive control unit
SW--205
26
Front lift UP external control switch
SW--206
26
Front lift DOWN external control switch
SEN--208
26
Front PTO sensor
LMP--210
9
Number plate light
87666787A - 11 - 2007
Connection for CAN line (4 PIN)
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
107
WIRING DIAGRAMS 1--2--3--4
MPM0715A
28 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
108
FOUR--WHEEL DRIVE CIRCUIT (Diagram 1)
GND--7 C--24 SW--35 GND--38
Dashboard ground Digital instrument connection 4WD control switch Rear ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
109 FOUR--WHEEL DRIVE CIRCUIT -- DIAGRAM 1
MPL0070A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
110
BATTERY CUT--OUT CIRCUIT (Diagram 2)
GND--7
Dashboard ground
SW--30
Battery cut--out circuit switch
C--31 CB--31
Connection for battery cut--out circuit on engine Battery cut--out circuit jumper
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
111 BATTERY CUT--OUT CIRCUIT -- DIAGRAM 2
CB- 31
MPL0065A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
112
POWER SOCKETS, WIPER/WASHER PUMPS CIRCUIT (Diagram 3)
C--4 GND--38
25A and 40A power socket connection Rear ground
C--41
Seat connection
M--42
Front and rear window washer pumps
C--46
8A two--pin socket
C--47
40 A four--pole power socket (North America)
C--49
25A two--pin socket
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
113
POWER SOCKETS, WIPER/WASHER PUMPS CIRCUIT -- DIAGRAM 3
MPL0074A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
114
BRAKES, BRAKE LIGHTS, DIFFERENTIAL LOCK CIRCUIT (Diagram 4)
C--6 MOD--25
Transmission system connection (24 PIN) Fuse box and main relay RLY--1
Brake lights circuit
RLY--2
Differential lock circuit
RLY--3
Differential lock circuit
RLY--6
Differential lock circuit
RLY--7
4WD and brake lights circuit
F--19
Stop Lights
F--25
Electronic control unit power supply, (+battery), seat safety circuit
SW--36
Differential lock switch
SW--39
Parking brake switch
SW--116
Differential lock indicator switch
SOL--117
Differential lock solenoid valve
SW--136
Stoplamp switch
C--166
Brake lights signal test connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
115
BRAKES, BRAKE LIGHTS, DIFFERENTIAL LOCK CIRCUIT -- DIAGRAM 4
MPL0071A
87666787A - 11 - 2007
116
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
117
WIRING DIAGRAMS 5--6--7--8
MPM0716A
29 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
118
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (control switches and flasher) (Diagram 5)
GND--7
Dashboard ground
SW--10
Hazard lights switch
SW--17
Front grille work lights switch
MOD--23 SW--97
Electronic flasher External lights control switch
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
119
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (control switches and flasher) -- DIAGRAM 5
MPL0066A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
120
GRID HEATER CIRCUIT (Diagram 6)
GND--7 C--16
Dashboard ground Electronic thermostarter connection (6 PIN)
MOD--156 Grid heater electronic module RLY--157
Grid heater relay (coil)
RLY--158
Grid heater relay (contact)
RES--159
Grid Heater
F--160
125A Maxi--fuse
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
121 GRID--HEATER CIRCUIT -- DIAGRAM 6
MPL0075A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
122
INSTRUMENT AND SENSOR CIRCUIT (Diagram 7)
C--1
Front side connection -- engine (24 PIN)
C--6
Transmission system connection (24 PIN)
GND--7 MOD--11
C--24
Dashboard ground Instrument A
Right turn signal indicator (green)
B
Handbrake indicator (red)
C
Work lights indicator (amber)
D
Full--beam indicator light (blue)
E
Left turn signal indicator (green)
F
Battery charging system malfunction light (red)
G
Engine oil pressure warning indicator (red)
H
Power steering oil pressure indicator (red)
I
Power Shuttle alarm
J
PTO indicator
K
4WD indicator (indicator)
L
High gear range engaged indicator (green)
M
Low gear range engaged indicator
N
Side lights indicator (green)
O
Clogged engine air filter indicator (amber)
P
Second trailer turn signal indicator (green)
Q
First trailer turn signal indicator (green)
R
Brake fluid level indicator (amber)
S
Grid heater indicator (amber)
T
4WD fault indicator
U
Front power take--off indicator
V
Trailer brake indicator (red)
W
Instrument lighting
X
Automatic four--wheel drive indicator (green)
Y
Front lift unit indicator
Z
Differential lock indicator (amber)
a
Fuel gauge
b
Engine coolant temperature gauge
Digital instrument connection
SEN--123
Fuel level transmitter
SEN--130
Power take--off rpm sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
123 INSTRUMENT AND SENSOR CIRCUIT -- DIAGRAM 7
MPL0067A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
124
POWER TAKE--OFF AND SAFETY DEVICE CIRCUIT (Diagram 8)
C--6
Transmission system connection (24 PIN)
C--15
Gearbox neutral connection
SW--104
Front PTO switch
GND--106 Four--wheel drive indicator ground SW--111
Rear PTO switch
SEN--112
Power steering indicator light pressure switch
SW--114
Gearbox neutral switch
SW--115
Splitter switch
SEN--124
Four--wheel drive indicator pressure switch
SOL--135
Four--wheel drive solenoid valve
C--175
* **
Four--wheel drive system connection (4 PIN)
Standard version Splitter version
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
125
POWER TAKE--OFF AND SAFETY DEVICE CIRCUIT -- DIAGRAM 8
MPL0069A
87666787A - 11 - 2007
126
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
127
WIRING DIAGRAMS 9--10--11--12
MPM0717A
30 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
128
SEVEN--PIN SOCKET AND NUMBER PLATE LIGHT CIRCUIT (Diagram 9)
C--14
7--pin socket connection
C--14A
ISO seven--pin socket
C--14B
North American seven--pin socket
GND--38
Rear ground
LMP--210
Number plate light
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
129
SEVEN--PIN SOCKET AND NUMBER PLATE LIGHT CIRCUIT -- DIAGRAM 9
MPL0076A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
130
EXTERNAL LIGHTS AND HORN CIRCUIT (Diagram 10)
C--5
Front lights connection
GND--7
Dashboard ground
LMP--20
RH front direction indicator and side light
LMP--22
LH front direction indicator and side light
MOD--25
Fuse box and main relay F--9
Direction indicator and hazard lights
F--10
Horn, full beam flasher, seat safety circuit
GND--38
Rear ground
LMP--45
RH tail light
LMP--48
LH tail light
AUD--118
Horn
LMP--119
Grille LH front work light
LMP--120
Front LH headlamp
LMP--121
Front RH headlamp
LMP--122
Grille RH front work light
* **
ISO version North America version
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
131 EXTERNAL LIGHTS AND HORN CIRCUIT -- DIAGRAM 10
MPL0077A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
132
POWER SUPPLIES 1 CIRCUIT (Diagram 11)
SW--19 MOD--25
F--26
Start switch Fuse box and main relay F--1
Front right--hand and rear left--hand side lights, side lights indicator
F--2
Front left--hand and rear right--hand side lights, control instrument panel light
F--3
ISO side lights, or 7--pin work light (North America)
F--4
Full beam headlights
F--5
Dipped beam headlights
F--11
Starter safety circuit
F--12
Engine cut--out electromagnet
F--13
Power Shuttle circuit
F--14
Power Shuttle circuit
F--15
Swivel position lights, seat, cab users relay
F--16
Trailer brake and hydraulic adjustment circuit
F--20
GRID--HEATER control unit circuit
F--30
Radio
30A maxi--fuse (40A for North America)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
133 POWER SUPPLIES 1 CIRCUIT -- DIAGRAM 11
MPL0080A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
134
POWER SUPPLIES 2 CIRCUIT (Diagram 12)
GND--7 MOD--25
Dashboard ground Fuse box and main relay RLY--2
Differential lock circuit
RLY--3
Differential lock circuit
RLY--4
Differential lock circuit
RLY--5
Full beam headlight circuit
RLY--6
Dipped beam headlight circuit
RLY--13
Engine starter circuit maxi--relay
F--6
+Instrument common
F--7
Differential lock circuit, four--wheel drive circuit
F--8
8A power socket, digital instrument
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
135 POWER SUPPLIES 2 CIRCUIT -- DIAGRAM 12
MPL0072A
87666787A - 11 - 2007
136
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
137
WIRING DIAGRAMS 13--14--15
MPM0718A
31 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
138
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT (Diagram 13)
C--1
Front side connection -- engine (24 PIN)
GND--7
Dashboard ground
BAT--83
Battery
ALT--84
Alternator
M--85
Starter motor
SEN--86
Brake fluid level sensor
SEN--87
Air filter clogged sensor
SEN--89
Sediment unit filter sensor
M--90
Air--conditioner compressor
SEN--91
Filter/dryer sensor
SEN--92
Engine oil pressure sensor
SEN--93
Coolant temperature sensor
SOL--94
Engine cutout electromagnet
SOL--95
Solenoid valve to cut out starting advance, depending on temperature
SW--96
Starting advance thermometric cut--out switch
F--168
50A mega--fuse
F--169
50A mega--fuse
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
139
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT -- DIAGRAM 13
MPL0068A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
140
INTERMEDIATE CONNECTIONS CIRCUIT (Diagram 14)
C--2
Cab system connection (20 PIN)
C--21
Power--Shuttle system connection (6 PIN)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
141 INTERMEDIATE CONNECTIONS CIRCUIT -- DIAGRAM 14
MPL0078A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
142
TRAILER BRAKE CIRCUIT (Diagram 15)
C--3
Trailer brake circuit intermediate connection (4 PIN)
C--6
Transmission system connection (24 PIN) Dashboard ground
GND--7
Trailer brake circuit main connection (4 PIN)
C--8
Operator present switch
SW--32 SEN--107
Trailer brake indicator light pressure switch
SEN--108
Trailer brake circuit safety pressure switch
SOL--109
Trailer brake solenoid valves
RLY--110
Trailer brake circuit relay RLY--9
Trailer brake circuit
RLY--10
Trailer brake circuit
RLY--13
Trailer brake circuit
SEN--129
Advance speed sensor
SEN--176 (NEF) Engine rpm sensor (for engine on models 4040 and 4050) SEN--176 (F5C) GND--181
87666787A - 11 - 2007
Engine rpm sensor (for F5C engine) Trailer brake circuit ground
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
143 TRAILER BRAKE CIRCUIT -- DIAGRAM 15
MPL0079A
87666787A - 11 - 2007
144
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
145
WIRING DIAGRAMS 16--17--18--19--20--21
MPM0719A
32 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
146
CAB VENTILATION AND AIR--CONDITIONING CIRCUIT (Diagram 16)
GND--57 C--62
Cab ground Fan unit connection
RES--66
Fan speed resistor unit
SW--67
Ventilation and air--conditioning system electric fan switch
M--68
Ventilation and air--conditioning system electric fan
LMP--69
Fan control unit lamp
RLY--70
Conditioner relay
SEN--71
Air--conditioner electronic thermostat
SW--72
Air conditioner control switch
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
147
CAB VENTILATION AND AIR--CONDITIONING CIRCUIT -- DIAGRAM 16
MPL0085A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
148
ROTATING BEACON CIRCUIT (Diagram 17)
C--2
Cab system connection (20 PIN)
C--29
Rotating beacon power socket
GND--57 C--62 SW--63 C--88
Cab ground Fan unit connection Rotating beacon control switch Cigar/Cigarette Lighter
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
149 ROTATING BEACON CIRCUIT -- DIAGRAM 17
MPL0086A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
150
SUPPLEMENTARY DIRECTION INDICATOR LIGHTS AND RADIO CIRCUIT (Diagram 18)
C--2
Cab system connection (20 PIN)
GND--57
Cab ground
MOD--58
Radio
AUD--60
RH speaker
AUD--61
LH speaker
LMP--80
RH cab SMV light
LMP--81
LH cab SMV light
C--184
LH cab SMV light connection
C--185
RH cab SMV light connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
151
SUPPLEMENTARY DIRECTION INDICATOR LIGHTS AND RADIO CIRCUIT -- DIAGRAM 18
MPL0087A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
152
CAB POWER SUPPLIES CIRCUIT (Diagram 19)
C--2
Cab system connection (20 PIN)
GND--57
Cab ground
MOD--75
Fuse box and cab relays RLY--1
Rear work lights circuit
RLY--2
Ignition switch controlled cab users circuit
RLY--3
Air--conditioner compressor circuit
RLY--4
Front work lights circuit
F--1
Front work lights
F--2
Rear work lights
F--3
Rotating beacon, cigar lighter, overhead lighting, radio
F--4
Rear window wiper/washer
F--5
Windscreen wiper/washer
F--6
Air conditioning, fan unit
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
153 CAB POWER SUPPLIES CIRCUIT -- DIAGRAM 19
MPL0088A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
154
WINDSCREEN AND REAR WINDOW WASHER/WIPER CIRCUIT (Diagram 20)
C--2
Cab system connection (20 PIN)
SW--52
Front windscreen washer switch
SW--53
Windscreen wiper switch
M--54 SW--55 M--56 GND--57
Wiper motor Rear window washer/wiper switch Rear wiper motor Cab ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
155 WIPER/WASHER CIRCUIT -- DIAGRAM 20
MPL0089A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
156
WORK LIGHTS CIRCUIT (Diagram 21)
C--2 GND--57 C--73
Cab system connection (20 PIN) Cab ground Front work lights connection
SW--74
Front work lights switch
LMP--76
Cab front RH work light
LMP--77
Cab front LH work light
LMP--78
Cab rear RH work light
LMP--79
Cab rear LH work light
LMP--82
Cab overhead lighting
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
157 WORK LIGHTS CIRCUIT -- DIAGRAM 21
MPL0090A
87666787A - 11 - 2007
158
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
159
WIRING DIAGRAMS 22--23--24--25--26--27
MPM0720A
33 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
160
POWER--SHUTTLE CIRCUIT 8+8 / 16+16 (dashboard side) (Diagram 22)
C--9
Power--Shuttle transmission system connection (24 PIN)
C--21
Power--Shuttle system connection (6 PIN)
MOD--150 Power Shuttle control unit SW--151
Clutch pedal switch
SW--152
Power Shuttle control lever
SEN--153
Clutch pedal sensor
GND--155 Dashboard Power Shuttle ground C--167
Connection for CAN line (4 PIN)
NC = Not connected
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
161
POWER SHUTTLE CIRCUIT 8+8 / 16+16 (dashboard side) -- DIAGRAM 22
MPL0083A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
162
POWER SHUTTLE CIRCUIT (transmission side) (Diagram 23)
C--9
Power--Shuttle transmission system connection (24 PIN)
SOL--140
Dump solenoid valve
SW--141
G1 ranges switch
SW--142
C1 gears switch
SOL--146
Lo clutch solenoid valve
SOL--147
Hi clutch solenoid valve
SEN--148
Transmission oil temperature sensor
SEN--182
Transmission oil pressure sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
163 POWER SHUTTLE CIRCUIT (transmission side) -- DIAGRAM 23
MPL0084A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
164
POWER--SHUTTLE CIRCUIT 32+16 / 44+16 (dashboard side) (Diagram 24)
C--9
Power--Shuttle transmission system connection (24 PIN)
C--21
Power--Shuttle system connection (6 PIN)
MOD--150 Power Shuttle control unit SW--151
Clutch pedal switch
SW--152
Power Shuttle control lever
SEN--153
Clutch pedal sensor
GND--155 Dashboard Power Shuttle ground C--167
Connection for CAN line (4 PIN)
NC = Not connected
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
165
POWER SHUTTLE CIRCUIT 32+16 / 44+16 (dashboard side) -- DIAGRAM 24
MPL0081A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
166
POWER SHUTTLE CIRCUIT (transmission side) (Diagram 25)
C--9
Power--Shuttle transmission system connection (24 PIN)
SOL--138
HI--LO mode solenoid valve
SOL--139
Shuttle mode solenoid valve
SOL--140
Dump solenoid valve
SW--141
G1 ranges switch
SW--142
C1 gears switch
SW--143
Creeper switch
SOL--146
Lo clutch solenoid valve
SOL--147
Hi clutch solenoid valve
SEN--148
Transmission oil temperature sensor
SW--183
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
SEN--203
Shuttle position sensor
* **
Version with Power Shuttle 44+16 e 32+16 with Dual Command (2 Speed Power Shift) function Version with Power Shuttle 44+16 e 32+16 with Dual Command (2 Speed Power Shift) function (paddy field version)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
167 POWER SHUTTLE CIRCUIT (transmission side) -- DIAGRAM 25
MPL0082A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
168
FRONT PTO CIRCUIT (Diagram 26)
SW--12 C--13
Front PTO switch Front PTO and lift system connection (13 PIN)
SOL--99
Front lift UP solenoid valve
SOL--100
Front lift DOWN solenoid valve
SEN--101
Front lift arms position sensor
MOD--102 Front electronic lift control panel SW--103
Front lift up/down control switch
MOD--204 Four--wheel drive control unit SW--205
Front lift UP external control switch
SW--206
Front lift DOWN external control switch
SEN--208
Front PTO sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
169 FRONT PTO CIRCUIT -- DIAGRAM 26
MPL0091A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
170
DIGITAL INSTRUMENT CIRCUIT (Diagram 27)
MOD--11
Instrument
C--24
Digital instrument connection
C--28
Diagnostics connection
SW--161
”Up/Down” control push--button
SW--162
”Enter” control push--button
C--167
Connection for CAN line (4 PIN)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
171 DIGITAL INSTRUMENT CIRCUIT -- DIAGRAM 27
MPM0698A
87666787A - 11 - 2007
172
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
173
VERSION 3
ELECTROHYDRAULIC FOUR--WHEEL DRIVE, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR ELECTRONIC LIFT Description
Wiring diagram circuits
Page
Circuit 1
Four--wheel drive circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Circuit 2
Battery cut--out circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Circuit 3
Power socket circuit, wiper/washer pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Circuit 4
Brakes, brake lights, differential lock circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Circuit 5
Front and rear electronic lift circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Circuit 6
Grid--heater circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Circuit 7
Instrument and sensor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Circuit 8
Power take--off and safety device circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Circuit 9
Direction indicator and hazard lights circuit (control switches and flasher) . . . . . . . . . . . 200
Circuit 10
External lights and horn circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Circuit 11
Power supplies 1 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Circuit 12
Power supplies 2 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Circuit 13
Seven--pin socket and number plate light circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Circuit 14
Intermediate connections circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Circuit 15
Trailer brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Circuit 16
Diagnostics connection CAN line circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Circuit 17
Engine, sensors and transmitters circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Circuit 18
Cab ventilation and air--conditioning circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Circuit 19
Rotating beacon circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Circuit 20
Supplementary direction indicator lights and radio circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Circuit 21
Cab power supply circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Circuit 22
Windscreen and rear window washer/wiper circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Circuit 23
Work lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Circuit 24
Power Shuttle 8+8 / 16+16 circuit (dashboard side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Circuit 25
Power Shuttle circuit (transmission side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Circuit 26
Power Shuttle 32+16 / 44+16 circuit (dashboard side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Circuit 27
Power Shuttle circuit (transmission side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Circuit 28
Front PTO circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Circuit 29
Digital instrument circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
174
ELECTRICAL CIRCUITS COMPONENTS VERSION 3
COMPONENT
NUMBER DIAGRAM
C--1
7, 17
C--2
14, 19, 20, 21, 22, 23
C--3
15
Trailer brake circuit intermediate connection (4 PIN)
C--4
3
25A / 40A socket connection
C--5
10
Front lights connection
C--6
1, 4, 7, 8
GND--7
2, 5, 6, 7, 9, 10, 12, 15, 16, 17
C--8
15
C--9
24, 25, 26, 27
SW--10
9
Hazard lights switch
MOD--11
7
Instrument
SW--12
28
Front PTO switch
C--13
28
Front PTO and lift system connection (13 PIN)
C--14
13
Seven--pin socket connection
C--15
8
Gearbox neutral connection
C--16
6
Electronic thermostarter connection (6 PIN)
SW--17
9
Front grille work lights switch
C--18
5
Rear electronic lift connection (8 PIN)
SW--19
11
Start switch
LMP--20
10
RH front direction indicator and side light
C--21
14, 24, 26
Power--Shuttle system connection (6 PIN)
LMP--22
10
LH front direction indicator and side light
MOD--23
9
Electronic flasher
MOD--25
4, 5, 10, 11, 12
F--26
11
30A maxi--fuse (40A for North America)
MOD--27
5
Rear lift electronic control unit
C--28
16
Diagnostics connection
C--29
19
Rotating beacon power socket
SW--30
2
Battery cut--out circuit switch
C--31
2
Connection for battery cut--out circuit on engine
SW--32
7
Operator present switch
SW--34
5
Rear electronic lift up/down switch
87666787A - 11 - 2007
DESCRIPTION
Front side connection -- engine (24 PIN) Cab system connection (20 PIN)
Transmission system connection (24 PIN) Dashboard ground Trailer brake circuit main connection (4 PIN) Power--Shuttle transmission system connection (24 PIN)
Fuse box and main relay
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
175
SW--35
1
4WD control switch
SW--36
4
Differential lock switch
SW--37
5
LH rear external electronic lift up/down switch
GND--38
2, 3, 5, 10, 13
SW--39
4
Parking brake switch
MOD--40
5
Working depth adjustment and rear electronic lift control panel
C--41
3
Seat connection
M--42
3
Front and rear window washer pumps
MOD--43
5
Rear electronic lift control panel
SW--44
5
RH rear external electronic lift up/down switch
LMP--45
10
RH tail light
C--46
3
8A two--pin socket
C--47
3
40 A four--pole power socket (North America)
LMP--48
10
LH tail light
C--49
3
25A two--pin socket
SW--52
22
Front windscreen washer switch
SW--53
22
Windscreen wiper switch
M--54
22
Wiper motor
SW--55
22
Rear window washer/wiper switch
M--56
22
Rear wiper motor
GND--57
18, 19, 20, 21, 22, 23
MOD--58
20
Radio
AUD--60
20
RH speaker
AUD--61
20
LH speaker
C--62
18, 19
SW--63
19
Rotating beacon control switch
RES--66
18
Fan speed resistor unit
SW--67
18
Ventilation and air--conditioning system electric fan switch
M--68
18
Ventilation and air--conditioning system electric fan
LMP--69
18
Fan control unit lamp
RLY--70
18
Conditioner relay
SEN--71
18
Air--conditioner electronic thermostat
SW--72
18
Air conditioner control switch
C--73
23
Front work lights connection
SW--74
23
Work lights switch
MOD--75
21
Fuse box and cab relays
LMP--76
23
Cab front RH work light
LMP--77
23
Cab front LH work light
LMP--78
23
Cab rear RH work light
Rear ground
Cab ground
Fan unit connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
176 LMP--79
23
Cab rear LH work light
LMP--80
20
RH cab SMV light
LMP--81
20
LH cab SMV light
LMP--82
23
Cab overhead lighting
BAT--83
17
Battery
ALT--84
17
Alternator
M--85
17
Starter motor
SEN--86
17
Brake fluid level sensor
SEN--87
17
Air filter clogged sensor
C--88
19
Cigar/Cigarette Lighter
SEN--89
17
Sediment unit filter sensor
M--90
17
Air--conditioner compressor
SEN--91
17
Filter/dryer sensor
SEN--92
17
Engine oil pressure sensor
SEN--93
17
Coolant temperature sensor
SOL--94
17
Engine cutout electromagnet
SOL--95
17
Solenoid valve to cut out starting advance, depending on temperature
SW--96
17
Starting advance thermometric cut--out switch
SW--97
9
External lights control switch
SOL--99
28
Front lift UP solenoid valve
SOL--100
28
Front lift DOWN solenoid valve
SEN--101
28
Front lift arms position sensor
MOD--102
28
Front electronic lift control panel
SW--103
28
Front lift up/down control switch
SW--104
8
Front PTO switch
GND--106
1, 8
Four--wheel drive indicator ground
SEN--107
15
Trailer brake indicator light pressure switch
SEN--108
15
Trailer brake circuit safety pressure switch
SOL--109
15
Trailer brake solenoid valves
RLY--110
15
Trailer brake circuit relay
SW--111
8
Rear PTO switch
SEN--112
8
Power steering indicator light pressure switch
SW--114
8
Gearbox neutral switch
SW--115
8
Splitter switch
SW--116
4
Differential lock indicator switch
SOL--117
4
Differential lock solenoid valve
AUD--118
10
Horn
LMP--119
10
Grille LH front work light
LMP--120
10
Front LH headlamp
LMP--121
10
Front RH headlamp
LMP--122
10
Grille RH front work light
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 SEN--123
7
Fuel level transmitter
SEN--129
7
Advance speed sensor
SEN--130
7
Power take--off rpm sensor
SEN--131
5
Draft sensor
SEN--132
5
Arms position sensor
SOL--133
5
Rear electronic lift DOWN solenoid valve
SOL--134
5
Rear electronic lift UP solenoid valve
SW--136
4
Stoplamp switch
SOL--138
27
HI--LO mode solenoid valve
SOL--139
27
Shuttle mode solenoid valve
SOL--140
25, 27
Dump solenoid valve
SW--141
25, 27
G1 ranges switch
SW--142
25, 27
C1 gears switch
SW--143
27
Creeper switch
SOL--146
25, 27
Lo clutch solenoid valve
SOL--147
25, 27
Hi clutch solenoid valve
SEN--148
25, 27
Transmission oil temperature sensor
MOD--150
24, 26
Power Shuttle control unit
SW--151
24, 26
Clutch pedal switch
SW--152
24, 26
Power Shuttle control lever
SEN--153
24, 26
Clutch pedal sensor
GND--155
24, 26
Dashboard Power Shuttle ground
MOD--156
6
Grid heater electronic module
RLY--157
6
Grid heater relay (coil)
RLY--158
6
Grid heater relay (contact)
RES--159
6
Grid Heater
F--160
6
125A Maxi--fuse
SW--161
7
”Up/Down” control push--button
SW--162
7
”Enter” control push--button
C--166
4
Brake lights signal test connection
C--167
14, 24, 26
F--168
17
50A mega--fuse
F--169
17
50A mega--fuse
C--170
5
Front lift system connection (8 PIN)
SW--171
5
Front lift main switch
D--172
12
Diode
SW--173
9
Lights switch
SW--174
9
Twin Power switch
C--175
1
Four--wheel drive system connection (4 PIN)
SEN--176
17
Engine rpm sensor
GND--181
15
Trailer brake circuit ground
SEN--182
25, 23
177
Connection for CAN line (4 PIN)
Transmission oil pressure sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
178 SW--183
27
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
C--184
20
LH cab SMV light connection
C--185
20
RH cab SMV light connection
SEN--203
27
Shuttle position sensor
MOD--204
28
Four--wheel drive control unit
SW--205
28
Front lift UP external control switch
SW--206
28
Front lift DOWN external control switch
SEN--208
28
Front PTO sensor
LMP--210
13
Number plate light
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
179
WIRING DIAGRAMS 1--2--3--4
MPM0709A
34 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
180
FOUR--WHEEL DRIVE CIRCUIT (Diagram 1)
C--6 SW--35
Transmission system connection (24 PIN) 4WD control switch
GND--106 Four--wheel drive indicator ground C--175
Four--wheel drive system connection (4 PIN)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
181 FOUR--WHEEL DRIVE CIRCUIT -- DIAGRAM 1
MPL0092A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
182
BATTERY CUT--OUT CIRCUIT (Diagram 2)
GND--7
Dashboard ground
SW--30
Battery cut--out circuit switch
C--31 CB--31 GND--38
Connection for battery cut--out circuit on engine Battery cut--out circuit jumpers Rear ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
183 BATTERY CUT--OUT CIRCUIT -- DIAGRAM 2
MPL0093A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
184
POWER SOCKETS, WIPER/WASHER PUMPS CIRCUIT (Diagram 3)
C--4 GND--38
25A and 40A power socket connection Rear ground
C--41
Seat connection
M--42
Front and rear window washer pumps
C--46
8A two--pin socket
C--47
40 A four--pole power socket (North America)
C--49
25A two--pin socket
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
185
POWER SOCKETS, WIPER/WASHER PUMPS CIRCUIT -- DIAGRAM 3
MPL0094A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
186
BRAKES, BRAKE LIGHTS, DIFFERENTIAL LOCK CIRCUIT (Diagram 4)
C--6 MOD--25
Transmission system connection (24 PIN) Fuse box and main relay RLY--1
Brake lights circuit
RLY--2
Differential lock circuit
RLY--3
Differential lock circuit
RLY--6
Differential lock circuit
RLY--1
(Connection D) Four--wheel drive, brake lights circuit
F--19
Stop Lights
SW--36
Differential lock switch
SW--39
Parking brake switch
SW--116
Differential lock indicator switch
SOL--117
Differential lock solenoid valve
SW--136
Stoplamp switch
C--166
Brake lights signal test connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
187
BRAKES, BRAKE LIGHTS, DIFFERENTIAL LOCK CIRCUIT -- DIAGRAM 4
MPL0095A
87666787A - 11 - 2007
188
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
189
WIRING DIAGRAMS 5--6--7--8
MPM0710A
35 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
190
FRONT AND REAR ELECTRONIC LIFT CIRCUIT (Diagram 5)
GND--7 C--18 MOD--25
MOD--27
Dashboard ground Rear electronic lift connection (8 PIN) Fuse box and main relay F--22
Front lift circuit
F--23
Front lift circuit
Rear lift electronic control unit
SW--34
Rear electronic lift up/down switch
SW--37
LH rear external electronic lift up/down switch
GND--38
Rear ground
MOD--40
Working depth adjustment and rear electronic lift control panel
MOD--43
Rear electronic lift control panel
SW--44
RH rear external electronic lift up/down switch
SEN--131
Draft sensor
SEN--132
Arms position sensor
SOL--133
Rear electronic lift DOWN solenoid valve
SOL--134
Rear electronic lift UP solenoid valve
C--170
Front lift system connection (8 PIN)
SW--171
Front lift main switch
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
191 FRONT AND REAR ELECTRONIC LIFT CIRCUIT -- DIAGRAM 5
MPL0096A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
192
GRID HEATER CIRCUIT (Diagram 6)
GND--7 C--16
Dashboard ground Electronic thermostarter connection (6 PIN)
MOD--156 Grid heater electronic module RLY--157
Grid heater relay (coil)
RLY--158
Grid heater relay (contact)
RES--159
Grid Heater
F--160
125A Maxi--fuse
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
193 GRID--HEATER CIRCUIT -- DIAGRAM 6
MPL0097A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
194
INSTRUMENT AND SENSOR CIRCUIT (Diagram 7) C--1
Front side connection -- engine (24 PIN)
C--6
Transmission system connection (24 PIN)
GND--7 MOD--11
SW--32
Dashboard ground Instrument A
Right turn signal indicator (green)
B
Handbrake indicator (red)
C
Work lights indicator (amber)
D
Full--beam indicator light (blue)
E
Left turn signal indicator (green)
F
Battery charging system malfunction light (red)
G
Engine oil pressure warning indicator (red)
H
Power steering oil pressure indicator (red)
I
Power Shuttle alarm
J
PTO indicator
K
4WD indicator (indicator)
L
High gear range engaged indicator (green)
M
Low gear range engaged indicator
N
Side lights indicator (green)
O
Clogged engine air filter indicator (amber)
P
Second trailer turn signal indicator (green)
Q
First trailer turn signal indicator (green)
R
Brake fluid level indicator (amber)
S
Grid heater indicator (amber)
T
4WD fault indicator
U
Front power take--off indicator
V
Trailer brake indicator (red)
W
Instrument lighting
X
Automatic four--wheel drive indicator (green)
Y
Front lift unit indicator
Z
Differential lock indicator (amber)
a
Fuel gauge
b
Engine coolant temperature gauge
Operator present switch
SEN--123
Fuel level transmitter
SEN--129
Advance speed sensor
SEN--130
Power take--off rpm sensor
SW--161
”Up/Down” control push--button
SW--162
”Enter” control push--button
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
195 INSTRUMENT AND SENSOR CIRCUIT -- DIAGRAM 7
MPL0098A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
196
POWER TAKE--OFF AND SAFETY DEVICE CIRCUIT (Diagram 8)
C--6
Transmission system connection (24 PIN)
C--15
Gearbox neutral connection
SW--104
Front PTO switch
GND--106 Four--wheel drive indicator ground SW--111
Rear PTO switch
SEN--112
Power steering indicator light pressure switch
SW--114
Gearbox neutral switch
SW--115
Splitter switch
* **
Standard version Splitter version
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
197
POWER TAKE--OFF AND SAFETY DEVICE CIRCUIT -- DIAGRAM 8
MPL0099A
87666787A - 11 - 2007
198
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
199
WIRING DIAGRAMS 9--10--11--12--13
MPM0711A
36 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
200
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (control switches and flasher) (Diagram 9)
GND--7
Dashboard ground
SW--10
Hazard lights switch
SW--17
Front grille work lights switch
MOD--23 SW--97
Electronic flasher External lights control switch
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
201
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (control switches and flasher) -- DIAGRAM 9
MPL0100A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
202
EXTERNAL LIGHTS AND HORN CIRCUIT (Diagram 10)
C--5
Front lights connection
GND--7
Dashboard ground
LMP--20
RH front direction indicator and side light
LMP--22
LH front direction indicator and side light
MOD--25
Fuse box and main relay F--9
Direction indicator and hazard lights
F--10
Horn, full beam flasher
GND--38
Rear ground
LMP--45
RH tail light
LMP--48
LH tail light
AUD--118
Horn
LMP--119
Grille LH front work light
LMP--120
Front LH headlamp
LMP--121
Front RH headlamp
LMP--122
Grille RH front work light
* **
ISO version North America version
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
203 EXTERNAL LIGHTS AND HORN CIRCUIT -- DIAGRAM 10
MPL0101A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
204
POWER SUPPLIES 1 CIRCUIT (Diagram 11)
SW--19 MOD--25
F--26
Start switch Fuse box and main relay F--1
Front right--hand and rear left--hand side lights, side lights indicator
F--2
Front left--hand and rear right--hand side lights, control instrument panel light
F--3
ISO side lights, or 7--pin work light (North America)
F--4
Full beam headlights
F--5
Dipped beam headlights
F--6
+instrument common, +external push--buttons, electronic lift indicator lights
F--7
Differential lock circuit, 4WD
F--11
Starter safety circuit
F--12
Engine cut--out electromagnet
F--13
Power Shuttle circuit
F--14
Power Shuttle circuit
F--15
Swivel position lights, seat, cab users relay
F--16
Trailer brake and hydraulic adjustment circuit
F--17
Electronic lift circuit
F--20
GRID--HEATER control unit circuit
F--21
Front lift circuit
F--24
Front lift circuit
F--25
Electronic control unit power supply, (+battery), seat safety circuit
F--30
Radio
30A maxi--fuse (40A for North America)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
205 POWER SUPPLIES 1 CIRCUIT -- DIAGRAM 11
MPL0102A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
206
POWER SUPPLIES 2 CIRCUIT (Diagram 12)
GND--7 MOD--25
Dashboard ground Fuse box and main relay RLY--2
Differential lock circuit
RLY--3
Differential lock circuit
RLY--4
Differential lock circuit
RLY--5
Full beam headlight circuit
RLY--6
Dipped beam headlight circuit
RLY--13
Engine starter circuit maxi--relay
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
207 POWER SUPPLIES 2 CIRCUIT -- DIAGRAM 12
MPL0103A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
208
SEVEN--PIN SOCKET AND NUMBER PLATE LIGHT CIRCUIT (Diagram 13)
C--14
7--pin socket connection
C--14A
ISO seven--pin socket
C--14B
North American seven--pin socket
GND--38
Rear ground
LMP--210
Number plate light
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
209
SEVEN--PIN SOCKET AND NUMBER PLATE LIGHT CIRCUIT -- DIAGRAM 13
MPL0104A
87666787A - 11 - 2007
210
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
211
WIRING DIAGRAMS 14--15--16--17
MPM0712A
37 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
212
INTERMEDIATE CONNECTIONS CIRCUIT (Diagram 14)
C--2
Cab system connection (20 PIN)
C--21
Power--Shuttle system connection (6 PIN)
C--167
Connection for CAN line (4 PIN)
NC = Not connected
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
213 INTERMEDIATE CONNECTIONS CIRCUIT -- DIAGRAM 14
MPL0105A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
214
TRAILER BRAKE CIRCUIT (Diagram 15)
C--3 GND--7
Trailer brake circuit intermediate connection (4 PIN) Dashboard ground
C--8
Trailer brake circuit main connection (4 PIN)
SEN--107
Trailer brake indicator light pressure switch
SEN--108
Trailer brake circuit safety pressure switch
SOL--109
Trailer brake solenoid valves
RLY--110
Trailer brake circuit relay RLY--9
Trailer brake circuit
RLY--10
Trailer brake circuit
RLY--13
Trailer brake circuit
GND--181 Trailer brake circuit ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
215 TRAILER BRAKE CIRCUIT -- DIAGRAM 15
MPL0106A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
216
DIAGNOSTICS CONNECTION CAN LINE CIRCUIT (Diagram 16)
GND--7 C--28
Dashboard ground Diagnostics connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
217
DIAGNOSTICS CONNECTION CAN LINE CIRCUIT -- DIAGRAM 16
MPL0107A
87666787A - 11 - 2007
218
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 ENGINE, SENSORS AND TRANSMITTERS CIRCUIT (Diagram 17)
C--1
Front side connection -- engine (24 PIN)
GND--7
Dashboard ground
BAT--83
Battery
ALT--84
Alternator
M--85
Starter motor
SEN--86
Brake fluid level sensor
SEN--87
Air filter clogged sensor
SEN--89
Sediment unit filter sensor
M--90
Air--conditioner compressor
SEN--91
Filter/dryer sensor
SEN--92
Engine oil pressure sensor
SEN--93
Coolant temperature sensor
SOL--94
Engine cutout electromagnet
SOL--95
Solenoid valve to cut out starting advance, depending on temperature
SW--96
Starting advance thermometric cut--out switch
F--168
50A mega--fuse
F--169
50A mega--fuse
SEN--176 (NEF)
Engine rpm sensor (for engine on models 4040 and 4050)
SEN--176 (F5C)
Engine rpm sensor (for F5C engine)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
219
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT -- DIAGRAM 17
MPL0108A
87666787A - 11 - 2007
220
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
221
WIRING DIAGRAMS 18--19--20--21--22--23
MPM0713A
38 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
222
CAB VENTILATION AND AIR--CONDITIONING CIRCUIT (Diagram 18)
GND--57 C--62
Cab ground Fan unit connection
RES--66
Fan speed resistor unit
SW--67
Ventilation and air--conditioning system electric fan switch
M--68
Ventilation and air--conditioning system electric fan
LMP--69
Fan control unit lamp
RLY--70
Conditioner relay
SEN--71
Air--conditioner electronic thermostat
SW--72
Air conditioner control switch
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
223
CAB VENTILATION AND AIR--CONDITIONING CIRCUIT -- DIAGRAM 18
MPL0113A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
224
ROTATING BEACON CIRCUIT (Diagram 19)
C--2
Cab system connection (20 PIN)
C--29
Rotating beacon power socket
GND--57 C--62 SW--63 C--88
Cab ground Fan unit connection Rotating beacon control switch Cigar/Cigarette Lighter
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
225 ROTATING BEACON CIRCUIT -- DIAGRAM 19
MPL0114A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
226
SUPPLEMENTARY DIRECTION INDICATOR LIGHTS AND RADIO CIRCUIT (Diagram 20)
C--2
Cab system connection (20 PIN)
GND--57
Cab ground
MOD--58
Radio
AUD--60
RH speaker
AUD--61
LH speaker
LMP--80
RH cab SMV light
LMP--81
LH cab SMV light
C--184
LH cab SMV light connection
C--185
RH cab SMV light connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
227
SUPPLEMENTARY DIRECTION INDICATOR LIGHTS AND RADIO CIRCUIT -- DIAGRAM 20
MPL0115A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
228
CAB POWER SUPPLIES CIRCUIT (Diagram 21)
C--2
Cab system connection (20 PIN)
GND--57
Cab ground
MOD--75
Fuse box and cab relays RLY--1
Rear work lights circuit
RLY--2
Ignition switch controlled cab users circuit
RLY--3
Air--conditioner compressor circuit
RLY--4
Front work lights circuit
F--1
Front work lights
F--2
Rear work lights
F--3
Rotating beacon, cigar lighter, overhead lighting, radio
F--4
Rear window wiper/washer
F--5
Windscreen wiper/washer
F--6
Air conditioning, fan unit
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
229 CAB POWER SUPPLY CIRCUIT -- DIAGRAM 21
MPL0116A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
230
WINDSCREEN AND REAR WINDOW WASHER/WIPER CIRCUIT (Diagram 22)
C--2
Cab system connection (20 PIN)
SW--52
Front windscreen washer switch
SW--53
Windscreen wiper switch
M--54 SW--55 M--56 GND--57
Wiper motor Rear window washer/wiper switch Rear wiper motor Cab ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
231 WIPER/WASHER CIRCUIT -- DIAGRAM 22
MPL0117A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
232
WORK LIGHTS CIRCUIT (Diagram 23)
C--2 GND--57 C--73
Cab system connection (20 PIN) Cab ground Front work lights connection
SW--74
Front work lights switch
LMP--76
Cab front RH work light
LMP--77
Cab front LH work light
LMP--78
Cab rear RH work light
LMP--79
Cab rear LH work light
LMP--82
Cab overhead lighting
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
233 WORK LIGHTS CIRCUIT -- DIAGRAM 23
MPL0118A
87666787A - 11 - 2007
234
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
235
WIRING DIAGRAMS 24--25--26--27--28
MPM0714A
39 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
236
POWER--SHUTTLE CIRCUIT 8+8 / 16+16 (dashboard side) (Diagram 24)
C--9
Power--Shuttle transmission system connection (24 PIN)
C--21
Power--Shuttle system connection (6 PIN)
MOD--150 Power Shuttle control unit SW--151
Clutch pedal switch
SW--152
Power Shuttle control lever
SEN--153
Clutch pedal sensor
GND--155 Dashboard Power Shuttle ground C--167
Connection for CAN line (4 PIN)
NC = Not connected
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
237
POWER SHUTTLE CIRCUIT 8+8 / 16+16 (dashboard side) -- DIAGRAM 24
MPL0111A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
238
POWER SHUTTLE CIRCUIT (transmission side) (Diagram 25)
C--9
Power--Shuttle transmission system connection (24 PIN)
SOL--140
Dump solenoid valve
SW--141
G1 ranges switch
SW--142
C1 gears switch
SOL--146
Lo clutch solenoid valve
SOL--147
Hi clutch solenoid valve
SEN--148
Transmission oil temperature sensor
SEN--182
Transmission oil pressure sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
239 POWER SHUTTLE CIRCUIT (transmission side) -- DIAGRAM 25
MPL0112A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
240
POWER--SHUTTLE CIRCUIT 32+16 / 44+16 (dashboard side) (Diagram 26)
C--9
Power--Shuttle transmission system connection (24 PIN)
C--21
Power--Shuttle system connection (6 PIN)
MOD--150 Power Shuttle control unit SW--151
Clutch pedal switch
SW--152
Power Shuttle control lever
SEN--153
Clutch pedal sensor
GND--155 Dashboard Power Shuttle ground C--167
Connection for CAN line (4 PIN)
NC = Not connected
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
241
POWER SHUTTLE CIRCUIT 32+16 / 44+16 (dashboard side) -- DIAGRAM 26
MPL0109A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
242
POWER SHUTTLE CIRCUIT (transmission side) (Diagram 27)
C--9
Power--Shuttle transmission system connection (24 PIN)
SOL--138
HI--LO mode solenoid valve
SOL--139
Shuttle mode solenoid valve
SOL--140
Dump solenoid valve
SW--141
G1 ranges switch
SW--142
C1 gears switch
SW--143
Creeper switch
SOL--146
Lo clutch solenoid valve
SOL--147
Hi clutch solenoid valve
SEN--148
Transmission oil temperature sensor
SW--183
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
SEN--203
Shuttle position sensor
* **
Version with Power Shuttle 44+16 e 32+16 with Dual Command (2 Speed Power Shift) function Version with Power Shuttle 44+16 e 32+16 with Dual Command (2 Speed Power Shift) function (paddy field version)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
243 POWER SHUTTLE CIRCUIT (transmission side) -- DIAGRAM 27
MPL0110A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
244
FRONT PTO CIRCUIT (Diagram 28)
SW--12 C--13
Front PTO switch Front PTO and lift system connection (13 PIN)
SOL--99
Front lift UP solenoid valve
SOL--100
Front lift DOWN solenoid valve
SEN--101
Front lift arms position sensor
MOD--102 Front electronic lift control panel SW--103
Front lift up/down control switch
MOD--204 Four--wheel drive control unit SW--205
Front lift UP external control switch
SW--206
Front lift DOWN external control switch
SEN--208
Front PTO sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
245 FRONT PTO CIRCUIT -- DIAGRAM 28
MPL0119A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
246
DIGITAL INSTRUMENT CIRCUIT (Diagram 29)
MOD--11
Instrument
C--24
Digital instrument connection
C--28
Diagnostics connection
SW--161
”Up/Down” control push--button
SW--162
”Enter” control push--button
C--167
Connection for CAN line (4 PIN)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
247 DIGITAL INSTRUMENT CIRCUIT -- DIAGRAM 29
MPM0698A
87666787A - 11 - 2007
248
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
249
VERSION 4 PERMANENT FOUR--WHEEL DRIVE, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR MECHANICAL LIFT
Description
Wiring diagram circuits
Page
Circuit 1
Four--wheel drive circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Circuit 2
Battery cut--out circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Circuit 3
Power socket circuit, wiper/washer pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Circuit 4
Brakes, brake lights, differential lock circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Circuit 5
Direction indicator and hazard lights circuit (control switches and flasher) . . . . . . . . . . . 266
Circuit 6
Grid--heater circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Circuit 7
Instrument and sensor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Circuit 8
Power take--off and safety device circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Circuit 9
Seven--pin socket and number plate light circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Circuit 10
External lights and horn circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Circuit 11
Power supplies 1 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Circuit 12
Power supplies 2 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Circuit 13
Trailer brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Circuit 14
Intermediate connections circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Circuit 15
Engine, sensors and transmitters circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Circuit 16
Diagnostics connection CAN line circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Circuit 17
Cab ventilation and air--conditioning circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Circuit 18
Rotating beacon circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Circuit 19
Supplementary direction indicator lights and radio circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Circuit 20
Cab power supply circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Circuit 21
Windscreen and rear window washer/wiper circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Circuit 22
Work lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Circuit 23
Power Shuttle circuit 8+8 / 16+16 (dashboard side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Circuit 24
Power Shuttle circuit (transmission side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Circuit 25
Power Shuttle 32+16 / 44+16 circuit (dashboard side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Circuit 26
Power Shuttle circuit (transmission side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Circuit 27
Front PTO circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
250
ELECTRICAL CIRCUITS COMPONENTS VERSION 4
COMPONENT
NUMBER DIAGRAM
C--1
7, 15
C--2
14, 18, 19, 20, 21, 22
C--3
13
Trailer brake circuit intermediate connection (4 PIN)
C--4
3
25A / 40A socket connection
C--5
10
Front lights connection
C--6
1, 4, 6, 7, 8
GND--7
1, 2, 5, 6, 7, 10, 12, 13, 15, 16
C--8
13
C--9
23, 24, 25, 26
SW--10
5
Hazard lights switch
MOD--11
7
Instrument
SW--12
27
Front PTO switch
C--13
27
Front PTO and lift system connection (13 PIN)
C--14
9
Seven--pin socket connection
C--15
8
Gearbox neutral connection
C--16
6
Electronic thermostarter connection (6 PIN)
SW--17
5
Front grille work lights switch
SW--19
11
Start switch
LMP--20
10
RH front direction indicator and side light
C--21
14, 23, 25
Power--Shuttle system connection (6 PIN)
LMP--22
10
LH front direction indicator and side light
MOD--23
5
Electronic flasher
MOD--25
4, 10, 11, 12
F--26
11
30A maxi--fuse (40A for North America)
C--28
16
Diagnostics connection
C--29
18
Rotating beacon power socket
SW--30
2
Battery cut--out circuit switch
C--31
2
Connection for battery cut--out circuit on engine
SW--32
7
Operator present switch
SEN--33
1
Tilt sensor
SW--35
1
4WD control switch
SW--36
4
Differential lock switch
GND--38
1, 2, 3, 9, 10
87666787A - 11 - 2007
DESCRIPTION
Front side connection -- engine (24 PIN) Cab system connection (20 PIN)
Transmission system connection (24 PIN) Dashboard ground Trailer brake circuit main connection (4 PIN) Power--Shuttle transmission system connection (24 PIN)
Fuse box and main relay
Rear ground
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
251
SW--39
4
Parking brake switch
C--41
3
Seat connection
M--42
3
Front and rear window washer pumps
LMP--45
10
RH tail light
C--46
3
8A two--pin socket
C--47
3
40 A four--pole power socket (North America)
LMP--48
10
LH tail light
C--49
3
25A two--pin socket
SW--52
21
Front windscreen washer switch
SW--53
21
Windscreen wiper switch
M--54
21
Wiper motor
SW--55
21
Rear window washer/wiper switch
M--56
21
Rear wiper motor
GND--57
17, 18, 19, 20, 21, 22
MOD--58
19
Radio
AUD--60
19
RH speaker
AUD--61
19
LH speaker
C--62
17, 18
SW--63
18
Rotating beacon control switch
MOD--64
1
Permanent 4WD control unit
RES--66
17
Fan speed resistor unit
SW--67
17
Ventilation and air--conditioning system electric fan switch
M--68
17
Ventilation and air--conditioning system electric fan
LMP--69
17
Fan control unit lamp
RLY--70
17
Conditioner relay
SEN--71
17
Air--conditioner electronic thermostat
SW--72
17
Air conditioner control switch
C--73
22
Front work lights connection
SW--74
22
Work lights switch
MOD--75
20
Fuse box and cab relays
LMP--76
22
Cab front RH work light
LMP--77
22
Cab front LH work light
LMP--78
22
Cab rear RH work light
LMP--79
22
Cab rear LH work light
LMP--80
19
RH cab SMV light
LMP--81
19
LH cab SMV light
LMP--82
22
Cab overhead lighting
BAT--83
15
Battery
ALT--84
15
Alternator
M--85
15
Starter motor
SEN--86
15
Brake fluid level sensor
Cab ground
Fan unit connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
252 SEN--87
15
Air filter clogged sensor
C--88
18
Cigar/Cigarette Lighter
SEN--89
15
Sediment unit filter sensor
M--90
15
Air--conditioner compressor
SEN--91
15
Filter/dryer sensor
SEN--92
15
Engine oil pressure sensor
SEN--93
15
Coolant temperature sensor
SOL--94
15
Engine cutout electromagnet
SOL--95
15
Solenoid valve to cut out starting advance, depending on temperature
SW--96
15
Starting advance thermometric cut--out switch
SW--97
5
External lights control switch
SOL--99
27
Front lift UP solenoid valve
SOL--100
27
Front lift DOWN solenoid valve
SEN--101
27
Front lift arms position sensor
MOD--102
27
Front electronic lift control panel
SW--103
27
Front lift up/down control switch
SW--105
5
Front electronic lift block switch
GND--106
1, 6
Four--wheel drive indicator ground
SEN--107
13
Trailer brake indicator light pressure switch
SEN--108
13
Trailer brake circuit safety pressure switch
SOL--109
13
Trailer brake solenoid valves
RLY--110
13
Trailer brake circuit relay
SW--111
8
Rear PTO switch
SEN--112
8
Power steering indicator light pressure switch
SW--113
5
Lights switch
SW--114
8
Gearbox neutral switch
SW--115
8
Splitter switch
SW--116
4
Differential lock indicator switch
SOL--117
4
Differential lock solenoid valve
AUD--118
10
Horn
LMP--119
10
Grille LH front work light
LMP--120
10
Front LH headlamp
LMP--121
10
Front RH headlamp
LMP--122
10
Grille RH front work light
SEN--124
1
Four--wheel drive indicator pressure switch
SW--125
6
Shuttle lever switch
SEN--126
1
Steering sensor
SEN--127
1
Rear axle speed sensor
SEN--128
1
Front axle speed sensor
SEN--130
7
Power take--off rpm sensor
SOL--135
1
Four--wheel drive solenoid valve
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
253
SW--136
4
Stoplamp switch
SOL--138
26
HI--LO mode solenoid valve
SOL--139
26
Shuttle mode solenoid valve
SOL--140
24, 26
Dump solenoid valve
SW--141
24. 26
G1 ranges switch
SW--142
24. 26
C1 gears switch
SW--143
26
Creeper switch
SOL--146
24, 26
Lo clutch solenoid valve
SOL--147
24, 26
Hi clutch solenoid valve
SEN--148
24, 26
Transmission oil temperature sensor
MOD--150
23, 25
Power Shuttle control unit
SW--151
23, 25
Clutch pedal switch
SW--152
23, 25
Power Shuttle control lever
SEN--153
23, 25
Clutch pedal sensor
GND--155
23, 15
Dashboard Power Shuttle ground
MOD--156
6
Grid heater electronic module
RLY--157
6
Grid heater relay (coil)
RLY--158
6
Grid heater relay (contact)
RES--159
6
Grid Heater
F--160
6
125A Maxi--fuse
SW--161
7
”Up/Down” control push--button
SW--162
7
”Enter” control push--button
C--166
4
Brake lights signal test connection
C--167
14, 23, 25
F--168
15
50A mega--fuse
F--169
15
50A mega--fuse
SEN--176
15
Engine rpm sensor
GND--181
13
Trailer brake circuit ground
SEN--182
24
Transmission oil pressure sensor
SW--183
26
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
C--184
19
LH cab SMV light connection
C--185
19
RH cab SMV light connection
SEN--203
26
Shuttle position sensor
MOD--204
27
Four--wheel drive control unit
SW--205
27
Front lift UP external control switch
SW--206
27
Front lift DOWN external control switch
SEN--208
27
Front PTO sensor
LMP--210
9
Number plate light
Connection for CAN line (4 PIN)
87666787A - 11 - 2007
254
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
255
WIRING DIAGRAMS 1--2--3--4
MPM0721A
40 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
256
FOUR--WHEEL DRIVE CIRCUIT (Diagram 1)
C--6
Transmission system connection (24 PIN)
GND--7
Dashboard ground
SEN--33
Tilt sensor
SW--35
4WD control switch
GND--38
Rear ground
MOD--64
Permanent 4WD control unit
GND--106 Four--wheel drive indicator ground SEN--124
Four--wheel drive indicator pressure switch
SEN--126
Steering sensor
SEN--127
Rear axle speed sensor
SEN--128
Front axle speed sensor
SOL--135
Four--wheel drive solenoid valve
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
257 FOUR--WHEEL DRIVE CIRCUIT -- DIAGRAM 1
MPM0680A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
258
BATTERY CUT--OUT CIRCUIT (Diagram 2)
GND--7
Dashboard ground
SW--30
Battery cut--out circuit switch
C--31 CB--31 GND--38
Connection for battery cut--out circuit on engine Battery cut--out circuit jumper Rear ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
259 BATTERY CUT--OUT CIRCUIT -- DIAGRAM 2
MPM0694A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
260
POWER SOCKETS, WIPER/WASHER PUMPS CIRCUIT (Diagram 3)
C--4 GND--38
25A and 40A power socket connection Rear ground
C--41
Seat connection
M--42
Front and rear window washer pumps
C--46
8A two--pin socket
C--47
40 A four--pole power socket (North America)
C--49
25A two--pin socket
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
261
POWER SOCKETS, WIPER/WASHER PUMPS CIRCUIT -- DIAGRAM 3
MPM0695A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
262
BRAKES, BRAKE LIGHTS, DIFFERENTIAL LOCK CIRCUIT (Diagram 4)
C--6 MOD--25
Transmission system connection (24 PIN) Fuse box and main relay RLY--1
Brake lights circuit
RLY--2
Differential lock circuit
RLY--3
Differential lock circuit
RLY--6
Differential lock circuit
F--19
Stop Lights
SW--36
Differential lock switch
SW--39
Parking brake switch
SW--116
Differential lock indicator switch
SOL--117
Differential lock solenoid valve
SW--136
Stoplamp switch
C--166
Brake lights signal test connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
263
BRAKES, BRAKE LIGHTS, DIFFERENTIAL LOCK CIRCUIT -- DIAGRAM 4
MPM0678A
87666787A - 11 - 2007
264
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
265
WIRING DIAGRAMS 5--6--7--8
MPM0722A
41 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
266
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (control switches and flasher) (Diagram 5)
GND--7
Dashboard ground
SW--10
Hazard lights switch
SW--17
Front grille work lights switch
MOD--23
Electronic flasher
SW--97
External lights control switch
SW--105
Front electronic lift block switch
SW--113
Lights switch
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
267
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (control switches and flasher) -- DIAGRAM 5
MPM0681A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
268
GRID HEATER CIRCUIT (Diagram 6)
C--6 GND--7 C--16
Transmission system connection (24 PIN) Dashboard ground Electronic thermostarter connection (6 PIN)
GND--106 Four--wheel drive indicator ground SW--125
Shuttle lever switch
MOD--156 Grid heater electronic module RLY--157
Grid heater relay (coil)
RLY--158
Grid heater relay (contact)
RES--159
Grid Heater
F--160
125A Maxi--fuse
603.54.430.02 - 07 - 2005
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
269 GRID--HEATER CIRCUIT -- DIAGRAM 6
MPM0696A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
270
INSTRUMENT AND SENSOR CIRCUIT (Diagram 7)
C--1
Front side connection -- engine (24 PIN)
C--6
Transmission system connection (24 PIN)
GND--7 MOD--11
SW--32
Dashboard ground Instrument A
Right turn signal indicator (green)
B
Handbrake indicator (red)
C
Work lights indicator (amber)
D
Full--beam indicator light (blue)
E
Left turn signal indicator (green)
F
Battery charging system malfunction light (red)
G
Engine oil pressure warning indicator (red)
H
Power steering oil pressure indicator (red)
I
Power Shuttle alarm
J
PTO indicator
K
4WD indicator (indicator)
L
High gear range engaged indicator (green)
M
Low gear range engaged indicator
N
Side lights indicator (green)
O
Clogged engine air filter indicator (amber)
P
Second trailer turn signal indicator (green)
Q
First trailer turn signal indicator (green)
R
Brake fluid level indicator (amber)
S
Grid heater indicator (amber)
T
4WD fault indicator
U
Front power take--off indicator
V
Trailer brake indicator (red)
W
Instrument lighting
X
Automatic four--wheel drive indicator (green)
Y
Front lift unit indicator
Z
Differential lock indicator (amber)
a
Fuel gauge
b
Engine coolant temperature gauge
Operator present switch
SEN--130
Power take--off rpm sensor
SW--161
”Up/Down” control push--button
SW--162
”Enter” control push--button
603.54.430.02 - 07 - 2005
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
271 INSTRUMENT AND SENSOR CIRCUIT -- DIAGRAM 7
MPL0152A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
272
POWER TAKE--OFF AND SAFETY DEVICE CIRCUIT (Diagram 8)
C--6
Transmission system connection (24 PIN)
C--15
Gearbox neutral connection
SW--111
Rear PTO switch
SEN--112
Power steering indicator light pressure switch
SW--114
Gearbox neutral switch
SW--115
Splitter switch
* **
Standard version Splitter version
603.54.430.02 - 07 - 2005
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
273
POWER TAKE--OFF AND SAFETY DEVICE CIRCUIT -- DIAGRAM 8
MPL0153A
87666787A - 11 - 2007
274
603.54.430.02 - 07 - 2005
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
275
WIRING DIAGRAMS 9--10--11--12
MPM0723A
42 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
276
SEVEN--PIN SOCKET AND NUMBER PLATE LIGHT CIRCUIT (Diagram 9)
C--14
7--pin socket connection
C--14A
ISO seven--pin socket
C--14B
North American seven--pin socket
GND--38
Rear ground
LMP--210
Number plate light
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
277
SEVEN--PIN SOCKET AND NUMBER PLATE LIGHT CIRCUIT -- DIAGRAM 9
MPL0154A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
278
EXTERNAL LIGHTS AND HORN CIRCUIT (Diagram 10)
C--5
Front lights connection
GND--7
Dashboard ground
LMP--20
RH front direction indicator and side light
LMP--22
LH front direction indicator and side light
MOD--25
Fuse box and main relay F--9
Direction indicator and hazard lights
F--10
Horn, full beam flasher
GND--38
Rear ground
LMP--45
RH tail light
LMP--48
LH tail light
AUD--118
Horn
LMP--119
Grille LH front work light
LMP--120
Front LH headlamp
LMP--121
Front RH headlamp
LMP--122
Grille RH front work light
* **
ISO version North America version
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
279 EXTERNAL LIGHTS AND HORN CIRCUIT -- DIAGRAM 10
MPL0155A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
280
POWER SUPPLIES 1 CIRCUIT (Diagram 11)
SW--19 MOD--25
F--26
Start switch Fuse box and main relay F--1
Front right--hand and rear left--hand side lights, side lights indicator
F--2
Front left--hand and rear right--hand side lights, control instrument panel light
F--3
ISO side lights, or 7--pin work light (North America)
F--4
Full beam headlights
F--5
Dipped beam headlights
F--11
Starter safety circuit
F--12
Engine cut--out electromagnet
F--13
Power Shuttle circuit
F--14
Power Shuttle circuit
F--15
Swivel position lights, seat, cab users relay
F--16
Trailer brake and hydraulic adjustment circuit
F--18
Permanent 4WD circuit
F--20
GRID--HEATER control unit circuit
F--25
Electronic control unit power supply, (+battery), seat safety circuit
F--30
Radio
30A maxi--fuse (40A for North America)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
281 POWER SUPPLIES 1 CIRCUIT -- DIAGRAM 11
MPM0693A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
282
POWER SUPPLIES 2 CIRCUIT (Diagram 12)
GND--7 MOD--25
Dashboard ground Fuse box and main relay RLY--2
Differential lock circuit
RLY--3
Differential lock circuit
RLY--4
Differential lock circuit
RLY--5
Full beam headlight circuit
RLY--6
Dipped beam headlight circuit
RLY--13
Engine starter circuit maxi--relay
F--6
+instrument common, +external push--buttons, electronic lift indicator lights
F--7
Differential lock circuit and front lift circuit
F--8
8A power socket, digital instrument
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
283 POWER SUPPLIES 2 CIRCUIT -- DIAGRAM 12
MPM0679A
87666787A - 11 - 2007
284
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
285
WIRING DIAGRAMS 13--14--15--16
MPM0724A
43 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
286
TRAILER BRAKE CIRCUIT (Diagram 13)
C--3 GND--7
Trailer brake circuit intermediate connection (4 PIN) Dashboard ground
C--8
Trailer brake circuit main connection (4 PIN)
SEN--107
Trailer brake indicator light pressure switch
SEN--108
Trailer brake circuit safety pressure switch
SOL--109
Trailer brake solenoid valves
RLY--110
Trailer brake circuit relay RLY--9
Trailer brake circuit
RLY--10
Trailer brake circuit
RLY--13
Trailer brake circuit
GND--181 Trailer brake circuit ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
287 TRAILER BRAKE CIRCUIT -- DIAGRAM 13
MPL0156A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
288
INTERMEDIATE CONNECTIONS CIRCUIT (Diagram 14)
C--2
Cab system connection (20 PIN)
C--21
Power--Shuttle system connection (6 PIN)
C--167
Connection for CAN line (4 PIN)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
289 INTERMEDIATE CONNECTIONS CIRCUIT -- DIAGRAM 14
MPL0157A
87666787A - 11 - 2007
290
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 ENGINE, SENSORS AND TRANSMITTERS CIRCUIT (Diagram 15)
C--1
Front side connection -- engine (24 PIN)
GND--7
Dashboard ground
BAT--83
Battery
ALT--84
Alternator
M--85
Starter motor
SEN--86
Brake fluid level sensor
SEN--87
Air filter clogged sensor
SEN--89
Sediment unit filter sensor
M--90
Air--conditioner compressor
SEN--91
Filter/dryer sensor
SEN--92
Engine oil pressure sensor
SEN--93
Coolant temperature sensor
SOL--94
Engine cutout electromagnet
SOL--95
Solenoid valve to cut out starting advance, depending on temperature
SW--96
Starting advance thermometric cut--out switch
F--168
50A mega--fuse
F--169
50A mega--fuse
SEN--176 (NEF)
Engine rpm sensor (for engine on models 4040 and 4050)
SEN--176 (F5C)
Engine rpm sensor (for F5C engine)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
291
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT -- DIAGRAM 15
MPL0158A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
292
DIAGNOSTICS CONNECTION CAN LINE CIRCUIT (Diagram 16)
GND--7 C--28
Dashboard ground Diagnostics connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
293
DIAGNOSTICS CONNECTION CAN LINE CIRCUIT -- DIAGRAM 16
MPL0159A
87666787A - 11 - 2007
294
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
295
WIRING DIAGRAMS 17--18--19--20--21--22--23
MPM0725A
44 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
296
CAB VENTILATION AND AIR--CONDITIONING CIRCUIT (Diagram 17)
GND--57 C--62
Cab ground Fan unit connection
RES--66
Fan speed resistor unit
SW--67
Ventilation and air--conditioning system electric fan switch
M--68
Ventilation and air--conditioning system electric fan
LMP--69
Fan control unit lamp
RLY--70
Conditioner relay
SEN--71
Air--conditioner electronic thermostat
SW--72
Air conditioner control switch
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
297
CAB VENTILATION AND AIR--CONDITIONING CIRCUIT -- DIAGRAM 17
MPM0686A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
298
ROTATING BEACON CIRCUIT (Diagram 18)
C--2
Cab system connection (20 PIN)
C--29
Rotating beacon power socket
GND--57 C--62 SW--63 C--88
Cab ground Fan unit connection Rotating beacon control switch Cigar/Cigarette Lighter
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
299 ROTATING BEACON CIRCUIT -- DIAGRAM 18
MPM0687A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
300
SUPPLEMENTARY DIRECTION INDICATOR LIGHTS AND RADIO CIRCUIT (Diagram 19)
C--2
Cab system connection (20 PIN)
GND--57
Cab ground
MOD--58
Radio
AUD--60
RH speaker
AUD--61
LH speaker
LMP--80
RH cab SMV light
LMP--81
LH cab SMV light
C--184
LH cab SMV light connection
C--185
RH cab SMV light connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
301
SUPPLEMENTARY DIRECTION INDICATOR LIGHTS AND RADIO CIRCUIT -- DIAGRAM 19
MPM0688A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
302
CAB POWER SUPPLIES CIRCUIT (Diagram 20)
C--2
Cab system connection (20 PIN)
GND--57
Cab ground
MOD--75
Fuse box and cab relays RLY--1
Rear work lights circuit
RLY--2
Ignition switch controlled cab users circuit
RLY--3
Air--conditioner compressor circuit
RLY--4
Front work lights circuit
F--1
Front work lights
F--2
Rear work lights
F--3
Rotating beacon, cigar lighter, overhead lighting, radio
F--4
Rear window wiper/washer
F--5
Windscreen wiper/washer
F--6
Air conditioning, fan unit
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
303 CAB POWER SUPPLY CIRCUIT -- DIAGRAM 20
MPM0689A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
304
WINDSCREEN AND REAR WINDOW WASHER/WIPER CIRCUIT (Diagram 21)
C--2
Cab system connection (20 PIN)
SW--52
Front windscreen washer switch
SW--53
Windscreen wiper switch
M--54 SW--55 M--56 GND--57
Wiper motor Rear window washer/wiper switch Rear wiper motor Cab ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
305 WIPER/WASHER CIRCUIT -- DIAGRAM 21
MPM0690A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
306
WORK LIGHTS CIRCUIT (Diagram 22)
C--2 GND--57 C--73
Cab system connection (20 PIN) Cab ground Front work lights connection
SW--74
Front work lights switch
LMP--76
Cab front RH work light
LMP--77
Cab front LH work light
LMP--78
Cab rear RH work light
LMP--79
Cab rear LH work light
LMP--82
Cab overhead lighting
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
307 WORK LIGHTS CIRCUIT -- DIAGRAM 22
MPM0691A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
308
POWER--SHUTTLE CIRCUIT 8+8 / 16+16 (dashboard side) (Diagram 23)
C--9
Power--Shuttle transmission system connection (24 PIN)
C--21
Power--Shuttle system connection (6 PIN)
MOD--150 Power Shuttle control unit SW--151
Clutch pedal switch
SW--152
Power Shuttle control lever
SEN--153
Clutch pedal sensor
GND--155 Dashboard Power Shuttle ground C--167
Connection for CAN line (4 PIN)
NC = Not connected
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
309
POWER SHUTTLE CIRCUIT 8+8 / 16+16 (dashboard side) -- DIAGRAM 23
MPM0684A
87666787A - 11 - 2007
310
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
311
WIRING DIAGRAMS 24--25--26--27
MPM0726A
45 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
312
POWER SHUTTLE CIRCUIT (transmission side) (Diagram 24)
C--9
Power--Shuttle transmission system connection (24 PIN)
SOL--140
Dump solenoid valve
SW--141
G1 ranges switch
SW--142
C1 gears switch
SOL--146
Lo clutch solenoid valve
SOL--147
Hi clutch solenoid valve
SEN--148
Transmission oil temperature sensor
SEN--182
Transmission oil pressure sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
313 POWER SHUTTLE CIRCUIT (transmission side) -- DIAGRAM 24
MPM0685A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
314
POWER--SHUTTLE CIRCUIT 32+16 / 44+16 (dashboard side) (Diagram 25)
C--9
Power--Shuttle transmission system connection (24 PIN)
C--21
Power--Shuttle system connection (6 PIN)
MOD--150 Power Shuttle control unit SW--151
Clutch pedal switch
SW--152
Power Shuttle control lever
SEN--153
Clutch pedal sensor
GND--155 Dashboard Power Shuttle ground C--167
Connection for CAN line (4 PIN)
NC = Not connected
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
315
POWER SHUTTLE CIRCUIT 32+16 / 44+16 (dashboard side) -- DIAGRAM 25
MPM0682A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
316
POWER SHUTTLE CIRCUIT (transmission side) (Diagram 26)
C--9
Power--Shuttle transmission system connection (24 PIN)
SOL--138
HI--LO mode solenoid valve
SOL--139
Shuttle mode solenoid valve
SOL--140
Dump solenoid valve
SW--141
G1 ranges switch
SW--142
C1 gears switch
SW--143
Creeper switch
SOL--146
Lo clutch solenoid valve
SOL--147
Hi clutch solenoid valve
SEN--148
Transmission oil temperature sensor
SW--183
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
SEN--203
Shuttle position sensor
* **
Version with Power Shuttle 44+16 e 32+16 with Dual Command (2 Speed Power Shift) function Version with Power Shuttle 44+16 e 32+16 with Dual Command (2 Speed Power Shift) function (paddy field version)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
317 POWER SHUTTLE CIRCUIT (transmission side) -- DIAGRAM 26
MPM0683A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
318
FRONT PTO CIRCUIT (Diagram 27)
SW--12 C--13
Front PTO switch Front PTO and lift system connection (13 PIN)
SOL--99
Front lift UP solenoid valve
SOL--100
Front lift DOWN solenoid valve
SEN--101
Front lift arms position sensor
MOD--102 Front electronic lift control panel SW--103
Front lift up/down control switch
MOD--204 Four--wheel drive control unit SW--205
Front lift UP external control switch
SW--206
Front lift DOWN external control switch
SEN--208
Front PTO sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
319 FRONT PTO CIRCUIT -- DIAGRAM 27
MPM0692A
87666787A - 11 - 2007
320
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
321
VERSION 5 PERMANENT FOUR--WHEEL DRIVE, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR ELECTRONIC LIFT
Description
Wiring diagram circuits
Page
Circuit 1
Four--wheel drive circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Circuit 2
Battery cut--out circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Circuit 3
Power socket circuit, wiper/washer pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Circuit 4
Brakes, brake lights, differential lock circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Circuit 5
Front and rear electronic lift circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Circuit 6
Grid--heater circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Circuit 7
Instrument and sensor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
Circuit 8
Power take--off and safety device circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Circuit 9
Direction indicator and hazard lights circuit (control switches and flasher) . . . . . . . . . . . 348
Circuit 10
External lights and horn circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Circuit 11
Power supplies 1 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Circuit 12
Power supplies 2 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Circuit 13
Seven--pin socket and number plate light circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
Circuit 14
Diagnostics connection CAN line circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Circuit 15
Trailer brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Circuit 16
Intermediate connections circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
Circuit 17
Engine, sensors and transmitters circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Circuit 18
Cab ventilation and air--conditioning circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
Circuit 19
Rotating beacon circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Circuit 20
Supplementary direction indicator lights and radio circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 374
Circuit 21
Cab power supply circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
Circuit 22
Windscreen and rear window washer/wiper circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
Circuit 23
Work lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Circuit 24
Power Shuttle 8+8 / 16+16 circuit (dashboard side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Circuit 25
Power Shuttle circuit (transmission side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Circuit 26
Power Shuttle 32+16 / 44+16 circuit (dashboard side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
Circuit 27
Power Shuttle circuit (transmission side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
Circuit 28
Front PTO circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
322
ELECTRICAL CIRCUITS COMPONENTS VERSION 5
COMPONENT
NUMBER DIAGRAM
C--1
7, 17
C--2
16, 20, 21, 22, 23
C--3
15
Trailer brake circuit intermediate connection (4 PIN)
C--4
3
25A / 40A socket connection
C--5
10
Front lights connection
C--6
1, 4, 6, 7, 8
GND--7
DESCRIPTION
Front side connection -- engine (24 PIN) Cab system connection (20 PIN)
Transmission system connection (24 PIN)
1, 2, 5, 6, 7, 9, 10, 12, Dashboard ground 14, 15, 17
C--8
15
C--9
24, 25, 26, 27
SW--10
9
Hazard lights switch
MOD--11
7
Instrument
SW--12
28
Front PTO switch
C--13
28
Front PTO and lift system connection (13 PIN)
C--14
13
Seven--pin socket connection
C--15
8
Gearbox neutral connection
C--16
6
Electronic thermostarter connection (6 PIN)
SW--17
9
Front grille work lights switch
C--18
5
Rear electronic lift connection (8 PIN)
SW--19
11
Start switch
LMP--20
10
RH front direction indicator and side light
C--21
16, 24, 26
Power--Shuttle system connection (6 PIN)
LMP--22
10
LH front direction indicator and side light
MOD--23
9
Electronic flasher
MOD--25
4, 9, 10, 11, 12
F--26
11
30A maxi--fuse (40A for North America)
MOD--27
5
Rear lift electronic control unit
C--28
14
Diagnostics connection
C--29
19
Rotating beacon power socket
SW--30
2
Battery cut--out circuit switch
C--31
2
Connection for battery cut--out circuit on engine
SW--32
7
Operator present switch
SEN--33
1
Tilt sensor
87666787A - 11 - 2007
Trailer brake circuit main connection (4 PIN) Power--Shuttle transmission system connection (24 PIN)
Fuse box and main relay
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
323
SW--34
5
Rear electronic lift up/down switch
SW--35
1
4WD control switch
SW--36
4
Differential lock switch
SW--37
5
LH rear external electronic lift up/down switch
GND--38
3, 5, 10, 13
SW--39
4
Parking brake switch
MOD--40
5
Working depth adjustment and rear electronic lift control panel
C--41
3
Seat connection
M--42
3
Front and rear window washer pumps
MOD--43
5
Rear electronic lift control panel
SW--44
5
RH rear external electronic lift up/down switch
LMP--45
10
RH tail light
C--46
3
8A two--pin socket
C--47
3
40 A four--pole power socket (North America)
LMP--48
10
LH tail light
C--49
3
25A two--pin socket
SW--52
22
Front windscreen washer switch
SW--53
22
Windscreen wiper switch
M--54
22
Wiper motor
SW--55
22
Rear window washer/wiper switch
M--56
22
Rear wiper motor
GND--57
18, 19, 20, 21, 22, 23
MOD--58
20
Radio
AUD--60
20
RH speaker
AUD--61
20
LH speaker
C--62
18
Fan unit connection
SW--63
19
Rotating beacon control switch
MOD--64
1
Permanent 4WD control unit
RES--66
18
Fan speed resistor unit
SW--67
18
Ventilation and air--conditioning system electric fan switch
M--68
18
Ventilation and air--conditioning system electric fan
LMP--69
18
Fan control unit lamp
RLY--70
18
Conditioner relay
SEN--71
18
Air--conditioner electronic thermostat
SW--72
18
Air conditioner control switch
C--73
23
Front work lights connection
SW--74
23
Work lights switch
MOD--75
21
Fuse box and cab relays
Rear ground
Cab ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
324 LMP--76
23
Cab front RH work light
LMP--77
23
Cab front LH work light
LMP--78
23
Cab rear RH work light
LMP--79
23
Cab rear LH work light
LMP--80
20
RH cab SMV light
LMP--81
20
LH cab SMV light
LMP--82
23
Cab overhead lighting
BAT--83
17
Battery
ALT--84
17
Alternator
M--85
17
Starter motor
SEN--86
17
Brake fluid level sensor
SEN--87
17
Air filter clogged sensor
C--88
19
Cigar/Cigarette Lighter
SEN--89
17
Sediment unit filter sensor
M--90
17
Air--conditioner compressor
SEN--91
17
Filter/dryer sensor
SEN--92
17
Engine oil pressure sensor
SEN--93
17
Coolant temperature sensor
SOL--94
17
Engine cutout electromagnet
SOL--95
17
Solenoid valve to cut out starting advance, depending on temperature
SW--96
17
Starting advance thermometric cut--out switch
SW--97
9
External lights control switch
SOL--99
28
Front lift UP solenoid valve
SOL--100
28
Front lift DOWN solenoid valve
SEN--101
28
Front lift arms position sensor
MOD--102
28
Front electronic lift control panel
SW--103
28
Front lift up/down control switch
SW--105
9
Front electronic lift block switch
GND--106
1, 6
Four--wheel drive indicator ground
SEN--107
15
Trailer brake indicator light pressure switch
SEN--108
15
Trailer brake circuit safety pressure switch
SOL--109
15
Trailer brake solenoid valves
RLY--110
15
Trailer brake circuit relay
SW--111
8
Rear PTO switch
SEN--112
8
Power steering indicator light pressure switch
SW--113
9
Lights switch
SW--114
8
Gearbox neutral switch
SW--115
8
Splitter switch
SW--116
4
Differential lock indicator switch
SOL--117
4
Differential lock solenoid valve
AUD--118
10
Horn
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 LMP--119
10
Grille LH front work light
LMP--120
10
Front LH headlamp
LMP--121
10
Front RH headlamp
LMP--122
10
Grille RH front work light
SEN--123
7
Fuel level transmitter
SEN--124
1
Four--wheel drive indicator pressure switch
SW--125
6
Shuttle lever switch
SEN--126
1
Steering sensor
SEN--127
1
Rear axle speed sensor
SEN--128
1
Front axle speed sensor
SEN--130
7
Power take--off rpm sensor
SEN--131
5
Draft sensor
SEN--132
5
Arms position sensor
SOL--133
5
Rear electronic lift DOWN solenoid valve
SOL--134
5
Rear electronic lift UP solenoid valve
SOL--135
1
Four--wheel drive solenoid valve
SW--136
4
Stoplamp switch
SOL--138
27
HI--LO mode solenoid valve
SOL--139
27
Shuttle mode solenoid valve
SOL--140
25, 27
Dump solenoid valve
SW--141
25, 27
G1 ranges switch
SW--142
25, 27
C1 gears switch
SW--143
27
Creeper switch
SOL--146
25, 27
Lo clutch solenoid valve
SOL--147
25, 27
Hi clutch solenoid valve
SEN--148
25, 27
Transmission oil temperature sensor
MOD--150
24, 26
Power Shuttle control unit
SW--151
24, 26
Clutch pedal switch
SW--152
24, 26
Power Shuttle control lever
SEN--153
24, 26
Clutch pedal sensor
GND--155
24, 26
Dashboard Power Shuttle ground
MOD--156
6
Grid heater electronic module
RLY--157
6
Grid heater relay (coil)
RLY--158
6
Grid heater relay (contact)
RES--159
6
Grid Heater
F--160
6
125A Maxi--fuse
SW--161
7
”Up/Down” control push--button
SW--162
7
”Enter” control push--button
C--166
4
Brake lights signal test connection
C--167
16, 24, 26
F--168
17
50A mega--fuse
F--169
17
50A mega--fuse
325
Connection for CAN line (4 PIN)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
326 SEN--176
17
Engine rpm sensor
GND--181
15
Trailer brake circuit ground
SEN--182
25
Transmission oil pressure sensor
SW--183
27
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
C--184
20
LH cab SMV light connection
C--185
20
RH cab SMV light connection
SEN--203
27
Shuttle position sensor
MOD--204
28
Four--wheel drive control unit
SW--205
28
Front lift UP external control switch
SW--206
28
Front lift DOWN external control switch
SEN--208
28
Front PTO sensor
LMP--210
13
Number plate light
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
327
WIRING DIAGRAMS 1--2--3--4
MPH2100A
46 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
328
FOUR--WHEEL DRIVE CIRCUIT (Diagram 1)
C--6
Transmission system connection (24 PIN)
GND--7
Dashboard ground
SEN--33
Tilt sensor
SW--35
4WD control switch
MOD--64
Permanent 4WD control unit
GND--106 Four--wheel drive indicator ground SEN--124
Four--wheel drive indicator pressure switch
SEN--126
Steering sensor
SEN--127
Rear axle speed sensor
SEN--128
Front axle speed sensor
SOL--135
Four--wheel drive solenoid valve
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
329 FOUR--WHEEL DRIVE CIRCUIT -- DIAGRAM 1
MPL0133A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
330
BATTERY CUT--OUT CIRCUIT (Diagram 2)
GND--7
Dashboard ground
SW--30
Battery cut--out circuit switch
C--31 CB--31
Connection for battery cut--out circuit on engine Battery cut--out circuit jumper
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
331 BATTERY CUT--OUT CIRCUIT -- DIAGRAM 2
MPL0124A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
332
POWER SOCKETS, WIPER/WASHER PUMPS CIRCUIT (Diagram 3)
C--4 GND--38
25A and 40A power socket connection Rear ground
C--41
Seat connection
M--42
Front and rear window washer pumps
C--46
8A two--pin socket
C--47
40 A four--pole power socket (North America)
C--49
25A two--pin socket
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
333
POWER SOCKETS, WIPER/WASHER PUMPS CIRCUIT -- DIAGRAM 3
MPL0125A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
334
BRAKES, BRAKE LIGHTS, DIFFERENTIAL LOCK CIRCUIT (Diagram 4)
C--6 MOD--25
Transmission system connection (24 PIN) Fuse box and main relay RLY--1
Brake lights circuit
RLY--2
Differential lock circuit
RLY--3
Differential lock circuit
RLY--6
Differential lock circuit
F--19
Stop Lights
F--25
Electronic control unit power supply, (+battery), seat safety circuit
SW--36
Differential lock switch
SW--39
Parking brake switch
SW--116
Differential lock indicator switch
SOL--117
Differential lock solenoid valve
SW--136
Stoplamp switch
C--166
Brake lights signal test connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
335
BRAKES, BRAKE LIGHTS, DIFFERENTIAL LOCK CIRCUIT -- DIAGRAM 4
MPL0134A
87666787A - 11 - 2007
336
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
337
WIRING DIAGRAMS 5--6--7--8
MPH2101A
47 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
338
FRONT AND REAR ELECTRONIC LIFT CIRCUIT (Diagram 5)
GND--7 C--18 MOD--27
Dashboard ground Rear electronic lift connection (8 PIN) Rear lift electronic control unit
SW--34
Rear electronic lift up/down switch
SW--37
LH rear external electronic lift up/down switch
GND--38
Rear ground
MOD--40
Working depth adjustment and rear electronic lift control panel
MOD--43
Rear electronic lift control panel
SW--44
RH rear external electronic lift up/down switch
SEN--131
Draft sensor
SEN--132
Arms position sensor
SOL--133
Rear electronic lift DOWN solenoid valve
SOL--134
Rear electronic lift UP solenoid valve
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
339 FRONT AND REAR ELECTRONIC LIFT CIRCUIT -- DIAGRAM 5
MPL0126A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
340
GRID HEATER CIRCUIT (Diagram 6)
C--6 GND--7 C--16
Transmission system connection (24 PIN) Dashboard ground Electronic thermostarter connection (6 PIN)
GND--106 Four--wheel drive indicator ground SW--125
Shuttle lever switch
MOD--156 Grid heater electronic module RLY--157
Grid heater relay (coil)
RLY--158
Grid heater relay (contact)
RES--159
Grid Heater
F--160
125A Maxi--fuse
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
341 GRID--HEATER CIRCUIT -- DIAGRAM 6
MPL0127A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
342
INSTRUMENT AND SENSOR CIRCUIT (Diagram 7)
C--1
Front side connection -- engine (24 PIN)
C--6
Transmission system connection (24 PIN)
GND--7 MOD--11 SW--32
Dashboard ground Instrument Operator present switch
SEN--123
Fuel level transmitter
SEN--130
Power take--off rpm sensor
SW--161
”Up/Down” control push--button
SW--162
”Enter” control push--button
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
343 INSTRUMENT AND SENSOR CIRCUIT -- DIAGRAM 7
MPL0128A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
344
POWER TAKE--OFF AND SAFETY DEVICE CIRCUIT (Diagram 8)
C--6
Transmission system connection (24 PIN)
C--15
Gearbox neutral connection
SW--111
Rear PTO switch
SEN--112
Power steering indicator light pressure switch
SW--114
Gearbox neutral switch
SW--115
Splitter switch
* **
Standard version Splitter version
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
345
POWER TAKE--OFF AND SAFETY DEVICE CIRCUIT -- DIAGRAM 8
MPL0129A
87666787A - 11 - 2007
346
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
347
WIRING DIAGRAMS 9--10--11--12--13
MPH2102A
48 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
348
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (control switches and flasher) (Diagram 9)
GND--7
Dashboard ground
SW--10
Hazard lights switch
SW--17
Front grille work lights switch
MOD--23
Electronic flasher
MOD--25
Fuse box and main relay RLY--6 F--8
Dipped beam headlight circuit 8A power socket, digital instrument
SW--97
External lights control switch
SW--105
Front electronic lift block switch
SW--113
Lights switch
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
349
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (control switches and flasher) -- DIAGRAM 9
MPL0135A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
350
EXTERNAL LIGHTS AND HORN CIRCUIT (Diagram 10)
C--5
Front lights connection
GND--7
Dashboard ground
LMP--20
RH front direction indicator and side light
LMP--22
LH front direction indicator and side light
MOD--25
Fuse box and main relay F--9
Direction indicator and hazard lights
F--10
Horn, full beam flasher
GND--38
Rear ground
LMP--45
RH tail light
LMP--48
LH tail light
AUD--118
Horn
LMP119
Grille LH front work light
LMP--120
Front LH headlamp
LMP--121
Front RH headlamp
LMP--122
Grille RH front work light
* **
ISO version North America version
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
351 EXTERNAL LIGHTS AND HORN CIRCUIT -- DIAGRAM 10
MPL0130A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
352
POWER SUPPLIES 1 CIRCUIT (Diagram 11)
SW--19 MOD--25
F--26
Start switch Fuse box and main relay F--1
Front right--hand and rear left--hand side lights, side lights indicator
F--2
Front left--hand and rear right--hand side lights, control instrument panel light
F--3
ISO side lights, or 7--pin work light (North America)
F--4
Full beam headlights
F--5
Dipped beam headlights
F--11
Starter safety circuit
F--12
Engine cut--out electromagnet
F--13
Power Shuttle circuit
F--14
Power Shuttle circuit
F--15
Swivel position lights, seat, cab users relay
F--16
Trailer brake and hydraulic adjustment circuit
F--17
Electronic lift circuit
F--18
Permanent 4WD circuit
F--20
GRID--HEATER control unit circuit
F--30
Radio
30A maxi--fuse (40A for North America)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
353 POWER SUPPLIES 1 CIRCUIT -- DIAGRAM 11
MPL0136A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
354
POWER SUPPLIES 2 CIRCUIT (Diagram 12)
GND--7 MOD--25
Dashboard ground Fuse box and main relay RLY--2
Differential lock circuit
RLY--3
Differential lock circuit
RLY--4
Differential lock circuit
RLY--5
Full beam headlight circuit
RLY--13
Engine starter circuit maxi--relay
F--6
+instrument common, +external push--buttons, electronic lift indicator lights
F--7
Differential lock circuit, four--wheel drive circuit
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
355 POWER SUPPLIES 2 CIRCUIT -- DIAGRAM 12
MPL0137A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
356
SEVEN--PIN SOCKET AND NUMBER PLATE LIGHT CIRCUIT (Diagram 13)
C--14
7--pin socket connection
C--14A
ISO seven--pin socket
C--14B
North American seven--pin socket
GND--38
Rear ground
LMP--210
Number plate light
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
357
SEVEN--PIN SOCKET AND NUMBER PLATE LIGHT CIRCUIT -- DIAGRAM 13
MPL0131A
87666787A - 11 - 2007
358
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
359
WIRING DIAGRAMS 14--15--16--17
MPH2103A
49 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
360
DIAGNOSTICS CONNECTION CAN LINE CIRCUIT (Diagram 14)
GND--7 C--28
Dashboard ground Diagnostics connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
361
DIAGNOSTICS CONNECTION CAN LINE CIRCUIT -- DIAGRAM 14
MPL0138A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
362
TRAILER BRAKE CIRCUIT (Diagram 15)
C--3 GND--7
Trailer brake circuit intermediate connection (4 PIN) Dashboard ground
C--8
Trailer brake circuit main connection (4 PIN)
SEN--107
Trailer brake indicator light pressure switch
SEN--108
Trailer brake circuit safety pressure switch
SOL--109
Trailer brake solenoid valves
RLY--110
Trailer brake circuit relay RLY--9
Trailer brake circuit
RLY--10
Trailer brake circuit
RLY--13
Trailer brake circuit
GND--181 Trailer brake circuit ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
363 TRAILER BRAKE CIRCUIT -- DIAGRAM 15
MPL0139A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
364
INTERMEDIATE CONNECTIONS CIRCUIT (Diagram 16)
C--2
Cab system connection (20 PIN)
C--21
Power--Shuttle system connection (6 PIN)
C--167
Connection for CAN line (4 PIN)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
365 INTERMEDIATE CONNECTIONS CIRCUIT -- DIAGRAM 16
MPL0140A
87666787A - 11 - 2007
366
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 ENGINE, SENSORS AND TRANSMITTERS CIRCUIT (Diagram 17)
C--1
Front side connection -- engine (24 PIN)
GND--7
Dashboard ground
BAT--83
Battery
ALT--84
Alternator
M--85
Starter motor
SEN--86
Brake fluid level sensor
SEN--87
Air filter clogged sensor
SEN--89
Sediment unit filter sensor
M--90
Air--conditioner compressor
SEN--91
Filter/dryer sensor
SEN--92
Engine oil pressure sensor
SEN--93
Coolant temperature sensor
SOL--94
Engine cutout electromagnet
SOL--95
Solenoid valve to cut out starting advance, depending on temperature
SW--96
Starting advance thermometric cut--out switch
F--168
50A mega--fuse
F--169
50A mega--fuse
SEN--176 (NEF)
Engine rpm sensor (for engine on models 4040 and 4050)
SEN--176 (N5C)
Engine rpm sensor (for F5C engine)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
367
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT -- DIAGRAM 17
MPL0132A
87666787A - 11 - 2007
368
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
369
WIRING DIAGRAMS 18--19--20--21--22--23
MPH2104A
50 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
370
CAB VENTILATION AND AIR--CONDITIONING CIRCUIT (Diagram 18)
GND--57 C--62
Cab ground Fan unit connection
RES--66
Fan speed resistor unit
SW--67
Ventilation and air--conditioning system electric fan switch
M--68
Ventilation and air--conditioning system electric fan
LMP--69
Fan control unit lamp
RLY--70
Conditioner relay
SEN--71
Air--conditioner electronic thermostat
SW--72
Air conditioner control switch
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
371
CAB VENTILATION AND AIR--CONDITIONING CIRCUIT -- DIAGRAM 18
MPL0145A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
372
ROTATING BEACON CIRCUIT (Diagram 19)
C--29 GND--57 SW--63 C--88
Rotating beacon power socket Cab ground Rotating beacon control switch Cigar/Cigarette Lighter
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
373 ROTATING BEACON CIRCUIT -- DIAGRAM 19
MPL0146A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
374
SUPPLEMENTARY DIRECTION INDICATOR LIGHTS AND RADIO CIRCUIT (Diagram 20)
C--2
Cab system connection (20 PIN)
GND--57
Cab ground
MOD--58
Radio
AUD--60
RH speaker
AUD--61
LH speaker
LMP--80
RH cab SMV light
LMP--81
LH cab SMV light
C--184
LH cab SMV light connection
C--185
RH cab SMV light connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
375
SUPPLEMENTARY DIRECTION INDICATOR LIGHTS AND RADIO CIRCUIT -- DIAGRAM 20
MPL0147A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
376
CAB POWER SUPPLY CIRCUIT (Diagram 21)
C--2
Cab system connection (20 PIN)
GND--57
Cab ground
MOD--75
Fuse box and cab relays RLY--1
Rear work lights circuit
RLY--2
Ignition switch controlled cab users circuit
RLY--3
Air--conditioner compressor circuit
RLY--4
Front work lights circuit
F--1
Front work lights
F--2
Rear work lights
F--3
Rotating beacon, cigar lighter, overhead lighting, radio
F--4
Rear window wiper/washer
F--5
Windscreen wiper/washer
F--6
Air conditioning, fan unit
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
377 CAB POWER SUPPLY CIRCUIT -- DIAGRAM 21
MPL0148A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
378
WINDSCREEN AND REAR WINDOW WASHER/WIPER CIRCUIT (Diagram 22)
C--2
Cab system connection (20 PIN)
SW--52
Front windscreen washer switch
SW--53
Windscreen wiper switch
M--54 SW--55 M--56 GND--57
Wiper motor Rear window washer/wiper switch Rear wiper motor Cab ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
379 WIPER/WASHER CIRCUIT -- DIAGRAM 22
MPL0149A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
380
WORK LIGHTS CIRCUIT (Diagram 23)
C--2 GND--57 C--73
Cab system connection (20 PIN) Cab ground Front work lights connection
SW--74
Work lights switch
LMP--76
Cab front RH work light
LMP--77
Cab front LH work light
LMP--78
Cab rear RH work light
LMP--79
Cab rear LH work light
LMP--82
Cab overhead lighting
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
381 WORK LIGHTS CIRCUIT -- DIAGRAM 23
MPL0150A
87666787A - 11 - 2007
382
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
383
WIRING DIAGRAMS 24--25--26--27--28
MPM0697A
51 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
384
POWER--SHUTTLE CIRCUIT 8+8 / 16+16 (dashboard side) (Diagram 24)
C--9
Power--Shuttle transmission system connection (24 PIN)
C--21
Power--Shuttle system connection (6 PIN)
MOD--150 Power Shuttle control unit SW--151
Clutch pedal switch
SW--152
Power Shuttle control lever
SEN--153
Clutch pedal sensor
GND--155 Dashboard Power Shuttle ground C--167
Connection for CAN line (4 PIN)
NC = Not connected
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
385
POWER SHUTTLE CIRCUIT 8+8 / 16+16 (dashboard side) -- DIAGRAM 24
MPL0143A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
386
POWER SHUTTLE CIRCUIT (transmission side) (Diagram 25)
C--9
Power--Shuttle transmission system connection (24 PIN)
SOL--140
Dump solenoid valve
SW--141
G1 ranges switch
SW--142
C1 gears switch
SOL--146
Lo clutch solenoid valve
SOL--147
Hi clutch solenoid valve
SEN--148
Transmission oil temperature sensor
SEN--182
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
387 POWER SHUTTLE CIRCUIT (transmission side) -- DIAGRAM 25
MPL0144A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
388
POWER--SHUTTLE CIRCUIT 32+16 / 44+16 (dashboard side) (Diagram 26)
C--9
Power--Shuttle transmission system connection (24 PIN)
C--21
Power--Shuttle system connection (6 PIN)
MOD--150 Power Shuttle control unit SW--151
Clutch pedal switch
SW--152
Power Shuttle control lever
SEN--153
Clutch pedal sensor
GND--155 Dashboard Power Shuttle ground C--167
Connection for CAN line (4 PIN)
NC = Not connected
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
389
POWER SHUTTLE CIRCUIT 32+16 / 44+16 (dashboard side) -- DIAGRAM 26
MPL0141A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
390
POWER SHUTTLE CIRCUIT (transmission side) (Diagram 27)
C--9
Power--Shuttle transmission system connection (24 PIN)
SOL--138
HI--LO mode solenoid valve
SOL--139
Shuttle mode solenoid valve
SOL--140
Dump solenoid valve
SW--141
G1 ranges switch
SW--142
C1 gears switch
SW--143
Creeper switch
SOL--146
Lo clutch solenoid valve
SOL--147
Hi clutch solenoid valve
SEN--148
Transmission oil temperature sensor
SW--183
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
SEN--203
Shuttle position sensor
* **
Version with Power Shuttle 44+16 e 32+16 with Dual Command (2 Speed Power Shift) function Version with Power Shuttle 44+16 e 32+16 with Dual Command (2 Speed Power Shift) function (paddy field version)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
391 POWER SHUTTLE CIRCUIT (transmission side) -- DIAGRAM 27
MPL0142A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
392
FRONT PTO CIRCUIT (Diagram 28)
SW--12 C--13
Front PTO switch Front PTO and lift system connection (13 PIN)
SOL--99
Front lift UP solenoid valve
SOL--100
Front lift DOWN solenoid valve
SEN--101
Front lift arms position sensor
MOD--102 Front electronic lift control panel SW--103
Front lift up/down control switch
MOD--204 Four--wheel drive control unit SW--205
Front lift UP external control switch
SW--206
Front lift DOWN external control switch
SEN--208
Front PTO sensor
87666787A - 11 - 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
393 FRONT PTO CIRCUIT − DIAGRAM 28
MPL0151A
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
394
ELECTRONIC CONTROL UNIT INPUT/OUTPUT WIRING DIAGRAM POWER SHUTTLE 16+16 (SB) 1. 2. 3. 4. 5. 6. 7. 8.
9.
10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Ignition switch (SW−19). Starter relay (RLY−13). Starter motor (M−85). Battery (BAT−83). Clutch pedal switch (SW−151), view in starting position (pedal pressed and shuttle level on neutral), with pedal released and shuttle lever engaged (not on neutral) it supplies current to the control unit (12VD) that will supply the forward and reverse clutches. Supply line to the sensors and potentiometers of 5 Volts that the control unit provides directly. Clutch pedal potentiometer (SEN−153). Shuttle lever (SW−152), composed of three switches: a) common switch − neutral position (starting), forward/reverse position 12VD supply to the two clutches A and B, b) switch with forward gear diagnostics, c) switch with reverse gear diagnostics. Transmission pressure switch (SEN−182) in versions: a) without power shuttle it is replaced by part 8 (SEN_112) of the ADIC control unit (ZA) b) with power shuttle and Dual Command (2−Speed Power Shift), the pressure switch is not needed in the starting phase, the control unit moves the synchro (Dual Command (2−Speed Power Shift) / power shuttle) to the opposite side from where it is at starting. From the movement of the synchronizer, controlled by the potentiometer (SEN−203) part 12 of the power shuttle / Dual Command (2−Speed Power Shift) control unit. The control unit, on receiving a signal from the potentiometer, understands the power steering pump that supplies the clutch pack oil works properly. Gear lever position switch (SW−142). Range lever position switch (SW141). Transmission temperature sensor (SEN−148). CAN BUS line wires input, inside the control unit there is the terminator (resistance 120 Ohm). Ground that the control unit supplies to the various sensors (observe the triangular end, on all the sensors where at a pin and marked with this symbol they receive ground straight from the control unit). Discharge solenoid (SOL−140). Reverse gear clutch B solenoid (SOL−147). Forward gear clutch A solenoid (SOL−146). Control unit supply: 12 VD − from clutch pedal switch, 12 VF and 12 VP − directly from the fuses. Control unit ground type
NOTE: A) the numbers in brackets are the correspondence with the sensors, switches, ...... of the diagram. B) On the control unit the connectors are identified with CN1b and corresponds to connector MOD−150.
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
395
INPUT/OUTPUT WIRING DIAGRAM FOR THE ELECTRONIC CONTROL UNIT OF POWER SHUTTLE 16+16 (SB)
5
1 +30 +50a
17
6 +15/1
+15
2
18
7
16 3
8
15
4
16 + 16 9
(SB)
10
11
12 19
13
87666787A2 − 06 − 2009
14
396
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
ELECTRONIC CONTROL UNIT INPUT/OUTPUT WIRING DIAGRAM POWER SHUTTLE / DUAL COMMAND (2 SPEED POWER SHIFT) 32+16 / 44+16 (SB) 1. 2. 3. 4. 5. 6. 7. 8.
9. 10. 11. 12.
13. 14. 15. 16.
17. 18. 19. 20. 21. 22. 23.
Ignition switch (SW−19). Starter relay (RLY−13). Starter motor (M−85). Battery (BAT−83). Clutch pedal switch (SW−151), view in starting position (pedal pressed and shuttle level on neutral), with pedal released and shuttle lever engaged (not on neutral) it supplies current to the control unit (12VD) that will supply the forward and reverse clutches. Supply line to the sensors and potentiometers of 5 Volts that the control unit provides directly. Clutch pedal potentiometer (SEN−153). Shuttle lever (SW−152), composed of three switches: a) common switch − neutral position (starting), forward/reverse position 12VD supply to the two clutches A and B, b) switch with forward gear diagnostics, c) switch with reverse gear diagnostics. Creeper unit position switch (SW−143) Gear lever position switch (SW−142). Range lever position switch (SW141). Shuttle synchronizer position potentiometer / Dual Command (2 Speed Power Shift) (SEN−203). In the starting phase the control unit moves the synchro (Dual Command (2−Speed Power Shift) / power shuttle) to the opposite side from where it is at starting. From the movement of the synchronizer, controlled by the potentiometer. This sends a signal to the control unit that understands the power steering pump that supplies the clutch pack oil works properly. Transmission temperature sensor (SEN−148). CAN BUS line wires input, inside the control unit there is the terminator (resistance 120 Ohm). Ground that the control unit supplies to the various sensors (observe the triangular end, on all the sensors where at a pin and marked with this symbol they receive ground straight from the control unit). Gear lever (SW−183) with buttons: a) HI used to select fast speed b) LO used to select slow speed c) DUMP used to change gears, within the same range, without pressing the clutch pedal. Discharge solenoid (SOL−140). Synchronizer movement solenoid in shuttle mode (SOL−139). Synchronizer movement solenoid in Dual Command (2 Speed Power Shift) mode (SOL138). Reverse gear clutch B solenoid (SOL−147). Forward gear clutch A solenoid (SOL−146). Control unit supply: 12 VD − from clutch pedal switch, 12 VF and 12 VP − directly from the fuses. Control unit ground type
NOTE: A) the numbers in brackets are the correspondence with the sensors, switches, ...... of the diagram. B) On the control unit the connectors are identified with CN1b and corresponds to connector MOD−150.
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
397
INPUT/OUTPUT WIRING DIAGRAM FOR THE ELECTRONIC CONTROL UNIT OF POWER SHUTTLE / DUAL COMMAND (2 SPEED POWER SHIFT) 32+16 / 44+16 (SB)
5
1 +30 +50a
21
6 +15/1
+15
2
18
7
20 19
3 18 8 4
9 17
32+16 / 44+16
10
(SB)
11 16
12 22
13
14
87666787A2 − 06 − 2009
15
398
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
INPUT/OUTPUT WIRING DIAGRAM FOR THE ELECTRONIC CONTROL UNIT OF THE FOUR−WHEEL DRIVE (SC) FOUR−WHEEL DRIVE, POWER TAKE−OFF AND FRONT LIFT (SD) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
Switch for engaging manual / automatic four−wheel drive (SW−−35). Pressure switch, normally closed left (SW−136B) brakes pump. Pressure switch, normally closed right (SW−136A) brakes pump. Tilt sensor (SEN−33). Four−wheel drive switches sensors supply fuse control line. Reverse gear switch, for manual transmissions only, (SW−125). Steering angle sensor mounted on axle (SEN−126). Rear shaft speed sensor (theoretical transmission speed) mounted in the four−wheel drive transmission (SEN−127). Front shaft speed sensor (front axle speed) mounted in the four−wheel drive transmission (SEN−128). Signal from the left indicator. Signal from the right indicator. CAN BUS line wires input. Ground that the control unit supplies to the various sensors (observe the triangular end, on all the sensors where at a pin and marked with this symbol they receive ground straight from the control unit). Four−wheel drive disengagement solenoid (SOL−135). Control unit supply. Electromagnetic clutch slip sensor (SEN−208). Supply line sent from the control unit (+5 Volt reference) to parts 18, 19 and 20. Potentiometer for upper limit of travel of lift (MOD−102) fitted on the dashboard. Potentiometer for lower limit of travel of lift arms (MOD−102) fitted on the dashboard. Potentiometer for travel of lift arms (SEN−101). Ground line sent from the control unit to parts 18, 19 and 20. Power take−off switch fitted on dashboard (SW−12). External push−buttons for lowering (SW−206) and lifting (SW−205). Push−button for fast lifting, lowering fitted on the dashboard SW−103). Lowering solenoid (SOL−100). Lifting solenoid (SOL−99). Electromagnetic clutch flor engaging front power take−off (SEN−208). Control unit ground type.
NOTE: A) the numbers in brackets are the correspondence with the sensors, switches, ...... of the diagram. B) On the control unit the connectors are identified with CN1a and CN1b corresponding respectively to the connectors MOD−204 (front power take−off and front lift) and MOD−64 (four−wheel drive).
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
399
INPUT/OUTPUT WIRING DIAGRAM FOR THE ELECTRONIC CONTROL UNIT OF THE FOUR−WHEEL DRIVE (SC) FOUR−WHEEL DRIVE, POWER TAKE−OFF AND FRONT LIFT (SD)
15
27
1
26
2 14
3
25
4 5
24
6 7 23 16
8
22
9 17 18
10
19
11
20 21
(SD) 13 12
87666787A2 − 06 − 2009
28
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
400
ELECTRONIC CONTROL UNIT INPUT/OUTPUT WIRING DIAGRAM EDC ELECTRONIC LIFT (SA) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
+8 Volt supply line that the control unit sends to the potentiometers and sensors. Working depth lever potentiometer (MOD−40). Lifting limit potentiometer (MOD−43). Lowering limit potentiometer (MOD−43). Drop rate limit potentiometer (MOD−43). Position / work potentiometer (MOD−43). Ground entry and work lift switch (SW−34). Raise / lower switches on the mudguards (SW−37, SW−44). Draft sensor (SEN−131). Arms position potentiometer (SEN−132). CAN BUS line wires input. Ground that the control unit supplies to the various sensors (observe the triangular end, on all the sensors where at a pin and marked with this symbol they receive ground straight from the control unit). Types of grounds. Disabled lift warning light (MOD−40). Lowering solenoid valve (SOL−133). Lifting solenoid valve (SOL−134) Control unit supplies.
NOTE: A) the numbers in brackets are the correspondence with the sensors, switches, ...... of the diagram. B) On the control unit the connectors are identified with CN1b and corresponds to connector MOD−27.
87666787A2 − 06 − 2009
404
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
1
SECTION 55 -- ELECTRICAL SYSTEM Chapter 7 -- ELECTRIC CIRCUITS TRACTORS FITTED WITH PLATFORM
CONTENT
Section
Description
Page
55 100
Electrical circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical circuit components (numerical order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuse and relay layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Power sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Ground location points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 How to use the wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Connector code reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Wire colour coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Symbols used in electrical circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Wiring diagram components (functional order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Version index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 VERSION 1 2WD models, rear mechanical lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 VERSION 2 Electrohydraulic four--wheel drive, electrohydraulic differential lock, mechanical rear lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 VERSION 3 Permanent four--wheel drive, electrohydraulic differential lock, mechanical rear lift . . . 133
87666787A - 11 - 2007
2
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
3
ELECTRICAL CIRCUIT COMPONENTS This section lists a description of the electrical components forming the tractors system. There are two lists, divided in the following order: 1. Numerical order (increasing) page 4;
DESCRIPTION
SUFFIX ALT
Alternator
AUD
Audio devices
BAT
Battery
CB
Battery cut--out
C Post Code
Ports Capacitor
D
Diode
F
Fuse
GND
Counterweights
LMP
Lamps
LED
LED
MOD
Control units
M
2. Functional order (divided by type of components) page 21. Below is an explanation of the suffixes related to each component.
Engine hp
RLY
Relays
RES
resistance
SEN
Sensor
SOL
Electric Solenoid
SW
Switch
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
4
ELECTRICAL CIRCUIT COMPONENTS (numerical order) C--1 C--3 C--4 C--5 C--6 GND--7 C--8 C--9 SW--10 MOD--11 SW--12 C--13 C--14 C--14A C--14B C--15 C--16 SW--17 SW--19 LMP--20 C--21 LMP--22 MOD--23 C--24 MOD--25 F--26 C--28 SW--32 SEN--33 SW--35 SW--36 GND--38 SW--39 C--41 LMP--45 C--46 C--47 LMP--48 C--49 MOD--64 BAT--83 ALT--84 M--85 SEN--86 SEN--87 SEN--89
Front side connection -- engine (24 PIN) Trailer brake circuit intermediate connection (4 PIN) 25A / 40A socket connection Front lights connection Transmission system connection (24 PIN) Dashboard ground Trailer brake circuit main connection (4 PIN) Power--shuttle system connection (24 PIN) Hazard lights switch Instrument Front PTO switch Front lift and PTO system connection (13 PIN) Seven--pin socket connection ISO seven--pin socket North American seven--pin socket Gearbox neutral connection Electronic thermostarter connection (6 PIN) Front grille work lights switch Starter switch RH front direction indicator and side light Power--Shuttle system connection (6 PIN) LH front direction indicator and side light Electronic flasher Digital instrument connection Fuse box and main relay 30A maxi--fuse (40A for North America) Diagnostics connection Operator present switch Tilt sensor 4WD control switch Differential lock switch Rear ground Parking brake switch Seat connection RH tail light 8A two--pin socket 40A four--pole socket (North America) LH tail light 25A two--pin socket Permanent 4WD control unit Battery Alternator Starter motor Brake fluid level sensor Air filter clogged sensor Sediment unit filter sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
5
ELECTRICAL CIRCUIT COMPONENTS (Continued) SEN--92 SEN--93 SOL--94 SOL--95 SW--96 SW--97 SOL--99 SOL--100 SEN--101 MOD--102 SW--103 SW--104 SW--105 GND--106 SEN--107 SEN--108 SOL--109 RLY--110 SW--111 SEN--112 SW--114 SW--115 SW--116 SOL--117 AUD--118 LMP--119 LMP--120 LMP--121 LMP--122 SEN--123 SEN--124 SW--125 SEN--126 SEN--127 SEN--128 SEN--129 SEN--130 SOL--135 SW--136 SOL--138 SOL--139 SOL--140 SW--141 SW--142 SW--143 SOL--146
Engine oil pressure sensor Coolant temperature sensor Engine cut--out electromagnet Solenoid valve to cut out starting advance, depending on temperature Starting advance thermometric cut--out switch External lights control switch Front lift UP solenoid valve Front lift DOWN solenoid valve Front lift arms position sensor Front electronic lift control panel Front lift up/down switch Front PTO switch Front electronic lift block switch 4WD indicator ground Trailer brake indicator light pressure switch Trailer brake circuit safety pressure switch Trailer brake solenoid valves Trailer brake circuit relay Rear PTO switch Power steering indicator light pressure switch Gearbox neutral switch Splitter switch Differential lock indicator switch Differential lock solenoid valve Horn Grille LH front work light Front LH headlamp Front RH headlamp Grille RH front work light Fuel level transmitter 4WD indicator pressure switch Shuttle lever switch Steering sensor Rear axle speed sensor Front axle speed sensor Ground speed sensor PTO rpm sensor 4WD solenoid valve Stoplamp switch Dual Command (2 Speed Power Shift) mode solenoid valve Shuttle mode solenoid valve Dump solenoid valve G1 ranges switch C1 gears switch Creeper switch Lo clutch solenoid valve
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
6
ELECTRICAL CIRCUIT COMPONENTS (Continued) SOL--147 SEN--148 MOD--150 SW--151 SW--152 SEN--153 GND--155 MOD--156 RLY--157 RLY--158 RES--159 F--160 SW--161 SW--162 C--166 C--167 F--169 C--175 SEN--176 MOD--177 LMP--178 C--179 C--180 GND--181 SEN--182 SW--183 SEN--203 MOD--204 SW--205 SW--206 SEN--208 LMP--212 LMP--213 LMP--214 GND--215
Hi clutch solenoid valve Transmission oil temperature sensor Power Shuttle control unit Clutch pedal switch Power Shuttle control lever Clutch pedal sensor Dashboard Power Shuttle ground Grid heater electronic module Grid heater relay (coil) Grid heater relay (contact) Grid heater 125A maxi--fuse ”Up/Down” control button ”Enter” control button Brake lights signal test connection Connection for CAN line (4 PIN) 50A mega--fuse Four--wheel drive system connection (4 PIN) Engine rpm sensor Digital instrument Work light Rear lights connection (2 PIN) Rear lights connection (6 PIN) Trailer brake circuit ground Transmission oil pressure sensor Dual Command (2 Speed Power Shift) and Dump Clutch buttons Shuttle position sensor Four--wheel drive control unit Front lift UP external control switch Front lift DOWN external control switch Front PTO sensor Number plate light RH two--faced headlight LH two--faced headlight Power sockets ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
7
LOCATION OF FUSES AND RELAYS DANGER: If electrical system relays need to be changed, check that correct spare parts are used and that they are fitted in the correct positions. The use of structurally or functionally different relays -- even if interchangeable -- could seriously compromise tractor control with dangerous results.
VERSION 1 (with roll bar) Fig. 1 Two--wheel drive models with mechanical lift, fitted for: -- Power Shuttle unit -- Digital instrument -- 30/40A power socket -- North America circuit -- Trailer Brake -- Electrohydraulic differential lock -- Grid--heater circuit
List of relay functions I.
Brake lights circuit.
II.
Differential lock circuit.
III.
Not used.
IV.
Differential lock circuit.
V.
Full beam headlight circuit.
VI.
Dipped beam headlight circuit.
VII.
Not used.
VIII.
Not used.
IX.
Not used.
X.
Side lights circuit.
XI.
Not used.
XII.
Not used.
XIII.
Engine starter circuit maxi--relay.
1
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
8 Main fusebox
Version 1 tractors, page 7 Valves
Amps.
PROTECTED CIRCUITS
1
5
Front right--hand and rear left--hand side lights, side lights indicator.
2
5
Front left--hand and rear right--hand side lights, control instrument panel light.
3
15
ISO side lights, or 7--pin work light (North America).
4
15
Full beam headlights.
5
15
Dipped beam headlights.
6
5
+ Instrument common.
7
10
Differential lock circuit.
8
10
8A power socket, digital instrument.
9
15
Direction indicator and hazard lights.
10
10
Horn, full beam flasher, seat safety circuit.
11
5
Starter safety circuit.
12
5
Engine cut--out electromagnet.
13
10
Power Shuttle circuit.
14
10
Power Shuttle circuit.
15
15
Swivel position lights.
16
10
Trailer brake and hydraulic adjustment circuit.
17
--
Not used.
18
--
Not used.
19
10
Stop Lights.
20
7.5
Electronic control unit power supply, +battery.
21
--
Not used.
22
--
Not used.
23
--
Not used.
24
--
Not used.
25
--
Not used.
26
--
Not used.
27
5
Rear work light circuit.
28
--
Not used.
Maxi--fuses 30A ISO power socket 40A North America power socket
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
9
VERSION 2 (with roll bar) Fig. 2 4--wheel drive models with: Electrohydraulic differential lock, electrohydraulic four--wheel drive and mechanical lift, fitted for: -------
Power Shuttle unit Digital instrument 30/40A power socket North America circuit Trailer Brake Grid--heater circuit
List of relay functions I.
Brake lights circuit.
II.
Differential lock circuit.
III.
Differential lock circuit.
IV.
Differential lock circuit.
V.
Full beam headlight circuit.
VI.
Dipped beam headlight circuit.
VII.
4WD and brake lights circuit.
VIII.
Not used.
IX.
Not used.
X.
Side lights circuit.
XI.
Not used.
XII.
Not used.
XIII.
Engine starter circuit maxi--relay.
2
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
10 Main fusebox
Version 2 tractors, page 9 Valves
Amps.
PROTECTED CIRCUITS
1
5
Front right--hand and rear left--hand side lights, side lights indicator.
2
5
Front left--hand and rear right--hand side lights, control instrument panel light.
3
15
ISO side lights, or 7--pin work light (North America).
4
15
Full beam headlights.
5
15
Dipped beam headlights.
6
5
+ Instrument common.
7
10
Differential lock circuit, four--wheel drive circuit.
8
10
8A power socket, digital instrument.
9
15
Direction indicator and hazard lights.
10
10
Horn, full beam flasher, seat safety circuit.
11
5
Starter safety circuit.
12
5
Engine cut--out electromagnet
13
10
Power Shuttle circuit.
14
10
Power Shuttle circuit.
15
15
Swivel position lights, seat.
16
10
Trailer brake and hydraulic adjustment circuit.
17
--
Not used.
18
--
Not used.
19
10
Stop Lights.
20
7.5
Electronic control unit power supply, (+battery).
21
--
Not used.
22
--
Not used.
23
--
Not used.
24
--
Not used.
25
--
Not used.
26
--
Not used.
27
5
Rear work light circuit.
28
--
Not used.
Maxi--fuses 30A ISO power socket 40A North America power socket
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
11
VERSION 3 (with roll bar) Fig. 3 4WD models with mechanical lift and electrohydraulic differential lock, fitted for: -- Power Shuttle unit -- Digital instrument -- 30/40A power socket -- North America circuit -- Trailer Brake -- Grid--heater circuit
List of relay functions I.
Brake lights circuit.
II.
Differential lock circuit.
III.
Differential lock circuit.
IV.
Differential lock circuit.
V.
Full beam headlight circuit.
VI.
Dipped beam headlight circuit.
VII.
Not used.
VIII.
Not used.
IX.
Not used.
X.
Side lights circuit.
XI.
Not used.
XII.
Not used.
XIII.
Engine starter circuit maxi--relay.
3
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
12 Main fusebox
Version 3 tractors, page 11 Valves
Amps.
PROTECTED CIRCUITS
1
5
Front right--hand and rear left--hand side lights, side lights indicator.
2
5
Front left--hand and rear right--hand side lights, control instrument panel light.
3
15
ISO side lights, or 7--pin work light (North America).
4
15
Full beam headlights.
5
15
Dipped beam headlights.
6
5
+ Instrument common.
7
10
Differential lock circuit, four--wheel drive circuit.
8
10
8A power socket, digital instrument.
9
15
Direction indicator and hazard lights.
10
10
Horn, full beam flasher, seat safety circuit.
11
5
Starter safety circuit.
12
5
Engine cut--out electromagnet.
13
10
Power Shuttle circuit.
14
10
Power Shuttle circuit.
15
15
Swivel position lights.
16
10
Trailer brake and hydraulic adjustment circuit.
17
5
Front lift circuit.
18
10
Permanent 4WD circuit.
19
10
Stop Lights.
20
7.5
Electronic control unit power supply, +battery.
21
--
Not used.
22
--
Not used.
23
--
Not used.
24
--
Not used.
25
--
Not used.
26
--
Not used.
27
5
Rear work light circuit.
28
--
Not used.
Maxi--fuses 30A ISO power socket 40A North America power socket
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
13
POWER SOCKETS (Fig. 4) The power sockets are located on the rear of the tractor, on the left--hand side. 1. Seven--pole socket. 2. 25 A two--pole power socket (ISO) 40 A four--pole power socket (North America)
MPE0204A
4 Seven--pole power socket (Fig. 5) The PTO contacts carry out the following functions: 1 -- L.
Left turn lamps.
2 -- 54G. Not used. 3 -- 31.
Ground.
4 -- R.
Right turn lamps.
5 -- 58R.
RH side lights.
6 -- 54.
Brake lights.
7 -- 58L.
LH side lights.
MPE0201A
5 25 A two--pole power socket (ISO version) (Fig. 6) Located under the seven--pole power socket and provided with two positive terminals and one ground, with the following positions: 82.
Key--controlled power.
54.
Direct power.
31.
Ground. MPE0200A
6 40 A power socket (North America version) (Fig. 7) Provides the following positions: 82.
Key--controlled power.
54.
Direct power.
31.
Ground.
58L.
Ground.
58R.
Direct power. MPE0202A
7 87666787A - 11 - 2007
14
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
GRID HEATER RELAY (Fig. 8) The power relay for the starter pre--heating system (1) is located in the engine compartment in the area underneath the brake fluid reservoir. The relay is connected with two 16 mm2 power cables (2) and a connector (3) to power the coil.
1
3 MPH1931A
2 8
GRID HEATER CONTROL MODULE (Fig.. 9) The pre--heating control module (1) is located inside the panel and it controls the above--described power relay.
1
MPH1929A
9
ELECTRONIC FLASHER MODULE (Fig. 10) This module (1) is located inside the panel on the left--hand side near the fuse and relay control unit (2). This electronic device governs the operation of the direction indicators and hazard lights of the entire tractor.
1
2 MPH1930
10
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
15
GROUND LOCATION POINTS A.
Control panel ground.
B.
Engine compartment ground.
C. Seat ground. D. Rear ground (power sockets, headlights). E.
Main rear ground (transmission).
F.
Chassis Ground.
G. Battery ground.
87666787A - 11 - 2007
16
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 GROUND POINTS LAYOUT
MPM1005A
11 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
17
HOW TO USE THE WIRING DIAGRAMS The wiring diagrams are included in each version (type of transmission) and they have been drawn up in a functional manner. This means that the complete wiring diagram of a certain tractor version has been drawn over a number of pages, each one of which includes the
38
S E ZIONE 55 -- IMP IANT O ELE TT R ICO -- CAP IT O LO 6
S EZ IONE 55 -- IMP IANT O ELE T T R ICO -- CAP IT O LO 6
CIRCUITO DOPPIA TRAZIONE (S ch em a 1)
Connes
s ione
G N D -- 7
Ma ssa
cru sco tto
S E N -- 33
C -- 6
S ens or e inc linaz ione
im piant o tr a s m is s ione
S W -- 35
In te r r u t to r e c o m ando doppia
doppia
t ra z ione
39
CIRCUITO DOPPIA TRAZIONE -- S CHEMA 1
( 2 4 p in)
tr a z ione
M O D -- 6 4
C ent r a lina
G N D -- 106
M a s s a s egnalat
S E N -- 124
P res s o s tat o s egnalat
S E N -- 126
S ens or e d i s te rz o
S E N -- 127
S ens or e v eloc ità a s s a le pos te rior e
S E N -- 128
S ens or e v eloc ità a s s a le ant er ior e
S O L -- 135
E let tr ov alv o la doppia
or e doppia
portion of circuit related to one or more functions (e.g. ”Front and rear electronic lift”; ”Direction indicators and hazard lights”, etc.). All these pages, if joined together would make a complete diagram of the tractor for each version.
per m anent
e
tr a z ione
or e doppia
tr a z ione
tr a z ione
MPG1331A 87666786
-- 11 -- 2007
87666786
-- 11 - 2007
MPM0701A
12 There are a number of guides to help assist in reading and understanding the wiring diagrams. 1. The wiring diagrams (2) are located on the right--hand pages; the titles and keys (1) are on the left--hand pages. The title defines the function to which the diagram refers, the key indicates all the components on that specific page of the diagram.
2. The components and connectors are identified by an abbreviation composed of an alphabetical portion and a numerical portion: -- the alphabetical portion indicates the type of component (e.g. F indicates a fuse, C indicates a connector, MOD indicates a module, SW indicates a switch, etc.), -- the numerical portion is a progressive number.
87666787A - 11 - 2007
18
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
3. On each connecting wire there is an abbreviation indicating the colour and cross--section of the wire: the first letter (1) indicates the main colour of the wire, the second letter (2) indicates the colour of the striping along the wire, the number (3) indicates the cross--section of the wire in mm2.
MPM0708A
13 4. To be able to follow the circuit in its entirety, each wire continuing onto a different page of the diagram ends with an arrow and a reference to the page on which it continues or from which it comes. This reference is composed of an abbreviation made up of a number indicating the sheet of the diagram on which the wire continues and one or more letters to indicate the wire on the page being referred to. The following example gives a reference between diagram 1 (ref. 1), for the cab version and diagram 3 (ref. 2) (Fig. 14, 15)
MPM0699A
14
MPM0700A
15 5. The termination of the wire on a component is indicated with the symbol of the connection (see the key of symbols used on the diagrams) and the number of the pin on which the wire is connected (ref. 1) (Fig. 16).
MPM0699A
16 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
19
CONNECTOR CODE READING The connections on the wiring diagrams are indicated as in the following example. In this example the abbreviation (1) indicates the number of the key of the connection while the second abbreviation (2) indicates the number of the pin of the same connection.
MPM0727A
17
WIRE COLOUR CODING A
Light Blue
HV
Grey/green
AN
Light blue/black
HG
Grey/yellow
AG
Light blue/yellow
I
Blue
AB
Light blue/white
LB
Blue/white
AV
Light blue/green
LN
Blue/black
AR
Light blue/red
LR
Blue/red
B
White
M
Brown
BR
White/red
MB
Brown/white
BN
White/black
MN
Brown/black
BL
White/blue
N
Black
BG
White/yellow
NZ
Black/purple
C
Orange
NB
Black/white
CB
Orange/white
NR
Black/red
CN
Orange/black
R
Red
CL
Orange/blue
RG
Red/yellow
G
Amber
RN
Red/black
GV
Yellow/green
RV
Red/green
GN
Yellow/black
S
Pink
GR
Yellow/red
SN
Pink/black
GL
Yellow/blue
SG
Pink/yellow
H
Grey
V
Green
HM
Grey/brown
VN
Green/black
HR
Grey/red
VB
Green/white
HN
Grey/black
Z
Purple
HB
Grey/white
ZB
Purple/white
HL
Grey/blue
ZN
Purple/black
87666787A - 11 - 2007
20
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
SYMBOLS USED IN ELECTRICAL CIRCUITS
Switch
Control switch
Sensor/Switch/Solenoid Valve
Sensor/Switch
Key--start Ignition Switch
Variable sensor
Motor
Diode
Light and warning indicator Ground Fuse
MPD2703A
87666787A - 11 - 2007
Connection
Rotating beacon power socket
Power fuse
Lamp
Relay
Battery
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
21
ELECTRICAL CIRCUIT COMPONENTS (functional order)
COMPONENT
DESCRIPTION
ALTERNATOR ALT--84
Alternator
AUDIO DEVICES AUD--118
Horn
BATTERY BAT--83
Battery
CONNECTIONS C--1
Front side connection -- engine (24 PIN)
C--3
Trailer brake circuit intermediate connection (4 PIN)
C--4
25A / 40A socket connection
C--5
Front lights connection
C--6
Transmission system connection (24 PIN)
C--8
Trailer brake circuit main connection (4 PIN)
C--9
Power--Shuttle transmission system connection (24 PIN)
C--13
Front PTO and lift system connection (13 PIN)
C--14
Seven--pin socket connection
C--14A
ISO seven--pin socket
C--14B
North American seven--pin socket
C--15
Gearbox neutral connection
C--16
Electronic thermostarter connection (6 PIN)
C--21
Power--Shuttle system connection (6 PIN)
C--24
Digital instrument connection
C--28
Diagnostics connection
C--41
Seat connection
C--166
Brake lights signal test connection
C--167
Connection for CAN line (4 PIN)
C--175
Four--wheel drive system connection (4 PIN)
C--179
Rear lights connection (2 PIN)
C--180
Rear lights connection (6 PIN)
FUSES F--26
30A maxi--fuse (40A for North America)
F--160
125A Maxi--fuse
F--169
50A mega--fuse
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
22
COMPONENT
DESCRIPTION
GROUND GND--7
Dashboard ground
GND--38
Rear ground
GND--106
Four--wheel drive indicator ground
GND--155
Dashboard Power Shuttle ground
GND--181
Trailer brake circuit ground
GND--215
Power sockets ground
LAMPS LMP--20
RH front direction indicator and side light
LMP--22
LH front direction indicator and side light
LMP--45
RH tail light
LMP--48
LH tail light
LMP--119
Grille LH front work light
LMP--120
Front LH headlamp
LMP--121
Front RH headlamp
LMP--122
Grille RH front work light
LMP--178
Work light
LMP--212
Number plate light
LMP--213
RH two--faced headlight
LMP--214
LH two--faced headlight
MOTORS M--85
Starter motor
ELECTRONIC MODULES - CONTROL UNITS MOD--11
Instrument
MOD--23
Electronic flasher
MOD--25
Fuse box and main relay
MOD--64
Permanent 4WD control unit
MOD--102
Front electronic lift control panel
MOD--150
Power Shuttle control unit
MOD--156
Grid heater electronic module
MOD--177
Digital instrument
MOD--204
Four--wheel drive control unit
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
COMPONENT
23
DESCRIPTION
RESISTORS RES--159
Grid Heater
RELAYS RLY--110
Trailer brake circuit relay
RLY--157
Grid heater relay (coil)
RLY--158
Grid heater relay (contact)
SENSORS SEN--33
Tilt sensor
SEN--86
Brake fluid level sensor
SEN--87
Air filter clogged sensor
SEN--89
Sediment unit filter sensor
SEN--92
Engine oil pressure sensor
SEN--93
Coolant temperature sensor
SEN--101
Front lift arms position sensor
SEN--107
Trailer brake indicator light pressure switch
SEN--108
Trailer brake circuit safety pressure switch
SEN--112
Power steering indicator light pressure switch
SEN--123
Fuel level transmitter
SEN--124
Four--wheel drive indicator pressure switch
SEN--126
Steering sensor
SEN--127
Rear axle speed sensor
SEN--128
Front axle speed sensor
SEN--129
Advance speed sensor
SEN--130
Power take--off rpm sensor
SEN--148
Transmission oil temperature sensor
SEN--153
Clutch pedal sensor
SEN--176
Engine rpm sensor
SEN--182
Transmission oil pressure sensor
SEN--203
Shuttle position sensor
SEN--208
Front PTO sensor
SOLENOID VALVES SOL--94
Engine cutout electromagnet
SOL--95
Solenoid valve to cut out starting advance, depending on temperature
SOL--99
Front lift UP solenoid valve
SOL--100
Front lift DOWN solenoid valve
SOL--109
Trailer brake solenoid valves
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
24
COMPONENT
DESCRIPTION
SOL--117
Differential lock solenoid valve
SOL--135
Four--wheel drive solenoid valve
SOL--138
HI--LO mode solenoid valve
SOL--139
Shuttle mode solenoid valve
SOL--140
Dump solenoid valve
SOL--146
Lo clutch solenoid valve
SOL--147
Hi clutch solenoid valve
CONTROL SWITCHES SW--10
Hazard lights switch
SW--12
Front PTO switch
SW--17
Front grille work lights switch
SW--19
Start switch
SW--32
Operator present switch
SW--35
4WD control switch
SW--36
Differential lock switch
SW--39
Parking brake switch
SW--96
Starting advance thermometric cut--out switch
SW--97
External lights control switch
SW--103
Front lift up/down control switch
SW--104
Front PTO switch
SW--105
Front electronic lift block switch
SW--111
Rear PTO switch
SW--114
Gearbox neutral switch
SW--115
Splitter switch
SW--116
Differential lock indicator switch
SW--125
Shuttle lever switch
SW--136
Stoplamp switch
SW--141
G1 ranges switch
SW--142
C1 gears switch
SW--143
Creeper switch
SW--151
Clutch pedal switch
SW--152
Power Shuttle control lever
SW--161
”Up/Down” control push--button
SW--162
”Enter” control push--button
SW--183
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
SW--205
Front lift UP external control switch
SW--206
Front lift DOWN external control switch
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
COMPONENT
25
DESCRIPTION
POWER SOCKETS C--46
8A two--pin socket
C--47
40 A four--pole power socket (North America)
C--49
25A two--pin socket
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
26
VERSION INDEX The following pages contain the wiring diagrams for the three versions of the platform model, specifically:
VERSION
DESCRIPTION
PAGE
1
2WD VERSION, REAR MECHANICAL LIFT
27 to 78
2
ELECTROHYDRAULIC FOUR--WHEEL DRIVE VERSION, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR MECHANICAL LIFT
79 to 132
3
PERMANENT FOUR--WHEEL DRIVE VERSION, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR MECHANICAL LIFT
133 to 186
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
27
VERSION 1 2WD MODELS, REAR MECHANICAL LIFT
Description
Wiring diagram circuits
Page
Circuit 1
Four--wheel drive circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Circuit 2
Grid--heater circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Circuit 3
Power socket circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Circuit 4
Brakes, brake lights, differential lock circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Circuit 5
Direction indicator and hazard lights circuit (control switches and flasher) . . . . . . . . . . . . 42
Circuit 6
External lights and horn circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Circuit 7
Power supplies 1 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Circuit 8
Instrument and sensor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Circuit 9
Power take--off and safety device circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Circuit 10
Seven--pin socket and number plate light circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Circuit 11
Safety and speed sensors, rear work light circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Circuit 12
Trailer brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Circuit 13
Power supplies 2 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Circuit 14
Engine, sensors and transmitters circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Circuit 15
Power Shuttle 8+8 / 16+16 circuit (dashboard side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Circuit 16
Power Shuttle circuit (transmission side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Circuit 17
Power Shuttle 32+16 / 44+16 circuit (dashboard side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Circuit 18
Power Shuttle circuit (transmission side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Circuit 19
Front PTO circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
28
ELECTRICAL CIRCUITS COMPONENTS VERSION 1
COMPONENT
NUMBER DIAGRAM
C--1
8, 14
C--3
12
Trailer brake circuit intermediate connection (4 PIN)
C--4
3
25A / 40A socket connection
C--5
6
Front lights connection
C--6
1, 4, 8, 9, 11
GND--7
2, 5, 6, 8, 12, 13, 14
C--8
12
C--9
15, 16, 17, 18
SW--10
5
Hazard lights switch
MOD--11
8
Instrument
SW--12
19
Front PTO switch
C--13
19
Front PTO and lift system connection (13 PIN)
C--14
10
Seven--pin socket connection
C--15
9
Gearbox neutral connection
C--16
2
Electronic thermostarter connection (6 PIN)
SW--17
5
Front grille work lights switch
SW--19
7
Start switch
LMP--20
6
RH front direction indicator and side light
C--21
11,15, 17
Power--Shuttle system connection (6 PIN)
LMP--22
6
LH front direction indicator and side light
MOD--23
5
Electronic flasher
MOD--25
4, 6, 7, 13
F--26
7
30A maxi--fuse (40A for North America)
SW--32
11
Operator present switch
SW--36
4
Differential lock switch
GND--38
3, 4, 6, 10
SW--39
4
Parking brake switch
LMP--45
6
RH tail light
C--46
3
8A two--pin socket
C--47
3
40 A four--pole power socket (North America)
LMP--48
6
LH tail light
C--49
3
25A two--pin socket
BAT--83
14
Battery
87666787A - 11 - 2007
DESCRIPTION
Front side connection -- engine (24 PIN)
Transmission system connection (24 PIN) Dashboard ground Trailer brake circuit main connection (4 PIN) Power--Shuttle transmission system connection (24 PIN)
Fuse box and main relay
Rear ground
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
29
ALT--84
14
Alternator
M--85
14
Starter motor
SEN--86
14
Brake fluid level sensor
SEN--87
14
Air filter clogged sensor
SEN--89
14
Sediment unit filter sensor
SEN--92
14
Engine oil pressure sensor
SEN--93
14
Coolant temperature sensor
SOL--94
14
Engine cutout electromagnet
SOL--95
14
Solenoid valve to cut out starting advance, depending on temperature
SW--96
14
Starting advance thermometric cut--out switch
SW--97
5
External lights control switch
SOL--99
19
Front lift UP solenoid valve
SOL--100
19
Front lift DOWN solenoid valve
SEN--101
19
Front lift arms position sensor
MOD--102
19
Front electronic lift control panel
SW--103
19
Front lift up/down control switch
SW--104
9
Front PTO switch
GND--106
1, 9
Four--wheel drive indicator ground
SEN--107
12
Trailer brake indicator light pressure switch
SEN--108
12
Trailer brake circuit safety pressure switch
SOL--109
12
Trailer brake solenoid valves
RLY--110
12
Trailer brake circuit relay
SW--111
9
Rear PTO switch
SEN--112
9
Power steering indicator light pressure switch
SW--114
9
Gearbox neutral switch
SW--115
9
Splitter switch
SW--116
4
Differential lock indicator switch
SOL--117
4
Differential lock solenoid valve
AUD--118
6
Horn
LMP--119
6
Grille LH front work light
LMP--120
6
Front LH headlamp
LMP--121
6
Front RH headlamp
LMP--122
6
Grille RH front work light
SEN--123
8
Fuel level transmitter
SEN--129
11
Advance speed sensor
SEN--130
8
Power take--off rpm sensor
SW--136
4
Stoplamp switch
SOL--138
18
HI--LO mode solenoid valve
SOL--139
18
Shuttle mode solenoid valve
SOL--140
16, 18
Dump solenoid valve
SW--141
16, 18
G1 ranges switch
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
30 SW--142
16, 18
C1 gears switch
SW--143
18
Creeper switch
SOL--146
16.18
Lo clutch solenoid valve
SOL--147
16, 18
Hi clutch solenoid valve
SEN--148
16, 18
Transmission oil temperature sensor
MOD--150
15, 17
Power Shuttle control unit
SW--151
15, 17
Clutch pedal switch
SW--152
15, 17
Power Shuttle control lever
SEN--153
15, 17
Clutch pedal sensor
GND--155
15, 17
Dashboard Power Shuttle ground
MOD--156
2
Grid heater electronic module
RLY--157
2
Grid heater relay (coil)
RLY--158
2
Grid heater relay (contact)
RES--159
2
Grid Heater
F--160
2
125A Maxi--fuse
C--166
4
Brake lights signal test connection
F--169
14
50A mega--fuse
C--175
1
Four--wheel drive system connection (4 PIN)
SEN--176
11
Engine rpm sensor
MOD--177
8
Digital instrument
LMP--178
11
Work light
C--179
6
Rear lights connection (2 PIN)
C--180
6
Rear lights connection (6 PIN)
GND--181
12
Trailer brake circuit ground
SEN--182
16
Transmission oil pressure sensor
SW--183
18
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
SEN--203
18
Shuttle position sensor
MOD--204
19
Four--wheel drive control unit
SW--205
19
Front lift UP external control switch
SW--206
19
Front lift DOWN external control switch
SEN--208
19
Front PTO sensor
LMP--212
6
Number plate light
LMP--213
6
RH two--faced headlight
LMP--214
6
LH two--faced headlight
GND--215
3
Power sockets ground
C--14A
10
ISO seven--pin socket
C--14B
10
North American seven--pin socket
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
31
WIRING DIAGRAMS 1--2--3--4
MPM0728A
18 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
32
FOUR--WHEEL DRIVE CIRCUIT (Diagram 1)
C--6
Transmission system connection (24 PIN)
GND--106 Four--wheel drive indicator ground C--175
Four--wheel drive system connection (4 PIN)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
33 FOUR--WHEEL DRIVE CIRCUIT -- DIAGRAM 1
MPM0762A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
34
GRID HEATER CIRCUIT (Diagram 2)
GND--7 C--16 MOD--156
Dashboard ground Electronic thermostarter connection (6 PIN) Grid heater electronic module
RLY--157/158 Grid heater relay RES--159 F--160
Grid Heater 125A Maxi--fuse
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
35 GRID HEATER CIRCUIT -- DIAGRAM 2
MPM0763A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
36
POWER SOCKET CIRCUIT (Diagram 3)
C--4 GND--38
25A / 40A socket connection Rear ground
C--46
8A two--pin socket
C--47
40 A four--pole power socket (North America)
C--49
25A two--pin socket
GND--215 Power sockets ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
37 POWER SOCKET CIRCUIT -- DIAGRAM 3
MPM0764A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
38
BRAKES, BRAKE LIGHTS, DIFFERENTIAL LOCK CIRCUIT (Diagram 4)
C--6 MOD--25
Transmission system connection (24 PIN) Fuse box and main relay F--19
SW--36 GND--38
Stop Lights
RLY--1
Brake lights circuit
RLY--2
Differential lock circuit
RLY--6
Dipped beam headlight circuit
Differential lock switch Rear ground
SW--39
Parking brake switch
SW--116
Differential lock indicator switch
SOL--117
Differential lock solenoid valve
SW--136
Stoplamp switch
C--166
Brake lights signal test connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
39
BRAKES, BRAKE LIGHTS, DIFFERENTIAL LOCK CIRCUIT -- DIAGRAM 4
MPM0765A
87666787A - 11 - 2007
40
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
41
*
North America version
WIRING DIAGRAMS 5--6--7
MPM0990A
19 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
42
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (control switches and flasher) (Diagram 5)
GND--7
Dashboard ground
SW--10
Hazard lights switch
SW--17
Front grille work lights switch
MOD--23 SW--97
Electronic flasher External lights control switch
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
43
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (control switches and flasher) -- DIAGRAM 5
MPM0766A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
44
EXTERNAL LIGHTS AND HORN CIRCUIT (Diagram 6)
C--5
Front lights connection
GND--7
Dashboard ground
LMP--20
RH front direction indicator and side light
LMP--22
LH front direction indicator and side light
MOD--25
Fuse box and main relay F--9
Direction indicator and hazard lights
F--10
Horn, full beam flasher, seat safety circuit
GND--38
Rear ground
LMP--45
RH tail light
LMP--48
LH tail light
AUD--118
Horn
LMP--119
Grille LH front work light
LMP--120
Front LH headlamp
LMP--121
Front RH headlamp
LMP--122
Grille RH front work light
C--179
Rear lights connection (2 PIN)
C--180
Rear lights connection (6 PIN)
LMP--212
Number plate light
LMP--213
RH two--faced headlight
LMP--214
LH two--faced headlight
* **
ISO version North America version
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
45 EXTERNAL LIGHTS AND HORN CIRCUIT -- DIAGRAM 6
MPM0767A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
46
POWER SUPPLIES 1 CIRCUIT (Diagram 7)
SW--19 MOD--25
F--26
Start switch Fuse box and main relay F--1
Front right--hand and rear left--hand side lights, side lights indicator
F--2
Front left--hand and rear right--hand side lights, control instrument panel light
F--3
ISO side lights, or 7--pin work light (North America)
F--4
Full beam headlights
F--5
Dipped beam headlights
F--6
+ Instrument common
F--7
Differential lock circuit
F--11
Starter safety circuit
F--12
Engine cut--out electromagnet
F--13
Power Shuttle circuit
F--14
Power Shuttle circuit
F--15
Swivel position lights
F--16
Trailer brake and hydraulic adjustment circuit
F--20
Electronic control unit power supply, +battery
F--25
Not used
F--27
Rear work light circuit
30A maxi--fuse (40A for North America)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
47 POWER SUPPLIES 1 CIRCUIT -- DIAGRAM 7
MPM0768A
87666787A - 11 - 2007
48
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
49
WIRING DIAGRAMS 8--9--10--11
MPM0991A
20 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
50
INSTRUMENT AND SENSOR CIRCUIT (Diagram 8) C--1
Front side connection -- engine (24 PIN)
C--6
Transmission system connection (24 PIN)
GND--7 MOD--11
Dashboard ground Instrument A
Right turn signal indicator (green)
B
Handbrake indicator (red)
C
Work lights indicator (amber)
D
Full--beam indicator light (blue)
E
Left turn signal indicator (green)
F
Battery charging system malfunction light (red)
G
Engine oil pressure warning indicator (red)
H
Power steering oil pressure indicator (red)
I
Power Shuttle alarm
J
PTO indicator
K
4WD indicator (indicator)
L
High gear range engaged indicator (green)
M
Low gear range engaged indicator
N
Side lights indicator (green)
O
Clogged engine air filter indicator (amber)
P
Second trailer turn signal indicator (green)
Q
First trailer turn signal indicator (green)
R
Brake fluid level indicator (amber)
S
Grid heater indicator (amber)
T
4WD fault indicator
U
Front power take--off indicator
V
Trailer brake indicator (red)
W
Instrument lighting
X
Automatic four--wheel drive indicator (green)
Y
Front lift unit indicator
Z
Differential lock indicator (amber)
a
Fuel gauge
b
Engine coolant temperature gauge
SEN--123
Fuel level transmitter
SEN--130
Power take--off rpm sensor
MOD--177
Digital instrument
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
51 INSTRUMENT AND SENSOR CIRCUIT -- DIAGRAM 8
MPM0769A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
52
POWER TAKE--OFF AND SAFETY DEVICE CIRCUIT (Diagram 9)
C--6
Transmission system connection (24 PIN)
C--15
Gearbox neutral connection
SW--104
Front PTO switch
GND--106 Four--wheel drive indicator ground SW--111
Rear PTO switch
SEN--112
Power steering indicator light pressure switch
SW--114
Gearbox neutral switch
SW--115
Splitter switch
* **
Standard version Splitter version
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
53
POWER TAKE--OFF AND SAFETY DEVICE CIRCUIT -- DIAGRAM 9
MPM0770A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
54
SEVEN--PIN SOCKET AND NUMBER PLATE LIGHT CIRCUIT (Diagram 10)
C--14
Seven--pin socket connection
GND--38
Rear ground
LMP--210
Number plate light
C--14A
ISO seven--pin socket
C--14B
North American seven--pin socket
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
55
SEVEN--PIN SOCKET AND NUMBER PLATE LIGHT CIRCUIT -- DIAGRAM 10
MPM0771A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
56
SAFETY AND SPEED SENSORS, REAR WORK LIGHT CIRCUIT (Diagram 11)
C--6
Transmission system connection (24 PIN)
C--21
Power--Shuttle system connection (6 PIN)
SW--32
Operator present switch
SEN--129
Advance speed sensor
SEN--176 (NEF)
Engine rpm sensor
SEN--176 (F5C)
Engine rpm sensor (for F5C engine)
LMP--178
87666787A - 11 - 2007
Work light
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
57
SAFETY AND SPEED SENSORS, REAR WORK LIGHT CIRCUIT -- DIAGRAM 11
MPM0772A
87666787A - 11 - 2007
58
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
59
WIRING DIAGRAMS 12--13--14
MPM0992A
21 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
60
TRAILER BRAKE CIRCUIT (Diagram 12)
C--3 GND--7
Trailer brake circuit intermediate connection (4 PIN) Dashboard ground
C--8
Trailer brake circuit main connection (4 PIN)
SEN--107
Trailer brake indicator light pressure switch
SEN--108
Trailer brake circuit safety pressure switch
SOL--109
Trailer brake solenoid valves
RLY--110
Trailer brake circuit relay RLY--9
Trailer brake circuit relay
RLY--10
Trailer brake circuit relay
RLY--13
Trailer brake circuit relay
GND--181 Trailer brake circuit ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
61 TRAILER BRAKE CIRCUIT -- DIAGRAM 12
MPM0773A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
62
POWER SUPPLIES 2 CIRCUIT (Diagram 13)
GND--7 MOD--25
Dashboard ground Fuse box and main relay RLY--4
Differential lock circuit
RLY--5
Full beam headlight circuit
RLY--6
Dipped beam headlight circuit
RLY--13
Engine starter circuit maxi--relay
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
63 POWER SUPPLIES 2 CIRCUIT -- DIAGRAM 13
MPM0774A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
64
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT (Diagram 14)
C--1
Front side connection -- engine (24 PIN)
GND--7
Dashboard ground
BAT--83
Battery
ALT--84
Alternator
M--85
Starter motor
SEN--86
Brake fluid level sensor
SEN--87
Air filter clogged sensor
SEN--89
Sediment unit filter sensor
SEN--92
Engine oil pressure sensor
SEN--93
Coolant temperature sensor
SOL--94
Engine cutout electromagnet
SOL--95
Solenoid valve to cut out starting advance, depending on temperature
SW--96
Starting advance thermometric cut--out switch
F--169
50A mega--fuse
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
65
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT -- DIAGRAM 14
MPM0775A
87666787A - 11 - 2007
66
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
67
WIRING DIAGRAMS 15--16--17--18--19
MPM0993A
22 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
68
POWER SHUTTLE CIRCUIT 8+8 / 16+16 (dashboard side) (Diagram 15)
C--9
Power--Shuttle transmission system connection (24 PIN)
C--21
Power--Shuttle system connection (6 PIN)
MOD--150 Power Shuttle control unit SW--151
Clutch pedal switch
SW--152
Power Shuttle control lever
SEN--153
Clutch pedal sensor
GND--155 Dashboard Power Shuttle ground NC = Not connected
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
69
POWER SHUTTLE CIRCUIT 8+8 / 16+16 (dashboard side) -- DIAGRAM 15
MPM0776A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
70
POWER SHUTTLE CIRCUIT (transmission side) (Diagram 16)
C--9
Power--Shuttle transmission system connection (24 PIN)
SOL--140
Dump solenoid valve
SW--141
G1 ranges switch
SW--142
C1 gears switch
SOL--146
Lo clutch solenoid valve
SOL--147
Hi clutch solenoid valve
SEN--148
Transmission oil temperature sensor
SEN--182
Transmission oil pressure sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
71 POWER SHUTTLE CIRCUIT (transmission side) -- DIAGRAM 16
MPM0777A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
72
POWER SHUTTLE CIRCUIT 32+16 / 44+16 (dashboard side) (Diagram 17)
C--9
Power--Shuttle transmission system connection (24 PIN)
C--21
Power--Shuttle system connection (6 PIN)
MOD--150 Power Shuttle control unit SW--151
Clutch pedal switch
SW--152
Power Shuttle control lever
SEN--153
Clutch pedal sensor
GND--155 Dashboard Power Shuttle ground NC = Not connected
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
73
POWER SHUTTLE CIRCUIT 32+16 / 44+16 (dashboard side) -- DIAGRAM 17
MPM0778A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
74
POWER SHUTTLE CIRCUIT (transmission side) (Diagram 18)
C--9
Power--Shuttle transmission system connection (24 PIN)
SOL--138
HI--LO mode solenoid valve
SOL--139
Shuttle mode solenoid valve
SOL--140
Dump solenoid valve
SW--141
G1 ranges switch
SW--142
C1 gears switch
SW--143
Creeper switch
SOL--146
Lo clutch solenoid valve
SOL--147
Hi clutch solenoid valve
SEN--148
Transmission oil temperature sensor
SW--183
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
SEN--203
Shuttle position sensor
* **
Version with Power Shuttle 44+16 e 32+16 with Dual Command (2 Speed Power Shift) function Version with Power Shuttle 44+16 e 32+16 with Dual Command (2 Speed Power Shift) function (paddy field version)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
75 POWER SHUTTLE CIRCUIT (transmission side) -- DIAGRAM 18
MPM0779A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
76
FRONT PTO CIRCUIT (Diagram 19)
SW--12 C--13
Front PTO switch Front PTO and lift system connection (13 PIN)
SOL--99
Front lift UP solenoid valve
SOL--100
Front lift DOWN solenoid valve
SEN--101
Front lift arms position sensor
MOD--102 Front electronic lift control panel SW--103
Front lift up/down control switch
MOD--204 Four--wheel drive control unit SW--205
Front lift UP external control switch
SW--206
Front lift DOWN external control switch
SEN--208
Front PTO sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
77 FRONT PTO CIRCUIT -- DIAGRAM 19
MPM0780A
87666787A - 11 - 2007
78
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
79
VERSION 2 ELECTROHYDRAULIC FOUR--WHEEL DRIVE, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR MECHANICAL LIFT
Description
Wiring diagram circuits
Page
Circuit 1
Four--wheel drive circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Circuit 2
Power take--off and safety device circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Circuit 3
Power socket circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Circuit 4
Brakes, brake lights, differential lock circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Circuit 5
Direction indicator and hazard lights circuit (control switches and flasher) . . . . . . . . . . . . 94
Circuit 6
Grid--heater circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Circuit 7
Power supplies 1 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Circuit 8
Power supplies 2 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Circuit 9
Instrument and sensor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Circuit 10
External lights and horn circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Circuit 11
Safety and speed sensors, rear work light circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Circuit 12
Engine, sensors and transmitters circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Circuit 13
Seven--pin socket and number plate light circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Circuit 14
Trailer brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Circuit 15
Power Shuttle 8+8 / 16+16 circuit (dashboard side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Circuit 16
Power Shuttle circuit (transmission side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Circuit 17
Power Shuttle 32+16 / 44+16 circuit (dashboard side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Circuit 18
Power Shuttle circuit (transmission side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Circuit 19
Front PTO circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Circuit 20
Digital instrument circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
80
ELECTRICAL CIRCUITS COMPONENTS VERSION 2
COMPONENT
NUMBER DIAGRAM
C--1
9, 12
C--3
14
Trailer brake circuit intermediate connection (4 PIN)
C--4
3
25A / 40A socket connection
C--5
10
Front lights connection
C--6
1, 2, 4, 9, 11
GND--7
1, 5, 6, 8, 9, 10, 12, 14
C--8
14
C--9
15, 16, 17, 18
SW--10
5
MOD--11
9, 20
SW--12
19
Front PTO switch
C--13
19
Front PTO and lift system connection (13 PIN)
C--14
13
Seven--pin socket connection
C--14A
13
ISO seven--pin socket
C--14B
13
North American seven--pin socket
C--16
6
Electronic thermostarter connection (6 PIN)
SW--17
5
Front grille work lights switch
SW--19
7
Start switch
LMP--20
10
RH front direction indicator and side light
C--21
11,15, 17
Power--Shuttle system connection (6 PIN)
LMP--22
10
LH front direction indicator and side light
MOD--23
5
Electronic flasher
C--24
20
Digital instrument connection
MOD--25
4, 7, 8, 10
F--26
7
30A maxi--fuse (40A for North America)
C--28
20
Diagnostics connection
SW--32
11
Operator present switch
SW--35
1
4WD control switch
SW--36
4
Differential lock switch
GND--38
3, 4, 10, 13
SW--39
4
Parking brake switch
C--41
3
Seat connection
LMP--45
10
RH tail light
C--46
3
8A two--pin socket
87666787A - 11 - 2007
DESCRIPTION
Front side connection -- engine (24 PIN)
Transmission system connection (24 PIN) Dashboard ground Trailer brake circuit main connection (4 PIN) Power--Shuttle transmission system connection (24 PIN) Hazard lights switch Instrument
Fuse box and main relay
Rear ground
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
81
C--47
3
40 A four--pole power socket (North America)
LMP--48
10
LH tail light
C--49
3
25A two--pin socket
BAT--83
12
Battery
ALT--84
12
Alternator
M--85
12
Starter motor
SEN--86
12
Brake fluid level sensor
SEN--87
12
Air filter clogged sensor
SEN--89
12
Sediment unit filter sensor
SEN--92
12
Engine oil pressure sensor
SEN--93
12
Coolant temperature sensor
SOL--94
12
Engine cutout electromagnet
SOL--95
12
Solenoid valve to cut out starting advance, depending on temperature
SW--96
12
Starting advance thermometric cut--out switch
SW--97
5
External lights control switch
SOL--99
19
Front lift UP solenoid valve
SOL--100
19
Front lift DOWN solenoid valve
SEN--101
19
Front lift arms position sensor
MOD--102
19
Front electronic lift control panel
SW--103
19
Front lift up/down control switch
SW--104
2
Front PTO switch
GND--106
1, 2
Four--wheel drive indicator ground
SEN--107
14
Trailer brake indicator light pressure switch
SEN--108
14
Trailer brake circuit safety pressure switch
SOL--109
14
Trailer brake solenoid valves
RLY--110
14
Trailer brake circuit relay
SW--111
2
Rear PTO switch
SEN--112
2
Power steering indicator light pressure switch
SW--114
2
Gearbox neutral switch
SW--115
2
Splitter switch
SW--116
4
Differential lock indicator switch
SOL--117
4
Differential lock solenoid valve
AUD--118
10
Horn
LMP--119
10
Grille LH front work light
LMP--120
10
Front LH headlamp
LMP--121
10
Front RH headlamp
LMP--122
10
Grille RH front work light
SEN--123
9
Fuel level transmitter
SEN--128
11
Front axle speed sensor
SEN--130
9
Power take--off rpm sensor
SW--136
4
Stoplamp switch
SOL--138
18
HI--LO mode solenoid valve 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
82 SOL--139
18
SOL--140
16, 18
Dump solenoid valve
SW--141
16, 18
G1 ranges switch
SW--142
16, 18
C1 gears switch
SW--143
18
Creeper switch
SOL--146
16.18
Lo clutch solenoid valve
SOL--147
16, 18
Hi clutch solenoid valve
SEN--148
16, 18
Transmission oil temperature sensor
MOD--150
15, 17
Power Shuttle control unit
SW--151
15, 17
Clutch pedal switch
SW--152
15, 17
Power Shuttle control lever
SEN--153
15, 17
Clutch pedal sensor
GND--155
15, 17
Dashboard Power Shuttle ground
MOD--156
6
Grid heater electronic module
RLY--157
6
Grid heater relay (coil)
RLY--158
6
Grid heater relay (contact)
RES--159
6
Grid Heater
F--160
6
125A Maxi--fuse
SW--161
20
”Up/Down” control push--button
SW--162
20
”Enter” control push--button
C--166
4
Brake lights signal test connection
C--167
20
Connection for CAN line (4 PIN)
F--169
12
50A mega--fuse
C--175
1
Four--wheel drive system connection (4 PIN)
SEN--176
11
Engine rpm sensor
MOD--177
9
Digital instrument
LMP--178
11
Work light
C--179
10
Rear lights connection (2 PIN)
C--180
10
Rear lights connection (6 PIN)
GND--181
14
Trailer brake circuit ground
SEN--182
16
Transmission oil pressure sensor
SW--183
18
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
SEN--203
18
Shuttle position sensor
MOD--204
19
Four--wheel drive control unit
SW--205
19
Front lift UP external control switch
SW--206
19
Front lift DOWN external control switch
SEN--208
19
Front PTO sensor
LMP--212
10
Number plate light
LMP--213
10
RH two--faced headlight
LMP--214
10
LH two--faced headlight
GND--215
3
Power sockets ground
87666787A - 11 - 2007
Shuttle mode solenoid valve
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
83
WIRING DIAGRAMS 1--2--3--4
MPM0995A
23 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
84
FOUR--WHEEL DRIVE CIRCUIT (Diagram 1)
C--6
Transmission system connection (24 PIN)
GND--7
Dashboard ground
SW--35
4WD control switch
GND--106 Four--wheel drive indicator ground C--175
Four--wheel drive system connection (4 PIN)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
85 FOUR--WHEEL DRIVE CIRCUIT -- DIAGRAM 1
MPM0781A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
86
POWER TAKE--OFF AND SAFETY DEVICE CIRCUIT (Diagram 2)
C--6 SW--104
Transmission system connection (24 PIN) Front PTO switch
GND--106 Four--wheel drive indicator ground SW--111
Rear PTO switch
SEN--112
Power steering indicator light pressure switch
SW--114
Gearbox neutral switch
SW--115
Splitter switch
* **
Standard version Splitter version
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
87
POWER TAKE--OFF AND SAFETY DEVICE CIRCUIT -- DIAGRAM 2
MPM0952A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
88
POWER SOCKET CIRCUIT (Diagram 3)
C--4 GND--38
25A / 40A socket connection Rear ground
C--41
Seat connection
C--46
8A two--pin socket
C--47
40 A four--pole power socket (North America)
C--49
25A two--pin socket
GND--215 Power sockets ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
89 POWER SOCKET CIRCUIT -- DIAGRAM 3
MPM0953A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
90
BRAKES, BRAKE LIGHTS, DIFFERENTIAL LOCK CIRCUIT (Diagram 4)
C--6 MOD--25
Transmission system connection (24 PIN) Fuse box and main relay F--19
SW--36 GND--38
Stop Lights
RLY--1
Brake lights circuit
RLY--2
Differential lock circuit
RLY--3
Differential lock circuit
RLY--6
Differential lock circuit
Differential lock switch Rear ground
SW--39
Parking brake switch
SW--116
Differential lock indicator switch
SOL--117
Differential lock solenoid valve
SW--136
Stoplamp switch
C--166
Brake lights signal test connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
91
BRAKES, BRAKE LIGHTS, DIFFERENTIAL LOCK CIRCUIT -- DIAGRAM 4
MPM0954A
87666787A - 11 - 2007
92
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
93
WIRING DIAGRAMS 5--6--7--8--9
MPM0996A
24 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
94
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (control switches and flasher) (Diagram 5)
GND--7
Dashboard ground
SW--10
Hazard lights switch
SW--17
Front grille work lights switch
MOD--23 SW--97
Electronic flasher External lights control switch
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
95
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (control switches and flasher) -- DIAGRAM 5
MPM0955A
87666787A - 11 - 2007
96
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 GRID HEATER CIRCUIT (Diagram 6)
GND--7 C--16 MOD--156 RLY--157/158 RES--159 F--160
87666787A - 11 - 2007
Dashboard ground Electronic thermostarter connection (6 PIN) Grid heater electronic module Grid heater relay Grid Heater 125A Maxi--fuse
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
97 GRID--HEATER CIRCUIT -- DIAGRAM 6
MPM0956A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
98 POWER SUPPLIES 1 CIRCUIT (Diagram 7)
SW--19 MOD--25
F--26
Start switch Fuse box and main relay F--1
Front right--hand and rear left--hand side lights, side lights indicator
F--2
Front left--hand and rear right--hand side lights, control instrument panel light
F--3
ISO side lights, or 7--pin work light (North America)
F--4
Full beam headlights
F--5
Dipped beam headlights
F--6
+ Instrument common
F--7
Differential lock circuit, four--wheel drive circuit
F--11
Starter safety circuit
F--12
Engine cut--out electromagnet
F--13
Power Shuttle circuit
F--14
Power Shuttle circuit
F--15
Swivel position lights, seat
F--16
Trailer brake and hydraulic adjustment circuit
F--20
Electronic control unit power supply, (+battery)
F--25
Not used
F--27
Rear work light circuit
30A maxi--fuse (40A for North America)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
99 POWER SUPPLIES 1 CIRCUIT -- DIAGRAM 7
MPM0957A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
100
POWER SUPPLIES 2 CIRCUIT (Diagram 8)
GND--7 MOD--25
Dashboard ground Fuse box and main relay F--8
8A power socket, digital instrument
RLY--1
Brake lights circuit
RLY--4
Differential lock circuit
RLY--5
Full beam headlight circuit
RLY--6
Dipped beam headlight circuit
RLY--13
Engine starter circuit maxi--relay
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
101 POWER SUPPLIES 2 CIRCUIT -- DIAGRAM 8
MPM0958A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
102
INSTRUMENT AND SENSOR CIRCUIT (Diagram 9)
C--1
Front side connection -- engine (24 PIN)
C--6
Transmission system connection (24 PIN)
GND--7 MOD--11
Dashboard ground Instrument A
Right turn signal indicator (green)
B
Handbrake indicator (red)
C
Work lights indicator (amber)
D
Full--beam indicator light (blue)
E
Left turn signal indicator (green)
F
Battery charging system malfunction light (red)
G
Engine oil pressure warning indicator (red)
H
Power steering oil pressure indicator (red)
I
Power Shuttle alarm
J
PTO indicator
K
4WD indicator (indicator)
L
High gear range engaged indicator (green)
M
Low gear range engaged indicator
N
Side lights indicator (green)
O
Clogged engine air filter indicator (amber)
P
Second trailer turn signal indicator (green)
Q
First trailer turn signal indicator (green)
R
Brake fluid level indicator (amber)
S
Grid heater indicator (amber)
T
4WD fault indicator
U
Front power take--off indicator
V
Trailer brake indicator (red)
W
Instrument lighting
X
Automatic four--wheel drive indicator (green)
Y
Front lift unit indicator
Z
Differential lock indicator (amber)
a
Fuel gauge
b
Engine coolant temperature gauge
SEN--123
Fuel level transmitter
SEN--130
Power take--off rpm sensor
MOD--177 Digital instrument 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
103 INSTRUMENT AND SENSOR CIRCUIT -- DIAGRAM 9
MPM0959A
87666787A - 11 - 2007
104
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
105
*
North America version
WIRING DIAGRAMS 10--11
MPM0997A
25 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
106
EXTERNAL LIGHTS AND HORN CIRCUIT (Diagram 10)
C--5
Front lights connection
GND--7
Dashboard ground
LMP--20
RH front direction indicator and side light
LMP--22
LH front direction indicator and side light
MOD--25
Fuse box and main relay F--9
Direction indicator and hazard lights
F--10
Horn, full beam flasher, seat safety circuit
GND--38
Rear ground
LMP--45
RH tail light
LMP--48
LH tail light
AUD--118
Horn
LMP--119
Grille LH front work light
LMP--120
Front LH headlamp
LMP--121
Front RH headlamp
LMP--122
Grille RH front work light
C--179
Rear lights connection (2 PIN)
C--180
Rear lights connection (6 PIN)
LMP--212
Number plate light
LMP--213
RH two--faced headlight
LMP--214
LH two--faced headlight
* **
ISO version North America version
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
107 EXTERNAL LIGHTS AND HORN CIRCUIT -- DIAGRAM 10
MPM0960A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
108
SAFETY AND SPEED SENSORS, REAR WORK LIGHT CIRCUIT (Diagram 11)
C--6
Transmission system connection (24 PIN)
C--21
Power--Shuttle system connection (6 PIN)
SW--32
Operator present switch
SEN--129
Advance speed sensor
SEN--176 (NEF) Engine rpm sensor (for engine on models 4040 and 4050) SEN--176 (F5C) Engine rpm sensor (for F5C engine) LMP--178
87666787A - 11 - 2007
Work light
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
109
SAFETY AND SPEED SENSORS, REAR WORK LIGHT CIRCUIT -- DIAGRAM 11
MPM0961A
87666787A - 11 - 2007
110
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
111
WIRING DIAGRAMS 12--13--14
MPM0998A
26 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
112
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT (Diagram 12)
C--1
Front side connection -- engine (24 PIN)
GND--7
Dashboard ground
BAT--83
Battery
ALT--84
Alternator
M--85
Starter motor
SEN--86
Brake fluid level sensor
SEN--87
Air filter clogged sensor
SEN--89
Sediment unit filter sensor
SEN--92
Engine oil pressure sensor
SEN--93
Coolant temperature sensor
SOL--94
Engine cutout electromagnet
SOL--95
Solenoid valve to cut out starting advance, depending on temperature
SW--96
Starting advance thermometric cut--out switch
F--169
50A mega--fuse
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
113
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT -- DIAGRAM 12
MPM0962A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
114
SEVEN--PIN SOCKET AND NUMBER PLATE LIGHT CIRCUIT (Diagram 13)
C--14
Seven--pin socket connection
C--14A
ISO seven--pin socket
C--14B
North American seven--pin socket
GND--38
Rear ground
LMP--210
Number plate light
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
115
SEVEN--PIN SOCKET AND NUMBER PLATE LIGHT CIRCUIT -- DIAGRAM 13
MPM0963A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
116
TRAILER BRAKE CIRCUIT (Diagram 14)
C--3 GND--7
Trailer brake circuit intermediate connection (4 PIN) Dashboard ground
C--8
Trailer brake circuit main connection (4 PIN)
SEN--107
Trailer brake indicator light pressure switch
SEN--108
Trailer brake circuit safety pressure switch
SOL--109
Trailer brake solenoid valves
RLY--110
Trailer brake circuit relay RLY--9
Trailer brake circuit relay
RLY--10
Trailer brake circuit relay
RLY--13
Trailer brake circuit relay
GND--181 Trailer brake circuit ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
117 TRAILER BRAKE CIRCUIT -- DIAGRAM 14
MPM0964A
87666787A - 11 - 2007
118
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
119
WIRING DIAGRAMS 15--16--17--18--19--20
MPM0999A
27 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
120
POWER SHUTTLE CIRCUIT 8+8 / 16+16 (dashboard side) (Diagram 15)
C--9
Power--Shuttle transmission system connection (24 PIN)
C--21
Power--Shuttle system connection (6 PIN)
MOD--150 Power Shuttle control unit SW--151
Clutch pedal switch
SW--152
Power Shuttle control lever
SEN--153
Clutch pedal sensor
GND--155 Dashboard Power Shuttle ground NC = Not connected
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
121
POWER SHUTTLE CIRCUIT 8+8 / 16+16 (dashboard side) -- DIAGRAM 15
MPM0965A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
122
POWER SHUTTLE CIRCUIT (transmission side) (Diagram 16)
C--9
Power--Shuttle transmission system connection (24 PIN)
SOL--140
Dump solenoid valve
SW--141
G1 ranges switch
SW--142
C1 gears switch
SOL--146
Lo clutch solenoid valve
SOL--147
Hi clutch solenoid valve
SEN--148
Transmission oil temperature sensor
SEN--182
Transmission oil pressure sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
123 POWER SHUTTLE CIRCUIT (transmission side) -- DIAGRAM 16
MPM0966A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
124
POWER SHUTTLE CIRCUIT 32+16 / 44+16 (dashboard side) (Diagram 17)
C--9
Power--Shuttle transmission system connection (24 PIN)
C--21
Power--Shuttle system connection (6 PIN)
MOD--150 Power Shuttle control unit SW--151
Clutch pedal switch
SW--152
Power Shuttle control lever
SEN--153
Clutch pedal sensor
GND--155 Dashboard Power Shuttle ground NC = Not connected
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
125
POWER SHUTTLE CIRCUIT 32+16 / 44+16 (dashboard side) -- DIAGRAM 17
MPM0967A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
126
POWER SHUTTLE CIRCUIT (transmission side) (Diagram 18)
C--9
Power--Shuttle transmission system connection (24 PIN)
SOL--138
HI--LO mode solenoid valve
SOL--139
Shuttle mode solenoid valve
SOL--140
Dump solenoid valve
SW--141
G1 ranges switch
SW--142
C1 gears switch
SW--143
Creeper switch
SOL--146
Lo clutch solenoid valve
SOL--147
Hi clutch solenoid valve
SEN--148
Transmission oil temperature sensor
SW--183
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
SEN--203
Shuttle position sensor
* **
Version with Power Shuttle 44+16 e 32+16 with Dual Command (2 Speed Power Shift) function Version with Power Shuttle 44+16 e 32+16 with Dual Command (2 Speed Power Shift) function (paddy field version)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
127 POWER SHUTTLE CIRCUIT (transmission side) -- DIAGRAM 18
MPM0968A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
128
FRONT PTO CIRCUIT (Diagram 19)
SW--12 C--13
Front PTO switch Front PTO and lift system connection (13 PIN)
SOL--99
Front lift UP solenoid valve
SOL--100
Front lift DOWN solenoid valve
SEN--101
Front lift arms position sensor
MOD--102 Front electronic lift control panel SW--103
Front lift up/down control switch
MOD--204 Four--wheel drive control unit SW--205
Front lift UP external control switch
SW--206
Front lift DOWN external control switch
SEN--208
Front PTO sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
129 FRONT PTO CIRCUIT -- DIAGRAM 19
MPM0969A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
130
DIGITAL INSTRUMENT CIRCUIT (Diagram 20)
MOD--11
Instrument
C--24
Digital instrument connection
C--28
Diagnostics connection
SW--161
”Up/Down” control push--button
SW--162
”Enter” control push--button
C--167
Connection for CAN line (4 PIN)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
131 DIGITAL INSTRUMENT CIRCUIT -- DIAGRAM 20
MPM0698A
87666787A - 11 - 2007
132
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
133
VERSION 3 PERMANENT FOUR--WHEEL DRIVE, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR MECHANICAL LIFT
Description
Wiring diagram circuits
Page
Circuit 1
Four--wheel drive circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Circuit 2
Power socket circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Circuit 3
Brakes, brake lights, differential lock circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Circuit 4
Direction indicator and hazard lights circuit (control switches and flasher) . . . . . . . . . . . 144
Circuit 5
Grid--heater circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Circuit 6
Instrument and sensor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Circuit 7
Power take--off and safety device circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Circuit 8
Seven--pin socket and number plate light circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Circuit 9
External lights and horn circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Circuit 10
Power supplies 1 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Circuit 11
Power supplies 2 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Circuit 12
Trailer brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Circuit 13
Intermediate connections circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Circuit 14
Engine, sensors and transmitters circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Circuit 15
Diagnostics connection CAN line circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Circuit 16
Power Shuttle 8+8 / 16+16 circuit (dashboard side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Circuit 17
Power Shuttle circuit (transmission side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Circuit 18
Power Shuttle 32+16 / 44+16 circuit (dashboard side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Circuit 19
Power Shuttle circuit (transmission side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Circuit 20
Front PTO circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
134
ELECTRICAL CIRCUITS COMPONENTS VERSION 3
COMPONENT
NUMBER DIAGRAM
C--1
6, 14
C--3
12
Trailer brake circuit intermediate connection (4 PIN)
C--4
2
25A / 40A socket connection
C--5
9
Front lights connection
C--6
1, 3, 5, 6, 7
GND--7
1, 4, 5, 6, 9, 11, 12, 14, 15
C--8
12
C--9
16, 17, 18, 19
SW--10
4
Hazard lights switch
MOD--11
6
Instrument
SW--12
20
Front PTO switch
C--13
20
Front PTO and lift system connection (13 PIN)
C--14
8
Seven--pin socket connection
C--14A
8
ISO seven--pin socket
C--14B
8
North American seven--pin socket
C--15
7
Gearbox neutral connection
C--16
5
Electronic thermostarter connection (6 PIN)
SW--17
4
Front grille work lights switch
SW--19
10
Start switch
LMP--20
9
RH front direction indicator and side light
C--21
13, 16, 18
Power--Shuttle system connection (6 PIN)
LMP--22
9
LH front direction indicator and side light
MOD--23
4
Electronic flasher
MOD--25
3, 9, 10, 11
F--26
10
30A maxi--fuse (40A for North America)
C--28
15
Diagnostics connection
SW--32
6
Operator present switch
SEN--33
1
Tilt sensor
SW--35
1
4WD control switch
SW--36
3
Differential lock switch
GND--38
2, 3, 8, 9
SW--39
3
Parking brake switch
C--46
2
8A two--pin socket
87666787A - 11 - 2007
DESCRIPTION
Front side connection -- engine (24 PIN)
Transmission system connection (24 PIN) Dashboard ground Trailer brake circuit main connection (4 PIN) Power--Shuttle transmission system connection (24 PIN)
Fuse box and main relay
Rear ground
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
135
C--47
2
40 A four--pole power socket (North America)
C--49
2
25A two--pin socket
MOD--64
1
Permanent 4WD control unit
BAT--83
14
Battery
ALT--84
14
Alternator
M--85
14
Starter motor
SEN--86
14
Brake fluid level sensor
SEN--87
14
Air filter clogged sensor
SEN--89
14
Sediment unit filter sensor
SEN--92
14
Engine oil pressure sensor
SEN--93
14
Coolant temperature sensor
SOL--94
14
Engine cutout electromagnet
SOL--95
14
Solenoid valve to cut out starting advance, depending on temperature
SW--96
14
Starting advance thermometric cut--out switch
SW--97
4
External lights control switch
SOL--99
20
Front lift UP solenoid valve
SOL--100
20
Front lift DOWN solenoid valve
SEN--101
20
Front lift arms position sensor
MOD--102
20
Front electronic lift control panel
SW--103
20
Front lift up/down control switch
SW--105
4
Front electronic lift block switch
SEN--107
12
Trailer brake indicator light pressure switch
GND--106
1, 5
Four--wheel drive indicator ground
SEN--108
12
Trailer brake circuit safety pressure switch
SOL--109
12
Trailer brake solenoid valves
RLY--110
12
Trailer brake circuit relay
SW--111
7
Rear PTO switch
SEN--112
7
Power steering indicator light pressure switch
SW--114
7
Gearbox neutral switch
SW--115
7
Splitter switch
SW--116
3
Differential lock indicator switch
SOL--117
3
Differential lock solenoid valve
AUD--118
9
Horn
LMP--119
9
Grille LH front work light
LMP--120
9
Front LH headlamp
LMP--121
9
Front RH headlamp
LMP--122
9
Grille RH front work light
SEN--123
6
Fuel level transmitter
SEN--124
1
Four--wheel drive indicator pressure switch
SW--125
5
Shuttle lever switch
SEN--126
1
Steering sensor
SEN--127
1
Rear axle speed sensor 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
136 SEN--128
1
Front axle speed sensor
SEN--130
6
Power take--off rpm sensor
SOL--135
1
Four--wheel drive solenoid valve
SW--136
3
Stoplamp switch
SOL--138
19
HI--LO mode solenoid valve
SOL--139
19
Shuttle mode solenoid valve
SOL--140
17, 19
Dump solenoid valve
SW--141
17, 19
G1 ranges switch
SW--142
17, 19
C1 gears switch
SW--143
19
Creeper switch
SOL--146
17, 19
Lo clutch solenoid valve
SOL--147
17, 19
Hi clutch solenoid valve
SEN--148
17, 19
Transmission oil temperature sensor
MOD--150
16, 18
Power Shuttle control unit
SW--151
16, 18
Clutch pedal switch
SW--152
16, 18
Power Shuttle control lever
SEN--153
16, 18
Clutch pedal sensor
GND--155
16, 18
Dashboard Power Shuttle ground
MOD--156
5
Grid heater electronic module
RLY--157
6
Grid heater relay (coil)
RLY--158
5
Grid heater relay (contact)
RES--159
5
Grid Heater
F--160
5
125A Maxi--fuse
SW--161
6
”Up/Down” control push--button
SW--162
6
”Enter” control push--button
C--166
3
Brake lights signal test connection
C--167
13, 16, 18
F--169
14
50A mega--fuse
SEN--176
14
Engine rpm sensor
LMP--178
9
Work light
C--179
13
Rear lights connection (2 PIN)
C--180
13
Rear lights connection (6 PIN)
GND--181
12
Trailer brake circuit ground
SEN--182
17
Transmission oil pressure sensor
SW--183
19
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
SEN--203
19
Shuttle position sensor
MOD--204
20
Four--wheel drive control unit
SW--205
20
Front lift UP external control switch
SW--206
20
Front lift DOWN external control switch
SEN--208
20
Front PTO sensor
GND--215
2
Power sockets ground
87666787A - 11 - 2007
Connection for CAN line (4 PIN)
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
137
WIRING DIAGRAMS 1--2--3--4
MPM1000A
28 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
138
FOUR--WHEEL DRIVE CIRCUIT (Diagram 1)
C--6
Transmission system connection (24 PIN)
GND--7
Dashboard ground
SEN--33
Tilt sensor
SW--35
4WD control switch
MOD--64
Permanent 4WD control unit
GND--106 Four--wheel drive indicator ground SEN--124
Four--wheel drive indicator pressure switch
SEN--126
Steering sensor
SEN--127
Rear axle speed sensor
SEN--128
Front axle speed sensor
SOL--135
Four--wheel drive solenoid valve
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
139 FOUR--WHEEL DRIVE CIRCUIT -- DIAGRAM 1
MPM0970A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
140
POWER SOCKET CIRCUIT (Diagram 2)
C--4 GND--38
25A / 40A socket connection Rear ground
C--46
8A two--pin socket
C--47
40 A four--pole power socket (North America)
C--49
25A two--pin socket
GND--215 Power sockets ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
141 POWER SOCKET CIRCUIT -- DIAGRAM 2
MPM0971A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
142
BRAKES, BRAKE LIGHTS, DIFFERENTIAL LOCK CIRCUIT (Diagram 3)
C--6 MOD--25
Transmission system connection (24 PIN) Fuse box and main relay F--19
SW--36 GND--38
Stop Lights
RLY--1
Brake lights circuit
RLY--2
Differential lock circuit
RLY--3
Differential lock circuit
RLY--6
Differential lock circuit
Differential lock switch Rear ground
SW--39
Parking brake switch
SW--116
Differential lock indicator switch
SOL--117
Differential lock solenoid valve
SW--136
Stoplamp switch
C--166
Brake lights signal test connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
143
BRAKES, BRAKE LIGHTS, DIFFERENTIAL LOCK CIRCUIT -- DIAGRAM 3
MPM0972A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
144
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (control switches and flasher) (Diagram 4)
GND--7
Dashboard ground
SW--10
Hazard lights switch
SW--17
Front grille work lights switch
MOD--23
Electronic flasher
SW--97
External lights control switch
SW--105
Front electronic lift block switch
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
145
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (control switches and flasher) -- DIAGRAM 4
MPM0973A
87666787A - 11 - 2007
146
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
147
WIRING DIAGRAMS 5--6--7--8
MPM1001A
29 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
148
GRID HEATER CIRCUIT (Diagram 5)
C--6 GND--7 C--16
Transmission system connection (24 PIN) Dashboard ground Electronic thermostarter connection (6 PIN)
GND--106
Four--wheel drive indicator ground
SW--125
Shuttle lever switch
MOD--156 RLY--157/158 RES--159 F--160
87666787A - 11 - 2007
Grid heater electronic module Grid heater relay Grid Heater 125A Maxi--fuse
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
149 GRID--HEATER CIRCUIT -- DIAGRAM 5
MPM0974A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
150
INSTRUMENT AND SENSOR CIRCUIT (Diagram 6) C--1
Front side connection -- engine (24 PIN)
C--6
Transmission system connection (24 PIN)
GND--7 MOD--11
SW--32
Dashboard ground Instrument A
Right turn signal indicator (green)
B
Handbrake indicator (red)
C
Work lights indicator (amber)
D
Full--beam indicator light (blue)
E
Left turn signal indicator (green)
F
Battery charging system malfunction light (red)
G
Engine oil pressure warning indicator (red)
H
Power steering oil pressure indicator (red)
I
Power Shuttle alarm
J
PTO indicator
K
4WD indicator (indicator)
L
High gear range engaged indicator (green)
M
Low gear range engaged indicator
N
Side lights indicator (green)
O
Clogged engine air filter indicator (amber)
P
Second trailer turn signal indicator (green)
Q
First trailer turn signal indicator (green)
R
Brake fluid level indicator (amber)
S
Grid heater indicator (amber)
T
4WD fault indicator
U
Front power take--off indicator
V
Trailer brake indicator (red)
W
Instrument lighting
X
Automatic four--wheel drive indicator (green)
Y
Front lift unit indicator
Z
Differential lock indicator (amber)
A
Fuel gauge
b
Engine coolant temperature gauge
Operator present switch
SEN--123
Fuel level transmitter
SEN--130
Power take--off rpm sensor
SW--161
”Up/Down” control push--button
SW--162
”Enter” control push--button
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
151 INSTRUMENT AND SENSOR CIRCUIT -- DIAGRAM 6
MPM0975A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
152
POWER TAKE--OFF AND SAFETY DEVICE CIRCUIT (Diagram 7)
C--6
Transmission system connection (24 PIN)
C--15
Gearbox neutral connection
SW--111
Rear PTO switch
SEN--112
Power steering indicator light pressure switch
SW--114
Gearbox neutral switch
SW--115
Splitter switch
* **
Standard version Splitter version
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
153
POWER TAKE--OFF AND SAFETY DEVICE CIRCUIT -- DIAGRAM 7
MPM0976A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
154 SEVEN--PIN SOCKET AND NUMBER PLATE LIGHT CIRCUIT (Diagram 8)
C--14
Seven--pin socket connection
C--14A
ISO seven--pin socket
C--14B
North American seven--pin socket
GND--38
Rear ground
LMP--210
Number plate light
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
155
SEVEN--PIN SOCKET AND NUMBER PLATE LIGHT CIRCUIT -- DIAGRAM 8
MPM0977A
87666787A - 11 - 2007
156
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
157
WIRING DIAGRAMS 9--10--11--12--13
MPM1002A
30 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
158
EXTERNAL LIGHTS AND HORN CIRCUIT (Diagram 9)
C--5
Front lights connection
GND--7
Dashboard ground
LMP--20
RH front direction indicator and side light
LMP--22
LH front direction indicator and side light
MOD--25
Fuse box and main relay F--9
Direction indicator and hazard lights
F--10
Horn, full beam flasher, seat safety circuit
GND--38
Rear ground
AUD--118
Horn
LMP--119
Grille LH front work light
LMP--120
Front LH headlamp
LMP--121
Front RH headlamp
LMP--122
Grille RH front work light
LMP--178
Work light
* **
ISO version North America version
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
159 EXTERNAL LIGHTS AND HORN CIRCUIT -- DIAGRAM 9
MPM0978A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
160
POWER SUPPLIES 1 CIRCUIT (Diagram 10)
SW--19 MOD--25
F--26
Start switch Fuse box and main relay F--1
Front right--hand and rear left--hand side lights, side lights indicator
F--2
Front left--hand and rear right--hand side lights, control instrument panel light
F--3
ISO side lights, or 7--pin work light (North America)
F--4
Full beam headlights
F--5
Dipped beam headlights
F--11
Starter safety circuit
F--12
Engine cut--out electromagnet
F--13
Power Shuttle circuit
F--14
Power Shuttle circuit
F--15
Swivel position lights
F--16
Trailer brake and hydraulic adjustment circuit
F--18
Permanent 4WD circuit
F--20
Electronic control unit power supply, +battery
F--25
Not used
F--27
Rear work light circuit
30A maxi--fuse (40A for North America)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
161 POWER SUPPLIES 1 CIRCUIT -- DIAGRAM 10
MPM0979A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
162
POWER SUPPLIES 2 CIRCUIT (Diagram 11)
GND--7 MOD--25
Dashboard ground Fuse box and main relay F--6
+ Instrument common
F--7
Differential lock circuit, four--wheel drive circuit
F--8
8A power socket, digital instrument
RLY--4
Differential lock circuit
RLY--5
Full beam headlight circuit
RLY--6
Dipped beam headlight circuit
RLY--13
Engine starter circuit maxi--relay
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
163 POWER SUPPLIES 2 CIRCUIT -- DIAGRAM 11
MPM0980A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
164
TRAILER BRAKE CIRCUIT (Diagram 12)
C--3 GND--7
Trailer brake circuit intermediate connection (4 PIN) Dashboard ground
C--8
Trailer brake circuit main connection (4 PIN)
SEN--107
Trailer brake indicator light pressure switch
SEN--108
Trailer brake circuit safety pressure switch
SOL--109
Trailer brake solenoid valves
RLY--110
Trailer brake circuit relay RLY--9
Trailer brake circuit
RLY--10
Trailer brake circuit
RLY--13
Trailer brake circuit
GND--181 Trailer brake circuit ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
165 TRAILER BRAKE CIRCUIT -- DIAGRAM 12
MPM0981A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
166
INTERMEDIATE CONNECTIONS CIRCUIT (Diagram 13)
C--21
Power--Shuttle system connection (6 PIN)
C--167
Connection for CAN line (4 PIN)
C--179
Rear lights connection (2 PIN)
C--180
Rear lights connection (6 PIN)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
167 INTERMEDIATE CONNECTIONS CIRCUIT -- DIAGRAM 13
MPM0982A
87666787A - 11 - 2007
168
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
169
WIRING DIAGRAMS 14--15
MPM1003A
31 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
170
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT (Diagram 14)
C--1
Front side connection -- engine (24 PIN)
GND--7
Dashboard ground
BAT--83
Battery
ALT--84
Alternator
M--85
Starter motor
SEN--86
Brake fluid level sensor
SEN--87
Air filter clogged sensor
SEN--89
Sediment unit filter sensor
SEN--92
Engine oil pressure sensor
SEN--93
Coolant temperature sensor
SOL--94
Engine cutout electromagnet
SOL--95
Solenoid valve to cut out starting advance, depending on temperature
SW--96
Starting advance thermometric cut--out switch
F--169
50A mega--fuse
SEN--176 (NEF)
Engine rpm sensor
SEN--176 (F5C)
Engine rpm sensor (for F5C engine)
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
171
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT -- DIAGRAM 14
MPM0983A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
172
DIAGNOSTICS CONNECTION CAN LINE CIRCUIT (Diagram 15)
GND--7 C--28
Dashboard ground Diagnostics connection
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
173
DIAGNOSTICS CONNECTION CAN LINE CIRCUIT -- DIAGRAM 15
MPM0984A
87666787A - 11 - 2007
174
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
175
WIRING DIAGRAMS 16--17--18--19--20
MPM1004A
32 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
176
POWER SHUTTLE CIRCUIT 8+8 / 16+16 (dashboard side) (Diagram 16)
C--9
Power--Shuttle transmission system connection (24 PIN)
C--21
Power--Shuttle system connection (6 PIN)
MOD--150 Power Shuttle control unit SW--151
Clutch pedal switch
SW--152
Power Shuttle control lever
SEN--153
Clutch pedal sensor
GND--155 Dashboard Power Shuttle ground C--167
Connection for CAN line (4 PIN)
NC = Not connected
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
177
POWER SHUTTLE CIRCUIT 8+8 / 16+16 (dashboard side) -- DIAGRAM 16
MPM0985A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
178
POWER SHUTTLE CIRCUIT (transmission side) (Diagram 17)
C--9
Power--Shuttle transmission system connection (24 PIN)
SOL--140
Dump solenoid valve
SW--141
G1 ranges switch
SW--142
C1 gears switch
SOL--146
Lo clutch solenoid valve
SOL--147
Hi clutch solenoid valve
SEN--148
Transmission oil temperature sensor
SEN--182
Transmission oil pressure sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
179 POWER SHUTTLE CIRCUIT (transmission side) -- DIAGRAM 17
MPM0986A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
180
POWER SHUTTLE CIRCUIT 32+16 / 44+16 (dashboard side) (Diagram 18)
C--9
Power--Shuttle transmission system connection (24 PIN)
C--21
Power--Shuttle system connection (6 PIN)
MOD--150 Power Shuttle control unit SW--151
Clutch pedal switch
SW--152
Power Shuttle control lever
SEN--153
Clutch pedal sensor
GND--155 Dashboard Power Shuttle ground C--167
Connection for CAN line (4 PIN)
NC = Not connected
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
181
POWER SHUTTLE CIRCUIT 32+16 / 44+16 (dashboard side) -- DIAGRAM 18
MPM0987A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
182
POWER SHUTTLE CIRCUIT (transmission side) (Diagram 19)
C--9
Power--Shuttle transmission system connection (24 PIN)
SOL--138
HI--LO mode solenoid valve
SOL--139
Shuttle mode solenoid valve
SOL--140
Dump solenoid valve
SW--141
G1 ranges switch
SW--142
C1 gears switch
SW--143
Creeper switch
SOL--146
Lo clutch solenoid valve
SOL--147
Hi clutch solenoid valve
SEN--148
Transmission oil temperature sensor
SW--183
Dual Command (2 Speed Power Shift) and Dump Clutch buttons
SEN--203
Shuttle position sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
183 POWER SHUTTLE CIRCUIT (transmission side) -- DIAGRAM 19
MPM0988A
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
184
FRONT PTO CIRCUIT (Diagram 20)
SW--12 C--13
Front PTO switch Front PTO and lift system connection (13 PIN)
SOL--99
Front lift UP solenoid valve
SOL--100
Front lift DOWN solenoid valve
SEN--101
Front lift arms position sensor
MOD--102 Front electronic lift control panel SW--103
Front lift up/down control switch
MOD--204 Four--wheel drive control unit SW--205
Front lift UP external control switch
SW--206
Front lift DOWN external control switch
SEN--208
Front PTO sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
185 FRONT PTO CIRCUIT -- DIAGRAM 20
MPM0989A
87666787A - 11 - 2007
186
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
1
SECTION 55 -- ELECTRICAL SYSTEM Chapter 8 -- CONNECTORS CONTENT Section
Description
Page
Electrical circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Types of versions for tractors with cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Types of versions for tractors without cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 List of connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
2
ELECTRICAL CIRCUIT COMPONENTS C--1 C--2 C--3 C--4 C--5 C--6 GND--7 C--8 C--9 SW--10 MOD--11 SW--12 C--13 C--14 C--14A C--14B C--15 C--16 SW--17 C--18 SW--19 LMP--20 C--21 LMP--22 MOD--23 C--24 MOD--25 F--26 MOD--27 C--28 C--29 SW--30 C--31 CB--31 SW--32 SEN--33 SW--34 SW--35 SW--36 SW--37 GND--38 SW--39 MOD--40 C--41 M--42 MOD--43
Front side connection -- engine (24 PIN) Cab system connection (20 PIN) Trailer brake circuit intermediate connection (4 PIN) 25A and 40A power socket connection Front lights connection Transmission system connection (24 PIN) Dashboard ground Trailer brake circuit main connection (4 PIN) Power--shuttle system connection (24 PIN) Hazard lights switch Instrument Front PTO switch Front lift and PTO system connection (13 PIN) 7--pin socket connection ISO seven--pin socket North American seven--pin socket Gearbox neutral connection Electronic thermostarter connection (6 PIN) Front grille work lights switch Rear electronic lift connection (8 PIN) Starter switch RH front direction indicator and side light Power--Shuttle system connection (6 PIN) LH front direction indicator and side light Electronic flasher Digital instrument connection Fuse box and main relay 30A maxi--fuse (40A for North America) Rear lift electronic control unit Diagnostics connection Rotating beacon socket Battery cut--out circuit switch Connection for battery cut--out circuit on engine Battery cut--out circuit jumper Operator present switch Tilt sensor Rear electronic lift up/down switch 4WD control switch Differential lock switch LH rear external electronic lift up/down switch Rear ground Parking brake switch Rear electronic lift indicator lights and working depth adjustment control panel Seat connection Front and rear window washer pump Rear electronic lift control panel
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
3
ELECTRICAL CIRCUIT COMPONENTS (Continued) SW--44 LMP--45 C--46 C--47 LMP--48 C--49 SW--52 SW--53 M--54 SW--55 M--56 GND--57 MOD--58 AUD--60 AUD--61 C--62 SW--63 MOD--64 RES66 SW--67 M--68 LMP--69 RLY--70 SEN--71 SW--72 C--73 SW--74 MOD--75 LMP--76 LMP--77 LMP--78 LMP--79 LMP--80 LMP--81 LMP--82 BAT--83 ALT--84 M--85 SEN--86 SEN--87 C--88 SEN--89 M--90 SEN--91 SEN--92 SEN--93
RH rear external electronic lift up/down switch RH tail light 8A two--pin socket 40 A four--pin socket (North America) LH tail light 25A two--pin socket Windscreen washer switch Windscreen wiper switch Wiper motor Rear window wiper/washer switch Rear wiper motor Cab ground Radio RH speaker LH speaker Fan unit connection Rotating beacon control switch Permanent 4WD control unit Fan speed resistor unit Ventilation and air--conditioning system electric fan switch Ventilation and air--conditioning system electric fan Fan control unit lamp Conditioner relay Electronic thermostat for air conditioner Air conditioner switch Front work lights connection Work lights switch Fuse box and cab relay Cab RH front work light Cab LH front work light Cab RH rear work light Cab LH rear work light RH cab SMV light LH cab SMV light Cab overhead lighting Battery Alternator Starter motor Brake fluid level sensor Air filter clogged sensor Cigar lighter Sediment unit filter sensor Conditioner compressor Filter/dryer sensor Engine oil pressure sensor Coolant temperature sensor
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
4
ELECTRICAL CIRCUIT COMPONENTS (Continued) SOL--94 SOL--95 SW--96 SW--97 SOL--99 SOL--100 SEN--101 MOD--102 SW--103 SW--104 SW--105 GND--106 SEN--107 SEN--108 SOL--109 RLY--110 SW--111 SEN--112 SW--113 SW--114 SW--115 SW--116 SOL--117 AUD--118 LMP--119 LMP--120 LMP--121 LMP--122 SEN--123 SEN--124 SW--125 SEN--126 SEN--127 SEN--128 SEN--129 SEN--130 SEN--131 SEN--132 SOL--133 SOL--134 SOL--135 SW--136 SOL--138 SOL--139 SOL--140 SW--141
Engine cut--out electromagnet Solenoid valve to cut out starting advance, depending on temperature Starting advance thermometric cut--out switch External lights control switch Front lift UP solenoid valve Front lift DOWN solenoid valve Front lift arms position sensor Front electronic lift control panel Front lift up/down switch Front PTO switch Front electronic lift block switch 4WD indicator ground Trailer brake indicator light pressure switch Trailer brake circuit safety pressure switch Trailer brake solenoid valves Trailer brake circuit relay Rear PTO switch Power steering indicator light pressure switch Lights switch Gearbox neutral switch Splitter switch Differential lock indicator switch Differential lock solenoid valve Horn Grille LH front work light Front LH headlamp Front RH headlamp Grille RH front work light Fuel level transmitter 4WD indicator pressure switch Shuttle lever switch Steering sensor Rear axle speed sensor Front axle speed sensor Ground speed sensor PTO rpm sensor Draft sensor Arms position sensor Rear electronic lift DOWN solenoid valve Rear electronic lift UP solenoid valve 4WD solenoid valve Stoplamp switch Dual Command (2 Speed Power Shift) mode solenoid valve Shuttle mode solenoid valve Dump solenoid valve G1 ranges switch
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
5
ELECTRICAL CIRCUIT COMPONENTS (Continued) SW--142 SW--143 SOL--146 SOL--147 SEN--148 MOD--150 SW--151 SW--152 SEN--153 GND--155 MOD--156 RLY--157 RLY--158 RES--159 F--160 SW--161 SW--162 C--166 C--167 F--168 F--169 C--170 SW--171 C--175 SEN--176 MOD--177 LMP--178 C--179 C--180 GND--181 SEN--182 SW--183 C--184 C--185 SEN--203 MOD--204 SW--205 SW--206 SEN--208 LMP--210 SW--211 LMP--212 LMP--213 LMP--214 GND--215
C1 gears switch Creeper switch Lo clutch solenoid valve Hi clutch solenoid valve Transmission oil temperature sensor Power Shuttle control unit Clutch pedal switch Power Shuttle control lever Clutch pedal sensor Dashboard Power Shuttle ground Grid heater electronic module Grid heater relay (coil) Grid heater relay (contact) Grid heater 125A maxi--fuse ”Up/Down” control button ”Enter” control button Brake lights signal test connection Connection for CAN line (4 PIN) 50A mega--fuse 50A mega--fuse Front lift system connection (8 PIN) Front lift main switch Four--wheel drive system connection (4 PIN) Engine rpm sensor Digital instrument Work light Rear lights connection (2 PIN) Rear lights connection (6 PIN) Trailer brake circuit ground Transmission oil pressure sensor Dual Command (2 Speed Power Shift) and Dump Clutch buttons LH cab SMV light connection RH cab SMV light connection Shuttle position sensor Four--wheel drive control unit Front lift UP external control switch Front lift DOWN external control switch Front PTO sensor Number plate light 4WD indicator switch Number plate light RH two--faced headlight LH two--faced headlight Power sockets ground
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
6
TYPES OF VERSIONS FOR TRACTORS WITH CAB
VERSION
DESCRIPTION
1
2WD VERSION, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR MECHANICAL LIFT
2
ELECTROHYDRAULIC FOUR--WHEEL DRIVE VERSION, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR MECHANICAL LIFT
3
ELECTROHYDRAULIC FOUR--WHEEL DRIVE VERSION, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR ELECTRONIC LIFT
4
PERMANENT FOUR--WHEEL DRIVE VERSION, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR MECHANICAL LIFT
5
PERMANENT FOUR--WHEEL DRIVE VERSION, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR ELECTRONIC LIFT
TYPES OF VERSIONS FOR TRACTORS WITHOUT CAB
VERSION
DESCRIPTION
1
2WD VERSION, REAR MECHANICAL LIFT
2
ELECTROHYDRAULIC FOUR--WHEEL DRIVE VERSION, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR MECHANICAL LIFT
3
PERMANENT FOUR--WHEEL DRIVE VERSION, ELECTROHYDRAULIC DIFFERENTIAL LOCK, REAR MECHANICAL LIFT
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
7
LIST OF CONNECTORS
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
8 Pin
Col.
Sect.
Pin
Col.
Sect.
A1
--
--
B5
MN
1.0
A2
MV
1.0
B6
--
--
A3
VN
1.0
B7
--
--
A4
N
1.0
B8
--
--
A5
ZB
1.0
C1
--
--
A6
--
--
C2
SG
1.0
A7
--
--
C3
HN
1.0
A8
--
--
C4
HV
1.0
B1
--
--
C5
L
1.0
B2
HR
1.0
C6
--
--
B3
RV
1.0
C7
--
--
B4
LR
1.0
C8
--
--
Sect.
Pin
Col.
Sect.
8 7 6 5 4 3 2 1 A
A
B
B
C
C
F
8 7 6 5 4 3 2 1
C--1--A
For model with cab. MAIN CABLE SIDE
1 Pin
Col.
A1
--
--
B5
MN
0.75
A2
MV
1.0
B6
--
--
A3
VN
1.0
B7
--
--
A4
N
1.0
B8
--
--
A5
ZB
1.0
C1
--
--
A6
--
--
C2
SG
1.0
A7
--
--
C3
HN
1.0
A8
--
--
C4
HV
1.0
B1
--
--
C5
L
1.0
B2
HR
1.0
C6
--
--
B3
RV
1.0
C7
--
--
B4
LR
1.0
C8
--
--
A
1
2 3 4 5 6 7
8
A
B
1
2 3 4 5 6 7
8
B
C
1
2 3 4 5 6 7
8
C
M
C--1--A
For model with cab. ENGINE CABLE SIDE
2
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
A1
--
--
B5
MN
1.0
A2
MV
1.0
B6
--
--
A3
VN
1.0
B7
--
--
A4
N
1.0
B8
--
--
A5
ZB
1.0
C1
--
--
A6
--
--
C2
SG
1.0
A7
--
--
C3
HN
1.0
A8
--
--
C4
HV
1.0
B1
--
--
C5
--
--
B2
HR
1.0
C6
--
--
B3
RV
1.0
C7
--
--
B4
LR
1.0
C8
--
--
9
8 7 6 5 4 3 2 1 A
A
B
B
C
C
F
8 7 6 5 4 3 2 1
C--1--A
For model without cab, version 2 and 3. MAIN CABLE SIDE
3 Pin
Col.
Sect.
Pin
Col.
Sect.
A1
--
--
B5
MN
1.0
A2
MV
1.0
B6
--
--
A3
VN
1.0
B7
--
--
A4
N
1.0
B8
--
--
A5
ZB
1.0
C1
--
--
A6
--
--
C2
SG
1.0
A7
--
--
C3
HN
0.75
A8
--
--
C4
HV
0.75
B1
--
--
C5
--
--
B2
HR
1.0
C6
--
--
B3
RV
1.0
C7
--
--
B4
LR
1.0
C8
--
--
8 7 6 5 4 3 2 1 A
A
B
B
C
C
F
8 7 6 5 4 3 2 1
C--1--A
For model without cab, version 1. MAIN CABLE SIDE
4
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
10 Pin
Col.
Sect.
Pin
Col.
Sect.
A1
--
--
B5
MN
1.0
A2
MV
1.0
B6
--
--
A
1
2 3 4 5 6 7
8
A
A3
VN
1.0
B7
--
--
B
1
2 3 4 5 6 7
8
B
A4
N
1.0
B8
--
--
C
1
2 3 4 5 6 7
8
C
A5
ZB
1.0
C1
--
--
A6
--
--
C2
SG
1.0
A7
--
--
C3
HN
1.0
A8
--
--
C4
HV
1.0
B1
--
--
C5
--
--
B2
HR
1.0
C6
--
--
B3
RV
1.0
C7
--
--
B4
LR
1.0
C8
--
--
M
C--1--A
For model without cab. ENGINE CABLE SIDE
5 Pin
Col.
Sect.
Pin
Col.
Sect.
1
R
10
--
--
--
C--1--B
For model without cab. MAIN CABLE SIDE
6 Pin
Col.
Sect.
Pin
Col.
Sect.
A
R
10
--
--
--
C--1--B
For model without cab. POWER CABLE SIDE
7 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
A
R
10
B
L
10
11
C--1--B
A
B
For model with cab. MAIN CABLE SIDE
8 Pin
Col.
Sect.
Pin
Col.
Sect.
A
R
10
B
L
10
C--1--B
For model with cab. POWER CABLE SIDE
9 Pin
Col.
Sect.
Pin
Col.
Sect.
1
HN
1.5
11
H
1.0
2
VN
1.5
12
BN
1.0
3
HB
0.5
13
LB
1.0
4
G
1.0
14
VG
1.0
5
L
1.0
15
--
--
6
BG
0.5
16
--
--
7
CL
1.0
17
--
--
8
BL
1.0
18
--
--
9
AB
1.0
19
--
--
10
GN
1.0
20
--
--
For model with cab, version 2 and 3. MAIN CABLE SIDE
9
8
7
6
20 19 18
5
4
17 16 15 14 13
3
2
1
12 11 10
F
C--2--A
9
8
7
6
5
4
3
2
1
10 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
12 Pin
Col.
Sect.
Pin
Col.
Sect.
1
HN
1.5
11
H
1.0
2
--
--
12
BN
1.0
3
--
--
13
LB
1.0
4
--
--
14
VG
1.0
5
L
1.0
15
--
--
6
BG
0.5
16
--
--
7
CL
1.0
17
--
--
8
BL
1.0
18
--
--
9
AB
1.0
19
--
--
10
GN
1.0
20
--
--
9
8
7
6
20 19 18
5
4
17 16 15 14 13
3
2
1
12 11 10
F
C--2--A
For model with cab, version 4 and 5. MAIN CABLE SIDE
9
8
7
6
5
4
3
2
1
11 Pin
Col.
Sect.
Pin
Col.
Sect.
1
HN
2
--
1.5
11
RG
1.0
--
12
RN
1.0
3
--
--
13
GR
1.0
4
--
--
14
VG
1.0
5
L
1.0
15
--
--
6
BG
0.5
16
--
--
7
CL
1.0
17
--
--
8
BL
0.5
18
--
--
9
AB
1.0
19
--
--
10
GN
1.0
20
--
--
For model with cab. CAB CABLE SIDE
1 2 3 4 10 11 12
5
13 14 15 16 17
6 7 8 9 18 19 20
M
C--2--A
1 2 3 4 5
6 7 8 9
12
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
L
10
--
--
--
13
C--2--B
For model with cab, version 2, 3, 4 and 5. MAIN CABLE SIDE F
13 Pin
Col.
Sect.
Pin
Col.
Sect.
1
L
4.0
--
--
--
C--2--B
For model with cab. CAB CABLE SIDE M
14
BR
1.0
4
HR
1.0 4
2
C--3
3
1.0
2
Sect.
AG
1
Col.
3
4
Pin
1.0
3
Sect.
HL
2
Col.
1
1
Pin
M
15 1.0
3
AG
1.0
2
BR
1.0
4
HR
1.0
C--3
1
HL
2
1
3
Sect.
4
Col.
1
Pin
2
Sect.
3
Col.
4
Pin
F
16 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
14 Pin
Col.
Sect.
Pin
Col.
Sect.
1
M
6.0
--
--
--
1
N
6.0
--
--
--
C--4
For model with cab, version 3, 4 and 5.
17 Pin
Col.
Sect.
Pin
Col.
Sect.
1
M
2.5
--
--
--
1
N
2.5
--
--
--
C--4
For NORTH AMERICAN model.
18 Pin
Col.
Sect.
Pin
Col.
Sect.
1
MV
6.0
--
--
--
C--4
For model without cab, version 1 and 3. MAIN CABLE SIDE F
19 Pin
Col.
Sect.
Pin
Col.
Sect.
1
M
6.0
--
--
--
C--4
For model without cab, version 2. MAIN CABLE SIDE F
20 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
M
4.0
--
--
--
15
C--4
For model without cab, ISO. SOCKET CABLE SIDE M
21 Pin
Col.
Sect.
Pin
Col.
Sect.
1
M
2.5
--
--
--
C--4
For model without cab, NORTH AMERICAN. SOCKET CABLE SIDE M
22
2
N
1.5
5
B
1.5
3
V
1.5
6
Z
1.0
5
5
6
6
4
MAIN CABLE SIDE
C--5 1
1.5
2
Sect.
H
3
Col.
4
F
4
Pin
1.5
1
Sect.
N
2
Col.
1
3
Pin
23
2
N
1.5
5
B
1.5
3
V
1.5
6
Z
1.0
FRONT LIGHTS CABLE SIDE
C--5 6
1.5
5
H
4
4
3
1.5
2
N
1
1
6
Sect.
5
Col.
4
Pin
3
Sect.
2
Col.
1
Pin
M
24 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
16 Pin
Col.
Sect.
Pin
Col.
Sect.
A1
AR
1.0
B5
--
--
A2
HL
1.0
B6
--
--
A3
--
--
B7
ZB
1.0
A4
S
0.75
B8
--
--
A5
CN
0.75
C1
LG
0.75
A6
--
--
C2
HG
0.75
A7
BC
0.75
C3
HV
1.0
A8
H
1.0
C4
--
--
B1
--
--
C5
--
--
B2
--
--
C6
--
--
B3
HB
0.75
C7
--
--
B4
RG
0.75
C8
MB
0.75
8 7 6 5 4 3 2 1 A
A
B
B
C
C
F
8 7 6 5 4 3 2 1
C--6--A
For model with cab, version 1. For model without cab, version 1. MAIN CABLE SIDE
25 Pin
Col.
Sect.
Pin
Col.
Sect.
A1
AR
1.0
B5
--
--
A2
HL
1.0
B6
--
--
A3
--
--
B7
ZB
1.0
A4
S
0.75
B8
--
--
A5
CN
0.75
C1
LG
0.75
A6
--
--
C2
HG
0.75
A7
BC
1.0
C3
HV
1.0
A8
H
1.0
C4
C
1.0
B1
--
--
C5
--
--
B2
--
--
C6
--
--
B3
HB
1.0
C7
--
--
B4
RG
0.75
C8
MB
0.75
8 7 6 5 4 3 2 1 A
A
B
B
C
C
F
8 7 6 5 4 3 2 1
C--6--A
For model with cab, version 2. MAIN CABLE SIDE
26
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
A1
AR
1.0
B5
--
--
A2
HL
1.0
B6
--
--
A3
--
--
B7
ZB
1.0
A4
S
0.75
B8
--
--
A5
CN
0.75
C1
LG
0.75
A6
--
--
C2
HG
0.75
A7
BC
0.75
C3
HV
1.0
A8
H
1.0
C4
C
1.0
B1
--
--
C5
--
--
B2
--
--
C6
--
--
B3
HB
0.75
C7
--
--
B4
RG
0.75
C8
MB
0.75
17
8 7 6 5 4 3 2 1 A
A
B
B
C
C
F
8 7 6 5 4 3 2 1
C--6--A
For model with cab, version 3. For model without cab, version 2. MAIN CABLE SIDE
27 Pin
Col.
Sect.
Pin
Col.
Sect.
A1
AR
1.0
B5
--
--
A2
HL
1.0
B6
--
--
A3
--
--
B7
ZB
1.0
A4
S
1.0
B8
--
--
A5
CN
1.0
C1
LG
1.0
A6
--
--
C2
HG
1.0
A7
BC
1.0
C3
HV
1.0
A8
H
1.0
C4
C
1.0
B1
--
--
C5
--
--
B2
--
--
C6
--
--
B3
HB
1.0
C7
--
--
B4
RG
1.0
C8
MB
1.0
A
1
2 3 4 5 6 7
8
A
B
1
2 3 4 5 6 7
8
B
C
1
2 3 4 5 6 7
8
C
M
C--6--A
For model with cab, version 1, 2 and 3. For model without cab, version 1 and 2. TRANSMISSION CABLE SIDE
28
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
18 Pin
Col.
Sect.
Pin
Col.
Sect.
A1
CL
1.0
B5
B
1.0
A2
HL
1.0
B6
AR
1.0
A3
MV
1.0
B7
--
--
A4
VN
1.0
B8
ZB
0.75
A5
CN
0.75
C1
CB
1.0
A6
S
0.75
C2
HG
0.75
A7
BC
0.75
C3
RG
0.75
A8
H
1.0
C4
C
1.0
B1
--
--
C5
SB
1.0
B2
--
--
C6
HV
1.0
B3
--
--
C7
--
--
B4
V
1.0
C8
MB
0.75
Col.
Sect.
8 7 6 5 4 3 2 1 A
A
B
B
C
C
F
8 7 6 5 4 3 2 1
C--6--A
For model with cab, version 4. For model without cab, version 3. MAIN CABLE SIDE
29 Pin
Col.
Sect.
Pin
A1
CL
1.0
B5
B
1.0
A2
HL
1.0
B6
AR
1.0
A3
MV
1.0
B7
--
--
A4
VN
1.0
B8
ZB
1.0
A5
CN
0.75
C1
CB
1.0
A6
S
0.75
C2
HG
0.75
A7
BC
0.75
C3
RG
0.75
A8
H
1.0
C4
C
1.0
B1
--
--
C5
SB
1.0
B2
--
--
C6
HV
1.0
B3
--
--
C7
--
--
B4
V
1.0
C8
MB
0.75
8 7 6 5 4 3 2 1 A
A
B
B
C
C
F
8 7 6 5 4 3 2 1
C--6--A
For model with cab, version 5. MAIN CABLE SIDE
30
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
A1
CL
1.0
B5
B
1.0
A2
HL
1.0
B6
AR
1.0
A3
MV
1.0
B7
--
--
A4
VN
1.0
B8
ZB
1.0
A5
CN
1.0
C1
CB
1.0
A6
S
1.0
C2
HG
1.0
A7
BC
1.0
C3
RG
1.0
A8
H
1.0
C4
C
1.0
B1
--
--
C5
SB
1.0
B2
--
--
C6
HV
1.0
B3
--
--
C7
--
--
B4
V
1.0
C8
MB
1.0
19
A
1
2 3 4 5 6 7
8
A
B
1
2 3 4 5 6 7
8
B
C
1
2 3 4 5 6 7
8
C
M
C--6--A
For model with cab, version 4 and 5. For model without cab, version 3. TRANSMISSION CABLE SIDE
31 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
0.5
8
N
1.0
2
N
0.5
9
N
1.5
3
N
1.0
10
N
1.5
4
N
1.0
11
N
1.0
5
N
1.0
12
N
2.5
6
N
1.0
13
N
0.5
7
N
1.0
14
N
1.0
GND--7
For model without cab, version 1.
32 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
0.5
8
N
1.0
2
N
1.0
9
N
1.5
3
N
1.0
10
N
1.5
4
N
1.0
11
N
0.5
5
N
1.0
12
N
2.5
6
N
1.0
13
N
0.5
7
N
1.0
14
N
1.0
GND--7
For model without cab, version 2.
33 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
20 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
9
N
1.0
2
N
6.0
10
N
1.5
3
N
1.0
11
N
1.5
4
N
1.0
12
N
0.5
5
N
1.0
13
N
2.5
6
N
1.0
14
N
0.5
7
N
1.0
15
N
1.0
8
N
1.0
16
N
0.5
GND--7
For model with cab, version 1. 34 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
0.5
9
N
1.0
2
N
1.0
10
N
1.0
3
N
6.0
11
N
1.5
4
N
1.0
12
N
1.5
5
N
1.0
13
N
0.5
6
N
1.0
14
N
2.5
7
N
1.0
15
N
0.5
8
N
1.0
16
N
1.0
GND--7
For model with cab, version 2. 35 Pin
Col.
Sect.
Pin
Col.
Sect.
1 2 3 4
N N N N
0.5 6.0 1.0 1.5
11 12 13 14
N N N N
1.0 1.5 1.5 0.5
5 6 7 8 9 10
N N N N N N
1.5 1.0 1.0 1.0 1.0 1.0
15 16 17 18 19 --
N N N N N --
2.5 0.5 1.0 0.5 1.0 --
GND--7
For model with cab, version 3.
36
Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
10
N
1.5
2
N
6.0
11
N
1.5
3
N
1.0
12
N
1.0
4
N
1.0
13
N
2.5
5
N
1.0
14
N
0.5
6
N
1.0
15
N
0.5
7
N
1.0
16
N
1.0
8
N
1.0
17
N
0.5
9
N
1.0
--
--
--
For model with cab, version 4.
87666787A - 11 - 2007
GND--7
37
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
11
N
1.5
2
N
6.0
12
N
1.5
3
N
1.0
13
N
1.0
4
N
1.0
14
N
2.5
5
N
1.0
15
N
0.5
7
N
1.0
16
N
1.0
8
N
1.0
17
N
0.5
9
N
1.0
18
N
1.0
10
N
1.0
19
N
0.5
21
GND--7
For model with cab, version 5.
38
Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
0.5
9
N
1.5
2
N
1.0
10
N
1.5
3
N
1.0
11
N
0.5
4
N
1.0
12
N
2.5
5
N
1.0
13
N
0.5
6
N
1.0
14
N
0.5
7
N
1.0
15
N
1.0
8
N
1.0
--
--
--
GND--7
For model without cab, version 3. 39 Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
3
AG
0.5
2
B
1.0
4
HL
1.0
--
B
0.5
--
--
--
C--8
1
Pin
2
For model with cab, version 2, 3 and 5. For model without cab. MAIN CABLE SIDE
4
3
F
40 Sect.
Pin
Col.
Sect.
1
N
1.0
3
AG
1.0
2
B
0.5
4
HL
1.0
TRAILER BRAKE CABLE SIDE
C--8
1 2 3 4
Col.
1 2 3 4
Pin
M
41 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
22 Pin
Col.
Sect.
Pin
Col.
Sect.
A1
MN
1.0
B5
BG
1.0
A2
HM
1.0
B6
VN
1.0
A3
HV
1.0
B7
AN
1.0
A4
AG
1.0
B8
ZB
1.0
A5
BN
1.0
C1
GR
1.0
A6
--
--
C2
AV
1.0
A7
GL
1.0
C3
MB
1.0
A8
BR
1.0
C4
SG
1.0
B1
N
1.0
C5
C
1.0
B2
GN
1.0
C6
AB
1.0
B3
N
1.0
C7
HG
1.0
B4
SN
1.0
C8
AR
1.0
8 7 6 5 4 3 2 1 A
A
B
B
C
C
F
8 7 6 5 4 3 2 1
C--9
For version with dual command (2--speed power shift)
42 Pin
Col.
Sect.
Pin
Col.
Sect.
A1
--
--
B5
BG
1.0
A2
HM
1.0
B6
VN
1.0
A3
HV
1.0
B7
AN
1.0
A4
AG
1.0
B8
ZB
1.0
A5
BN
1.0
C1
GR
1.0
A6
--
--
C2
AV
1.0
A7
GL
1.0
C3
MB
1.0
A8
BR
1.0
C4
SG
1.0
B1
--
--
C5
C
1.0
B2
GN
1.0
C6
AB
1.0
B3
ZN
1.0
C7
HG
1.0
B4
SN
1.0
C8
AR
1.0
A
1
2 3 4 5 6 7
8
A
B
1
2 3 4 5 6 7
8
B
C
1
2 3 4 5 6 7
8
C
M
C--9
For version with dual command (2--speed power shift), paddy field version
43
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
A1
MN
1.0
B5
BG
1.0
A2
HM
1.0
B6
VN
1.0
A3
--
--
B7
AN
1.0
A4
--
--
B8
ZB
1.0
A5
BN
1.0
C1
--
--
A6
--
--
C2
--
--
A7
GL
1.0
C3
--
--
A8
BR
1.0
C4
--
--
B1
N
1.0
C5
--
--
B2
--
--
C6
AB
1.0
B3
N
1.0
C7
--
--
B4
SN
1.0
C8
AR
1.0
23
8 7 6 5 4 3 2 1 A
A
B
B
C
C
F
8 7 6 5 4 3 2 1
C--9
For Power--Shuttle version.
44 Pin
Col.
Sect.
Pin
Col.
Sect.
A1
--
--
B5
BG
1.0
A2
HM
1.0
B6
VN
1.0
A3
--
--
B7
AN
1.0
A4
--
--
B8
ZB
1.0
A5
BN
1.0
C1
--
--
A6
--
--
C2
--
--
A7
GL
1.0
C3
--
--
A8
BR
1.0
C4
--
--
B1
--
--
C5
--
--
B2
--
--
C6
AB
1.0
B3
ZN
1.0
C7
--
--
B4
SN
1.0
C8
AR
1.0
A
1
2 3 4 5 6 7
8
A
B
1
2 3 4 5 6 7
8
B
C
1
2 3 4 5 6 7
8
C
M
C--9
For Power--Shuttle version.
45
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
1.0
3
--
--
2
H
1.0
4
--
--
For model with cab, version 3, 4 and 5. For model without cab.
SW--10--A
2
Sect.
BR
4
Col.
1
1
Pin
3
24
46 Pin
Col.
Sect.
Pin
Col.
Sect.
1
MV
1.0
2
N
0.5
For model with cab, version 1, 2 and 3. For model without cab.
SW--10--B
1
2
47 Pin
Col.
Sect.
Pin
Col.
Sect.
1
MV
1.0
2
N
1.0
SW--10--B
For model with cab, version 4 and 5. 1
2
48
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
HG
0.75
21
--
--
2
S
0.75
22
--
--
3
VN
1.0
23
--
--
4
N
0.5
24
--
--
5
ZB
0.75
25
--
--
6
--
--
26
--
--
7
HV
1.0
27
--
--
8
Z
0.5
28
--
--
9
--
--
29
LG
0.75
10
BR
0.75
30
RV
0.75
11
RG
0.75
31
M
0.75
12
--
--
32
LB
0.5
13
B
0.5
33
CL
0.75
14
A
0.75
34
CB
0.75
15
--
--
35
BN
0.5
16
V
0.5
36
MB
0.75
17
G
0.5
37
MN
1.0
18
AG
0.5
38
MV
1.0
19
HN
1.0
39
H
0.5
20
CN
0.75
40
--
--
25
1 11 21 31
10 20 30 40
MOD--11--A
For model without cab, version 1 and 2. 49 Pin
Col.
Sect.
Pin
Col.
Sect.
1
HG
0.75
21
--
--
2
S
0.75
22
--
--
3
VN
1.0
23
--
--
4
N
0.5
24
--
--
5
ZB
0.75
25
--
--
6
--
--
26
--
--
7
HV
1.0
27
--
--
8
Z
0.5
28
--
--
9
--
--
29
--
--
10
BR
1.0
30
RV
0.75
11
RG
0.75
31
M
0.75
12
--
--
32
LB
0.5
13
B
0.5
33
CL
0.75
14
A
0.75
34
CB
0.75
15
--
--
35
BN
0.5
16
V
0.5
36
MB
0.75
17
G
0.5
37
MN
1.0
18
AG
0.5
38
MV
1.0
19
HN
1.0
39
H
0.5
20
CN
0.75
40
--
--
1 11 21 31
10 20 30 40
MOD--11--A
For model without cab, version 3. 50
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
26 Pin
Col.
Sect.
Pin
Col.
Sect.
1
HG
0.75
21
--
--
2
S
0.75
22
--
--
3
VN
1.0
23
--
--
4
N
0.5
24
--
--
5
ZB
0.75
25
--
--
6
--
--
26
--
--
7
HV
1.0
27
--
--
8
Z
0.5
28
--
--
9
R
0.5
29
LG
0.75
10
BR
0.75
30
RV
0.75
11
RG
0.75
31
M
0.75
12
--
--
32
LB
0.5
13
B
0.5
33
CL
0.75
14
A
0.75
34
CB
0.75
15
BG
0.5
35
BN
0.5
16
V
0.5
36
MB
0.75
17
G
0.5
37
MN
1.0
18
AG
0.5
38
MV
1.0
19
HN
1.0
39
H
0.5
20
CN
0.75
40
--
--
1 11 21 31
10 20 30 40
MOD--11--A
For model with cab, version 1, 2 and 3. 51 Pin
Col.
Sect.
Pin
Col.
Sect.
1
HG
0.75
21
--
--
2
S
0.75
22
--
--
3
VN
1.0
23
--
--
4
N
0.5
24
--
--
5
ZB
0.75
25
--
--
6
--
--
26
--
--
7
HV
1.0
27
--
--
8
Z
0.5
28
--
--
9
R
0.5
29
--
--
10
BR
0.75
30
RV
0.75
11
RG
0.75
31
M
0.75
12
--
--
32
LB
0.5
13
B
0.5
33
CL
0.75
14
A
0.75
34
CB
0.75
15
BG
0.5
35
BN
0.5
16
V
0.5
36
MB
0.75
17
G
0.5
37
MN
1.0
18
AG
0.5
38
MV
1.0
19
HN
1.0
39
H
0.5
20
CN
0.75
40
--
--
1 11 21 31
10 20 30 40
MOD--11--A
For model with cab, version 4 and 5. 52
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
21
--
--
2
--
--
22
--
--
3
BL
0.5
23
--
--
4
--
--
24
--
--
5
--
--
25
--
--
6
--
--
26
--
--
7
--
--
27
--
--
8
--
--
28
--
--
9
--
--
29
--
--
10
--
--
30
--
--
11
RV
0.5
31
--
--
12
G
0.75
32
--
--
13
V
0.75
33
--
--
14
SN
0.75
34
--
--
15
BN
0.75
35
--
--
16
MN
0.75
36
--
--
17
LN
0.75
37
--
--
18
BC
0.75
38
--
--
19
HB
0.75
39
--
--
20
--
--
40
--
--
27
1 11 21 31
10 20 30 40
MOD--11--B
For model with cab, version 3. 53 Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
21
--
--
2
--
--
22
--
--
3
BL
0.5
23
--
--
4
--
--
24
--
--
5
--
--
25
--
--
6
--
--
26
--
--
7
--
--
27
--
--
8
--
--
28
--
--
9
--
--
29
--
--
10
--
--
30
--
--
11
RV
0.5
31
--
--
12
G
0.75
32
--
--
13
V
0.75
33
--
--
14
SN
0.75
34
--
--
15
BN
0.75
35
--
--
16
MN
0.75
36
--
--
17
LN
0.75
37
--
--
18
BC
0.75
38
--
--
19
--
--
39
--
--
20
--
--
40
--
--
1 11 21 31
10 20 30 40
MOD--11--B
For model with cab, version 4 and 5. 54
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
28 Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
21
--
--
2
--
--
22
--
--
3
BL
0.5
23
--
--
4
--
--
24
--
--
5
--
--
25
--
--
6
--
--
26
--
--
7
--
--
27
--
--
8
--
--
28
--
--
9
--
--
29
--
--
10
--
--
30
--
--
11
RV
0.5
31
--
--
12
G
0.75
32
--
--
13
V
0.75
33
--
--
14
SN
1.0
34
--
--
15
BN
1.0
35
--
--
16
MN
1.0
36
--
--
17
LN
1.0
37
--
--
18
BC
0.75
38
--
--
19
--
--
39
--
--
20
--
--
40
--
--
1 11 21 31
10 20 30 40
MOD--11--B
For model without cab, version 3. 55 Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
21
--
--
2
--
--
22
--
--
3
BL
0.5
23
--
--
4
--
--
24
--
--
5
--
--
25
--
--
6
--
--
26
--
--
7
--
--
27
--
--
8
--
--
28
--
--
9
--
--
29
--
--
10
--
--
30
--
--
11
V
0.5
31
--
--
12
G
0.75
32
--
--
13
V
0.75
33
--
--
14
SN
0.5
34
--
--
15
BN
0.5
35
--
--
16
MN
1.0
36
--
--
17
LN
1.0
37
--
--
18
CB
0.75
38
--
--
19
HB
0.75
39
--
--
20
--
--
40
--
--
1 11 21 31
10 20 30 40
MOD--11--B
ON DIGITAL INSTRUMENT CABLE 56
87666787A - 11 - 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 8 Col.
Sect.
Pin
Col.
Sect.
1
MV
0.5
3
R
0.5
2
HV
0.5
−
−
−
SW−12
2
2
3
3
1
1
Pin
29
57 Pin
Col.
Sect.
Pin
Col.
Sect.
A1
MV
1.0
B5
−
−
A2
BN
1.0
B6
−
−
A3
VB
1.0
B7
−
−
A4
−
−
B8
−
−
A5
AN
1.0
C1
ZN
1.0
A6
−
−
C2
V
1.0
A7
−
−
C3
−
−
A8
−
−
C4
A
1.0
B1
ZB
1.0
C5
−
−
B2
BG
1.0
C6
−
−
B3
AB
1.0
C7
−
−
B4
BR
1.0
C8
−
−
C−13
58
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 8
30 Pin
Col.
Sect.
Pin
Col.
Sect.
A1
MV
1.0
B5
−
−
A2
BN
1.0
B6
−
−
A3
VB
1.0
B7
−
−
A4
−
−
B8
−
−
A5
AN
1.0
C1
ZN
1.0
A6
−
−
C2
V
1.0
A7
−
−
C3
−
−
A8
−
−
C4
A
1.0
B1
ZB
1.0
C5
−
−
B2
BG
1.0
C6
−
−
B3
AB
1.0
C7
−
−
B4
BR
1.0
C8
−
−
Pin
Col.
Sect.
Pin
Col.
Sect.
1
B
1.0
4
GN
1.0
2
N
1.0
5
R
1.0
3
L
1.0
6
G
1.5
C−13
59
1
F 2
6
2
5 4
For model with cab, version 2, 3, 4 and 5. MAIN CABLE SIDE
3
1
C−14
60 Sect.
GN
1.0
2
N
1.0
5
R
1.0
3
L
1.0
6
G
1.0
C−14
2
5 4
For model without cab. MAIN CABLE SIDE
1
Col.
4
F 2
Pin
1.0
1
Sect.
B
3
Col.
1
6
Pin
61 87666787A2 − 06 − 2009
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Col.
Sect.
Pin
Col.
Sect.
1
G
1.0
4
M
1.0
2
B
1.0
5
R
1.0
3
V
1.0
6
N
1.0
C--14
2 6
Pin
31
M
1 3
4 5
For ISO model. SOCKET CONNECTION CABLE SIDE
62 Col.
Sect.
Pin
Col.
Sect.
1
G
1.0
4
M
1.0
2
B
1.5
5
R
1.0
3
V
1.0
6
N
1.5
C--14
2 6
Pin
M
1 3
4 5
For NORTH AMERICAN model. SOCKET CONNECTION CABLE SIDE
63 Col.
Sect.
Pin
Col.
Sect.
1
G
1.0
5
M
1.0
2
--
--
6
R
1.0
3
B
1.0
7
N
1.0
--
N
1.0
--
G
1.0
4
V
1.0
--
--
--
C--14--A
3 2
1
For ISO model.
4 7
5 6
Pin
64 Pin
Col.
Sect.
Pin
Col.
Sect.
1
B
1.5
5
V
1.0
2
N
1.5
6
M
1.0
3
G
1.0
7
--
--
4
R
1.0
--
--
--
C--14--B
For NORTH AMERICAN model.
65 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
32 Pin
Col.
Sect.
Pin
Col.
Sect.
1
H
1.0
2
HV
1.0
C--15
1
1
2
2
For model with cab, version 1, 2 and 3. For model without cab, version 1 and 2.
66 Pin
Col.
Sect.
Pin
Col.
Sect.
1
H
1.0
2
HB
1.0
C--15
1
1
2
2
For model with cab, version 4 and 5. For model without cab, version 3.
67 Sect.
Pin
Col.
Sect.
A
0.75
4
N
1.0
2
RN
1.0
5
RV
1.0
3
LR
1.0
6
HR
1.0
C--16
5
2
4
1
For model with cab, version 2, 3, 4 and 5. For model without cab. MAIN CABLE SIDE
3
Col.
1
6
Pin
68 1
GR
1.0
4
N
1.0
2
RN
1.0
5
RV
1.0
3
LR
1.0
6
HR
1.0
ELECTRONIC THERMOSTARTER CABLE SIDE
C--16
1
Sect.
2
Col.
3
Pin
4
Sect.
5
Col.
6
Pin
69 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Col.
Sect.
3
--
--
2
BL
1.5
4
--
--
For model with cab, version 3, 4 and 5. For model without cab.
SW--17--A
2
Pin
1.5
4
Sect.
B
1
Col.
1
3
Pin
33
70 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
2
N
0.5
For model with cab, version 3, 4 and 5. For model without cab.
SW--17--B
1
2
71 Col.
Sect.
Pin
Col.
Sect.
1
ZN
1.0
5
VB
1.0
2
AB
1.0
6
GV
1.0
3
SG
1.0
7
VG
1.0
4
RV
1.0
8
GR
1.0
C--18
4 3 2 1 8 7 6 5
Pin
For model with cab, version 3 and 5. MAIN CABLE SIDE
72 Col.
Sect.
1
ZN
1.5
5
VB
1.0
2
AB
1.0
6
GV
1.0
3
SG
1.0
7
VG
1.0
4
RV
1.0
8
GR
1.0
For model with cab, version 3 and 5. REAR ELECTRONIC LIFT CABLE SIDE
C--18
7 8
Pin
5 6
Sect.
3 4
Col.
1 2
Pin
73 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
34 Pin
Col.
Sect.
Pin
Col.
Sect.
15
M
2.5
--
--
--
SW--19
For model with cab, version 3, 4 and 5. For model without cab.
74 Pin
Col.
Sect.
Pin
Col.
Sect.
15B
M
2.5
--
--
--
SW--19
For model with cab, version 3, 4 and 5. For model without cab.
75 Pin
Col.
Sect.
Pin
Col.
Sect.
30
L
4.0
--
--
--
SW--19
For model with cab, version 3, 4 and 5. For model without cab.
76 Pin
Col.
Sect.
Pin
Col.
Sect.
50
H
1.0
--
--
--
SW--19
For model with cab, version 3, 4 and 5. For model without cab.
77 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
3
N
1.0
2
A
1.0
4
G
0.5
35
LMP--20
2
4
1
3
For model without cab, version 1 and 2.
78 Pin
Col.
Sect.
Pin
Col.
Sect.
1
G
0.5
3
A
1.0
2
N
1.0
4
H
1.0
LMP--20
2
4
1
3
For model with cab, version 3, 4 and 5.
79 Pin
Col.
Sect.
Pin
Col.
Sect.
1
G
0.5
3
A
1.0
2
N
1.0
4
--
--
LMP--20
2
4
1
3
For model without cab, version 3.
80 1
LB
0.5
4
HV
1.0
2
MN
1.5
5
Z
1.0
3
--
--
6
MV
1.0
For model with cab, version 2, 3, 4 and 5. For model without cab. MAIN CABLE SIDE
C--21
3
Sect.
2
Col.
1
Pin
6
Sect.
5
Col.
4
Pin
81 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Sect.
Pin
Col.
Sect.
LB
0.5
4
HV
1.0
2
MN
1.5
5
Z
1.0
3
R
0.5
6
MV
1.0
C--21
5
2 3
For Power--Shuttle version. POWER SHUTTLE SYSTEM CABLE SIDE
1
Col.
1
4
Pin
6
36
82 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
3
AN
1.0
2
N
1.0
4
--
--
LMP--22
2
4
1
3
For model without cab.
83 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
3
AN
1.0
2
N
1.0
4
BN
1.0
LMP--22
2
4
1
3
For model with cab, version 3, 4 and 5.
84
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
37
Pin
Col.
Sect.
Pin
Col.
Sect.
A1
H
2.5
B5
CL
0.75
A2
H
1.0
B6
AN
1.0
A3
L
1.0
B7
A
1.0
A4
BN
1.0
B8
N
2.5
A5
B
1.0
C1
--
--
A
8 7 6 5 4 3 2 1
A
A6
MV
1.0
C2
--
--
B
8 7 6 5 4 3 2 1
B
C
8 7 6 5 4 3 2 1
C
A7
CB
0.75
C3
--
--
A8
M
1.0
C4
--
--
B1
H
2.5
C5
--
--
B2
V
1.0
C6
--
--
B3
VB
1.0
C7
--
--
B4
BR
1.0
C8
--
--
LMP--23
For model with cab, version 3, 4 and 5. For model without cab.
85 Sect.
Pin
Col.
Sect.
1
HB
0.75
4
N
1.0
2
BC
0.75
5
C
0.5
3
RV
0.5
6
GN
0.5
C--24
5
2
4
1
For model with cab, version 1. MAIN CABLE SIDE
3
Col.
6
Pin
86 1
HB
1.0
4
N
1.0
2
BC
1.0
5
C
0.5
3
RV
0.5
6
GN
0.5
For model with cab, version 2. MAIN CABLE SIDE
C--24
3
Sect.
2
Col.
1
Pin
6
Sect.
5
Col.
4
Pin
87 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Sect.
Pin
Col.
Sect.
HB
0.75
4
N
1.0
2
BC
0.75
5
C
0.5
3
RV
0.5
6
GN
0.5
C--24
5
2 1
For model without cab, version 1 and 2. MAIN CABLE SIDE
3
Col.
1
6
Pin
4
38
F
88 Sect.
Pin
Col.
Sect.
HB
0.75
4
N
1.0
2
CB
0.75
5
C
0.5
3
V
0.5
6
GN
0.5
C--24
5
2
6
3
DIGITAL INSTRUMENT CABLE SIDE
1
Col.
1
4
Pin
M
89
4.0
12
M
1.0
L
4.0
12A
SG
1.0
3
AB
1.0
13
MV
1.0
3A
L
1.0
13A
M
1.0
--
--
17A
--
--
8
G
1.0
18
--
--
8A
B
1.5
18A
--
--
9
GN
1.0
19A
A
1.0
9A
B
1.0
19
L
1.0
10
G
1.0
20
M
1.0
10A
B
1.0
20A
LR
1.0
For model with cab, version 1. For model without cab, version 1.
87666787A - 11 - 2007
1
17
1.5
2
1.5
3
L VN
4
7 7A
5
1.0
6
1.0
M
7
HL
16
1A
16A
1.5
2A
1.5
3A
L HN
4A
6 6A
5A
1.5
6A
1.5
M
7A
BL
15
11A
15A
1.0
12A
1.0
M
13A
M
14A
5 5A
15A
1.5
16A
1.5
MN
11
M
14
12
14A
1.0
13
1.0
14
C M
15
4 4A
8
H
9
2 2A
10
1.0
8A
H
9A
11A
10A
1.0
17A
L
18A
1A
19A
1.0
20A
Sect.
H
16
Col.
11
17
Pin
1.0
18
Sect.
ZN
19
Col.
1
20
Pin
MOD--25--A
90
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
L
4.0
12A
SG
1.0
3
AB
1.0
13
M
1.0
3A
L
1.0
13A
MV
1.0
--
--
17A
--
--
8
G
1.0
18
--
--
8A
B
1.5
18A
--
--
9
GN
1.0
19A
A
1.0
9A
B
1.0
19
L
1.0
10
B
1.0
20
M
1.0
10A
G
1.0
20A
LR
1
Col.
Sect.
1
17
1.5
2
1.5
3
L VN
4
7 7A
5
1.0
6
1.0
M
7
HL
16
1A
16A
1.5
2A
1.5
3A
L HN
4A
6 6A
5A
1.5
6A
1.5
M
7A
BL
15
11A
15A
1.0
12A
1.0
M
13A
M
14A
5 5A
15A
1.5
16A
1.5
MN
11
M
14
12
14A
1.0
13
1.0
14
C M
15
4 4A
8
2A
9
1.0
10
1.0
M
8A
H
12
9A
11A
4.0
10A
1.0
H
17A
L
2
18A
1A
19A
1.0
20A
Sect.
H
16
Col.
11
17
Pin
1.0
18
Sect.
ZN
19
Col.
1
20
Pin
39
MOD--25--A
For model without cab, version 2. 91 Pin
Col.
Sect.
Pin
1.0
6A
HN
1.5
16
M
1.0
7
L
1.5
17A
--
--
7A
VN
1.5
17
--
--
8
G
1.5
18
--
--
8A
B
1.5
18A
--
--
9
GN
1.0
19A
A
1.0
9A
B
1.0
19
L
1.0
10
G
1.0
20
M
1.0
10A
B
1.0
20A
LR
1.0
11
H
1.0
--
--
--
For model with cab, version 2.
1
1.5
HL
2
M
16A
3
15
1.5
4
1.0
L
5
M
6
6
5A
7
1.5
8
1.0
BL
9
BL
--
10
15A
1.0
1A
1.0
M
2A
M
5
3A
4A
4A
1.5
5A
1.5
MN
6A
M
14
7A
14A
1.0
8A
1.0
C
9A
L
4
10A
3A
11A
1.0
12A
1.0
MV
13A
M
13A
14A
13
1.0
15A
4.0
AB
16A
L
3
17A
2A
18A
1.0
19A
SG
20A
12A
11
4.0
12
H
13
2
14
1.0
15
1.0
M
16
H
12
17
11A
1.0
18
1.0
L
19
ZN
20
1 1A
MOD--25--A
92
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
40
L
4.0
13
M
1.0
3
AB
1.0
13A
MV
1.0
3A
L
1.0
14
MN
1.5
M
1.5
17A
MV
1.5
8
G
1.5
18
--
--
8A
B
1.5
18A
--
--
9
GN
1.0
19
L
1.0
9A
B
1.0
19A
A
1.0
10
G
1.0
20
M
1.0
10A
B
1.0
20A
LR
1.0
11
H
1.0
--
--
--
Col.
Sect.
1
17
1.5
2
1.5
3
L VN
4
7 7A
5
1.0
6
1.0
HL
7
M
16A
1A
16
1.5
2A
1.5
3A
L HN
4A
6 6A
5A
1.0
6A
1.5
BL
7A
M
15A
11A
15
1.0
12A
1.0
M
13A
M
14A
5 5A
15A
1.5
16A
1.5
BL
11
M
--
12
14A
1.0
13
1.0
14
C M
15
4 4A
8
2A
9
1.0
10
1.0
SG
8A
M
12A
9A
12
4.0
10A
1.0
H
17A
L
2
18A
1A
19A
1.0
20A
Sect.
H
16
Col.
11A
17
Pin
1.0
18
Sect.
ZN
19
Col.
1
20
Pin
MOD--25--A
For model with cab, version 3. Pin
Col.
Sect.
Pin
93
1.0
6A
HN
1.5
16A
HL
1.0
7
L
1.5
17
--
--
7A
VN
1.5
17A
--
--
8
G
1.5
18
M
1.0
8A
B
1.5
18A
MN
1.0
9
GN
1.0
19
L
1.0
9A
B
1.0
19A
A
1.0
10
G
1.0
20
M
1.0
10A
B
1.0
20A
LR
1.0
11
H
1.0
--
--
--
For model with cab, version 4.
87666787A - 11 - 2007
1
1.5
M
2
BL
16
3
--
1.5
4
1.0
L
5
M
6
6
5A
7
1.0
8
1.5
BL
9
M
15A
10
15
1.0
1A
1.0
M
2A
M
5
3A
4A
4A
1.5
5A
1.5
M
6A
MN
14A
7A
14
1.0
8A
1.0
C
9A
L
4
10A
3A
11A
1.0
12A
1.0
MV
13A
M
13A
14A
13
1.0
15A
4.0
AB
16A
L
3
17A
2A
18A
1.0
19A
SG
20A
12A
11
4.0
12
H
13
2
14
1.0
15
1.0
M
16
H
12
17
11A
1.0
18
1.0
L
19
ZN
20
1 1A
MOD--25--A
94
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
L
4.0
13
M
1.0
3
AB
1.0
13A
MV
1.0
3A
L
1.0
14
MN
1.5
M
1.5
17A
MV
1.5
8
G
1.5
18
M
1.0
8A
B
1.5
18A
MN
1.0
9
GN
1.0
19
L
1.0
9A
B
1.0
19A
A
1.0
10
G
1.0
20
M
1.0
10A
B
1.0
20A
LR
1.0
11
H
1.0
--
--
--
Pin
Col.
Sect.
1
17
1.5
2
1.5
3
L VN
4
7 7A
5
1.0
6
1.0
HL
7
M
16A
1A
16
1.5
2A
1.5
3A
L HN
4A
6 6A
5A
1.5
6A
1.0
BL
7A
BL
--
11A
15A
1.0
12A
1.0
M
13A
M
14A
5 5A
15A
1.5
16A
1.5
M
11
M
15
12
14A
1.0
13
1.0
14
C M
15
4 4A
8
2A
9
1.0
10
1.0
SG
8A
M
12A
9A
12
4.0
10A
1.0
H
17A
L
2
18A
1A
19A
1.0
20A
Sect.
H
16
Col.
11A
17
Pin
1.0
18
Sect.
ZN
19
Col.
1
20
Pin
41
MOD--25--A
For model with cab, version 5. Pin
Col.
Sect.
95
1.0
6A
HN
1.5
16
M
1.0
7
L
1.5
17
--
--
7A
VN
1.5
17A
--
--
8
G
1.0
18
M
1.0
8A
B
1.5
18A
MN
1.0
9
GN
1.0
19A
A
1.0
9A
B
1.0
19
L
1.0
10
G
1.0
20
M
1.0
10A
B
1.0
20A
LR
1.0
1
1.5
HL
2
M
16A
3
15
1.5
4
1.0
L
5
M
6
6
5A
7
1.5
8
1.5
BL
9
MN
15A
10
14
1.0
1A
1.0
M
2A
M
5
3A
4A
4A
1.5
5A
1.0
M
6A
M
14A
7A
13A
1.0
8A
1.0
C
9A
L
4
10A
3A
11A
1.0
12A
1.0
MV
13A
SG
13
14A
12A
1.0
15A
4.0
AB
16A
L
3
17A
2A
18A
1.0
19A
M
20A
12
11
4.0
12
H
13
2
14
1.0
15
1.0
H
16
H
11A
17
11
1.0
18
1.0
L
19
ZN
20
1 1A
MOD--25--A
For model without cab, version 3. 96
87666787A - 11 - 2007
--
--
--
23A
--
--
30
--
--
24
--
--
30A
--
--
24A
--
--
R_85
N
1.0
25
L
1.0
R_30
RN
2.5
25A
LB
1.0
--
RN
1.0
26
--
--
R_87
L
2.5
26A
--
--
R_86
Z
1.0
27
M
1.0
--
Z
0.5
30
--
29A
29
29
--
28
--
--
27
--
23
26
22A
29A
--
28A
--
--
27A
--
28
26A
28A
--
21
--
--
22
--
22
23
21A
24
1.0
25
Sect.
BV
21A
Col.
27A
22A
Pin
--
23A
Sect.
--
24A
Col.
21
25A
Pin
30A
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
42
MOD--25--B
For model without cab, version 1 and 2.
30
85
86 87
--
--
29
--
--
23
--
--
29A
--
--
23A
--
--
30
--
--
24
--
--
30A
--
--
24A
--
--
R_85
N
1.0
25
L
1.0
R_30
RN
2.5
25A
LN
1.0
--
RN
1.0
26
--
--
R_87
L
2.5
26A
--
--
R_86
Z
1.0
27
M
1.0
--
Z
0.5
30
22A
29
--
28
--
27
28
21
--
22
--
23
22
24
--
25
1.0
--
21A
BV
28A
22A
27A
--
23A
--
--
24A
--
25A
21 21A
26
Sect.
29A
Col.
28A
Pin
27A
Sect.
26A
Col.
30A
97 Pin
MOD--25--B
For model without cab, version 3.
30
85
86 87
98
87666787A - 11 - 2007
--
--
--
23A
--
--
29A
--
--
24
--
--
30
M
1.0
24A
--
--
30A
VG
1.0
25
L
1.0
R_85
N
1.0
25A
LN
1.0
R_30
RN
2.5,1.0
26
--
--
R_87
L
2.5
26A
--
--
R_86
Z
1.0,0.5
30
--
29
29
28
--
28
--
--
27
--
23
26
22A
29A
--
28A
--
--
27A
--
28A
26A
27A
--
21
--
--
22
--
22
23
21A
24
--
25
Sect.
--
21A
Col.
27
22A
Pin
--
23A
Sect.
--
24A
Col.
21
43
25A
Pin
30A
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
MOD--25--B
For model with cab, version 1. 30
85
86 87
--
--
29
--
--
23
--
--
29A
--
--
23A
--
--
30
VG
1.0
24
--
--
30A
M
1.0
24A
--
--
R_85
N
1.0
25
L
1.0
R_30
RN
2.5
25A
LN
1.0
--
RN
1.0
26
--
--
R_87
L
2.5
26A
--
--
R_86
Z
1.0
27
--
--
--
Z
0.5
30
22A
29
--
28
--
27
28
21
--
22
--
23
22
24
--
25
--
--
21A
--
28A
22A
27A
--
23A
--
--
24A
--
25A
21 21A
26
Sect.
29A
Col.
28A
Pin
27A
Sect.
26A
Col.
30A
99 Pin
MOD--25--B
For model with cab, version 2.
30
85
86 87
100
87666787A - 11 - 2007
--
--
29A
--
--
23
MN
1.5
30
M
1.0
23A
SN
1.5
30A
VG
1.0
24
M
2.5
R_30
RN
2.5
24A
M
2.5
--
RN
1.0
25
L
1.0
R_86
Z
1.0
25A
LN
1.0
R_85
N
1.0
26
--
--
R_87
L
2.5
26A
--
--
--
Z
0.5
27
--
--
--
--
--
30 29
29
1.5
28
2.5
S
27
MN
26
-22A
29A
--
28A
--
--
27A
--
28A
26A
28
1.5
21
1.5
MN
22
Z
22
23
21A
24
--
25
Sect.
--
21A
Col.
27A
22A
Pin
1.5
23A
Sect.
L
24A
Col.
21
25A
Pin
30A
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
44
MOD--25--B
30
For model with cab, version 3. 85
86 87
--
--
29A
--
--
23
--
--
30
M
1.0
23A
--
--
30A
VG
1.0
24
--
--
R_30
RN
2.5
24A
--
--
--
RN
1.0
25
L
1.0
R_85
N
1.0
25A
LN
1.0
R_86
Z
1.0
26
--
--
--
Z
0.5
26A
--
--
R_87
L
2.5
27
--
--
--
--
--
27A
--
--
--
--
--
30
22A
29
--
28
--
27
29
21
--
22
--
23
22
24
--
25
--
--
21A
--
28
22A
28A
--
23A
--
--
24A
--
25A
21 21A
26
Sect.
29A
Col.
28A
Pin
27A
Sect.
26A
Col.
30A
101 Pin
MOD--25--B
30
For model with cab, version 4 and 5. 85
86 87
102
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Col.
Sect.
R4_85
N
0.5
R1_85
N
0.5
R4_86
HN
0.5
R1_86
H
0.5
R4_87
H
1.5
R1_87
R
1.0
R4_87A
--
--
R1_87A
--
--
R5_30
VN
1.5
R2_30
C
1.0
R5_85
N
0.5
R2_85
N
0.5
R5_86
VN
0.5
R2_86
RN
1.0
R5_87
V
1.5
R2_87
RV
1.0
--
V
0.5
R2_87A
H
0.5
R5_87A
--
--
R3_30
--
--
R6_30
RV
1.0
R3_85
--
--
R6_85
N
0.5
R3_86
--
--
R6_86
RG
1.0
R3_87
--
--
R6_87
Z
1.0
R3_87A
--
--
R6_87A
--
--
R4_30
HN
1.5
--
--
--
86 87a 85
86 87a 85
87
87
R6
Pin
1.0
30
30
86 87a 85
86 87a 85
87
87
MOD--25--C
R5
Sect.
A
R1
Col.
R2
Pin R1_30
45
30
30
86 87a 85
86 87a 85
87
87
30
R4
R3
For model without cab, version 1.
30
103 R1_30
A
1.0
R1_85
N
0.5
R4_85
N
0.5
R4_86
HN
0.5
R1_86
H
0.5
R4_87
H
1.5
R1_87
R
1.0
R4_87A
--
--
R1_87A
--
--
R5_30
VN
1.5
R2_30
C
1.0
R5_85
N
0.5
R2_85
N
0.5
R5_86
VN
0.5
R2_86
RG
0.5
R5_87
V
1.5
R2_87
RV
1.0
--
V
0.5
R2_87A
CL
0.5
R5_87A
--
--
R3_30
N
0.5
R6_30
RV
1.0
R3_85
N
0.5
R6_85
M
0.5
R3_86
RN
1.0
R6_86
Z
1.0
R3_87
M
0.5
R6_87
Z
1.0
R3_87A
CB
0.5
R6_87A
--
--
R4_30
HN
1.5
--
--
--
For model without cab, version 2.
86 87a 85
86 87a 85
87
87
R6
Sect.
30
30
86 87a 85
86 87a 85
87
87
MOD--25--C
R5
Col.
30
30
86 87a 85
86 87a 85
87
87
30
R4
Pin
R1
Sect.
R2
Col.
R3
Pin
30
104
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
1.0
R4_85
N
0.5
R1_85
C
0.5
R4_86
HN
0.5
R1_86
CL
0.5
R4_87
H
1.5
R1_87
R
1.0
R4_87A
--
--
R1_87A
--
--
R5_30
VN
1.5
R2_30
C
1.0
R5_85
N
0.5
R2_85
N
0.5
R5_86
VN
0.5
R2_86
RG
1.0
R5_87
V
0.5
R2_87
RV
1.0
--
V
1.5
R2_87A
CL
0.5
R5_87A
--
--
R3_30
N
0.5
R6_30
RV
1.0
R3_85
N
0.5
R6_85
M
0.5
R3_86
RN
1.0
R6_86
Z
1.0
R3_87
M
0.5
R6_87
Z
1.0
R3_87A
C
0.5
R6_87A
--
--
R4_30
HN
1.5
--
--
--
86 87a 85
86 87a 85
87
87
R6
Sect.
A
30
30
86 87a 85
86 87a 85
87
87
MOD--25--C
R5
Col.
R1
Pin R1_30
R2
46
30
30
86 87a 85
86 87a 85
87
87
30
R4
R3
For model without cab, version 3.
30
105 Col.
Sect.
R1_30
A
1.0
R1_85
N
0.5
R4_85
N
0.5
R4_86
HN
0.5
R1_86
H
0.5
R4_87
H
1.5
R1_87
R
1.0
R4_87A
--
--
R1_87A
--
--
R5_30
VN
1.5
R2_30
C
1.0
R5_85
N
0.5
R2_85
N
0.5
R5_86
VN
0.5
R2_86
RN
1.0
R5_87
V
1.5
R2_87
RV
1.0
--
V
0.5
R2_87A
H
0.5
R5_87A
--
--
R3_30
--
--
R6_30
RV
1.0
R3_85
--
--
R6_85
N
0.5
R3_86
--
--
R6_86
RG
0.5
R3_87
--
--
R6_87
Z
1.0
R3_87A
--
--
R6_87A
--
--
R4_30
HN
1.5
--
--
--
86 87a 85
87
87
30
30
86 87a 85
86 87a 85
87
87
MOD--25--C
30
30
86 87a 85
86 87a 85
87
87
30
R4
R3
For model with cab, version 1.
86 87a 85
R6
Pin
R5
Sect.
R1
Col.
R2
Pin
30
106
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Col.
Sect.
R4_85
N
0.5
R1_85
N
0.5
R4_86
HN
0.5
R1_86
H
0.5
R4_87
H
1.5
R1_87
R
1.0
R4_87A
--
--
R1_87A
--
--
R5_30
VN
1.5
R2_30
C
1.0
R5_85
N
0.5
R2_85
N
0.5
R5_86
VN
0.5
R2_86
RG
1.0
R5_87
V
1.5
R2_87
RV
1.0
--
V
0.5
R2_87A
CL
0.5
R5_87A
--
--
R3_30
N
0.5
R6_30
RV
1.0
R3_85
N
0.5
R6_85
M
0.5
R3_86
RN
1.0
R6_86
Z
1.0
R3_87
M
0.5
R6_87
Z
1.0
R3_87A
CB
0.5
R6_87A
--
--
R4_30
HN
1.5
--
--
--
86 87a 85
86 87a 85
87
87
R6
Pin
1.0
30
30
86 87a 85
86 87a 85
87
87
MOD--25--C
R5
Sect.
A
R1
Col.
R2
Pin R1_30
47
30
30
86 87a 85
86 87a 85
87
87
30
R4
R3
For model with cab, version 2 and 3.
30
107 R1_30
A
1.0
R4_30
HN
1.5
R1_85
C
0.5
R4_85
N
0.5
R1_86
CL
0.5
R4_86
HN
0.5
R1_87
R
1.0
R4_87
H
1.5
R1_87A
--
--
R4_87A
--
--
R2_30
C
1.0
R5_30
VN
1.5
R2_85
N
0.5
R5_85
N
0.5
R2_86
RG
1.0
R5_86
VN
0.5
R2_87
RV
1.0
R5_87
V
1.5
R2_87A
CL
0.5
R5_87A
--
--
R3_30
N
0.5
R6_30
RV
1.0
R3_85
N
0.5
R6_85
M
0.5
R3_86
RN
1.0
R6_86
Z
1.0
R3_87
M
0.5
R6_87
Z
1.0
R3_87A
C
0.5
R6_87A
--
--
For model with cab, version 4.
86 87a 85
86 87a 85
87
87
R6
Sect.
30
30
86 87a 85
86 87a 85
87
87
MOD--25--C
R5
Col.
30
30
86 87a 85
86 87a 85
87
87
30
R4
Pin
R1
Sect.
R2
Col.
R3
Pin
30
108
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
1.0
R4_30
HN
1.5
R1_85
C
1.0
R4_85
N
0.5
R1_86
CL
0.5
R4_86
HN
0.5
R1_87
R
1.0
R4_87
H
1.5
R1_87A
--
--
R4_87A
--
--
R2_30
C
1.0
R5_30
VN
1.5
R2_85
N
0.5
R5_85
N
0.5
R2_86
RG
1.0
R5_86
VN
0.5
R2_87
RV
1.0
R5_87
V
1.5
R2_87A
CL
0.5
R5_87A
--
--
R3_30
N
0.5
R6_30
RV
1.0
R3_85
N
0.5
R6_85
M
0.5
R3_86
RN
1.0
R6_86
Z
1.0
R3_87
M
0.5
R6_87
Z
1.0
R3_87A
C
1.0
R6_87A
--
--
86 87a 85
87
87
30
30
86 87a 85
86 87a 85
87
87
MOD--25--C
30
30
86 87a 85
86 87a 85
87
87
30
R4
R3
For model with cab, version 5.
86 87a 85
R6
Sect.
A
R5
Col.
R1
Pin R1_30
R2
48
30
109 Sect.
R1_30
--
--
R4_85
--
--
R1_85
--
--
R4_86
--
--
R1_86
--
--
R4_87
--
--
R1_87
--
--
R4_87A
--
--
R1_87A
--
--
R5_30
--
--
R2_30
--
--
R5_85
--
--
R2_85
--
--
R5_86
--
--
R2_86
--
--
R5_87
--
--
R2_87
--
--
R5_87A
--
--
R2_87A
--
--
R6_30
L
2.5
R3_30
--
--
R6_85
N
0.5
R3_85
--
--
--
N
1.0
R3_86
--
--
R6_86
BR
0.5
R3_87
--
--
R6_87
B
1.0
R3_87A
--
--
--
B
1.5
R4_30
--
--
R6_87A
--
--
86 87a 85
87
87
30
30
86 87a 85
86 87a 85
87
87
MOD--25--D
30
30
86 87a 85
86 87a 85
87
87
R9
For model without cab, version 1 and 3.
86 87a 85
R12
Col.
R11
Pin
R10
Sect.
R7
Col.
R8
Pin
30
30
110
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Sect.
--
--
R1_85
CB
0.5
R4_86
--
--
R1_86
CL
0.5
R4_87
--
--
R1_87
H
0.5
R4_87A
--
--
R1_87A
C
1.0
R5_30
--
--
R2_30
--
--
R5_85
--
--
R2_85
--
--
R5_86
--
--
R2_86
--
--
R5_87
--
--
R2_87
--
--
R5_87A
--
--
R2_87A
--
--
R6_30
L
2.5
R3_30
--
--
R6_85
N
0.5
R3_85
--
--
--
N
1.0
R3_86
--
--
R6_86
BR
0.5
R3_87
--
--
R6_87
B
1.0
R3_87A
--
--
--
B
1.5
R4_30
--
--
R6_87A
--
--
86 87a 85
86 87a 85
87
87
R12
Col.
R4_85
30
30
86 87a 85
86 87a 85
87
87
MOD--25--D
R11
Pin
1.0
30
30
86 87a 85
86 87a 85
87
87
R9
For model without cab, version 2.
R10
Sect.
C
R7
Col.
R8
Pin R1_30
49
30
30
111 R1_30
--
--
R6_30
L
2.5
R1_85
--
--
R4_85
--
--
R1_86
--
--
R4_86
--
--
R1_87
--
--
R4_87
--
--
R1_87A
--
--
R4_87A
--
--
R2_30
V
1.5
R5_30
--
--
R2_85
N
0.5
R5_85
--
--
R2_86
GR
0.5
R5_86
--
--
R2_87
VN
0.5
R5_87
--
--
--
VN
1.5
R5_87A
--
--
R2_87A
V
1.5
R6_85
N
0.5
R3_30
H
1.5
--
N
1.0
R3_85
N
0.5
R6_86
BR
0.5
R3_86
GR
0.5
R6_87
B
1.0
R3_87
HN
1.5
--
B
1.5
R3_87A
H
1.5
R6_87A
--
--
R4_30
--
--
--
--
--
For model with cab, version 1.
86 87a 85
86 87a 85
87
87
R12
Sect.
30
30
86 87a 85
86 87a 85
87
87
MOD--25--D
R11
Col.
30
30
86 87a 85
86 87a 85
87
87
R10
Pin
R7
Sect.
R8
Col.
R9
Pin
30
30
112
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Col.
Sect.
R4_85
--
--
R1_85
CB
0.5
R4_86
--
--
R1_86
CL
0.5
R4_87
--
--
R1_87
H
0.5
R4_87A
--
--
R1_87A
CN
1.0
R5_30
--
--
R2_30
V
1.5
R5_85
--
--
R2_85
N
0.5
R5_86
--
--
R2_86
GR
0.5
R5_87
--
--
R2_87
VN
--
--
R2_87A
V
0.5,1.5 R5_87A 1.5
R6_30
L
2.5
R3_30
H
1.5
R6_85
N
0.5
R3_85
N
0.5
--
N
1.0
R3_86
GR
0.5
R6_86
BR
0.5
R3_87
HN
1.5
R6_87
B
1.0
R3_87A
H
1.5
--
B
1.5
R4_30
--
--
R6_87A
--
--
86 87a 85
86 87a 85
87
87
R12
Pin
1.0
30
30
86 87a 85
86 87a 85
87
87
MOD--25--D
R11
Sect.
C
30
30
86 87a 85
86 87a 85
87
87
R9
For model with cab, version 2.
R10
Col.
R7
Pin R1_30
R8
50
30
30
113 R1_30
C
1.0
R4_30
--
--
R1_85
CB
0.5
R4_85
--
--
R1_86
CL
0.5
R4_86
--
--
R1_87
H
0.5
R4_87
--
--
R1_87A
CN
1.0
R4_87A
--
--
R2_30
V
1.5
R5_30
--
--
R2_85
N
0.5
R5_85
--
--
--
N
0.5
R5_86
--
--
R2_86
GR
0.5
R5_87
--
--
--
GR
0.5
R5_87A
--
--
R2_87
VN
0.5
R6_30
L
2.5
--
VN
1.5
R6_85
N
0.5
R2_87A
V
1.5
--
N
1.0
R3_30
H
1.5
R6_86
BR
0.5
R3_85
N
0.5
R6_87
B
1.0
R3_86
GR
0.5
--
B
1.5
R3_87
HN
1.5
R6_87A
--
--
R3_87A
H
1.5
--
--
--
For model with cab, version 3.
86 87a 85
86 87a 85
87
87
R12
Sect.
30
30
86 87a 85
86 87a 85
87
87
MOD--25--D
R11
Col.
30
30
86 87a 85
86 87a 85
87
87
R10
Pin
R7
Sect.
R8
Col.
R9
Pin
30
30
114
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
--
R1_85
--
--
R4_85
--
--
R1_86
--
--
R4_86
--
--
R1_87
--
--
R4_87
--
--
R1_87A
--
--
R4_87A
--
--
R2_30
V
1.5
R5_30
--
--
R2_85
N
0.5
R5_85
--
--
--
N
0.5
R5_86
--
--
R2_86
GR
0.5
R5_87
--
--
--
GR
0.5
R5_87A
--
--
R2_87
HN
1.5
R6_30
L
2.5
R2_87A
V
0.5
R6_85
N
0.5
--
V
1.5
--
N
1.0
R3_30
H
1.5
R6_86
BR
0.5
R3_85
N
0.5
R6_87
B
1.0
R3_86
GR
0.5
--
B
1.5
R3_87
HN
1.5
R6_87A
--
--
--
HN
1.5
--
--
--
R3_87A
H
1.5
--
--
--
86 87a 85
86 87a 85
87
87
R12
Sect.
--
30
30
86 87a 85
86 87a 85
87
87
MOD--25--D
R11
Col.
R4_30
30
30
86 87a 85
86 87a 85
87
87
30
For model with cab, version 4 and 5.
R10
Pin
--
R7
Sect.
--
R8
Col.
R9
Pin R1_30
51
30
115 Pin
Col.
Sect.
Pin
Col.
Sect.
A
M
6.0
B
M
6.0
F--26
For model with cab, version 3, 4 and 5. For model without cab. B
A
116
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
52 Pin
Col.
Sect.
Pin
Col.
Sect.
1
VB
0.5
18
GV
1.0
2
MV
1.0
19
C
0.5
3
MV
1.0
20
--
--
4
LB
0.5
21
HG
0.5
5
GR
1.0
22
SN
0.5
6
SG
1.0
23
S
0.5
7
ZN
1.0
24
AN
8
A
0.5
25
VG
1
9
10
17
0.5
18
25
1.0
26
34
9
--
--
26
--
--
10
--
--
27
LG
0.5
11
AB
1.0
28
HL
0.5
12
G
0.75
29
N
1.0
13
V
0.75
30
RV
1.0
14
B
0.5
31
H
0.5
15
--
--
32
--
--
16
--
--
33
--
--
17
BR
0.5
34
--
--
MOD--27--A
For model with cab, version 3 and 5.
117 Pin
Col.
Sect.
Pin
Col.
Sect.
A
N
0.5
F
--
--
B
C
0.5
G
BL
0.5
C
G
0.75
H
--
--
D
V
0.75
J
--
--
E
--
--
--
--
--
C--28
D
E
C A
B
F
J
G
H
For model with cab, version 2, 3, 4 and 5.
118 Pin
Col.
Sect.
Pin
Col.
Sect.
A
N
0.5
F
--
--
B
C
0.5
G
BL
0.5
C
G
0.75
H
--
--
D
V
0.75
J
--
--
E
--
--
--
--
--
C--28--B
D C J
For model with cab, version 3, 4 and 5. For model without cab, version 3
E
A
B
H
F G
119 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
3
--
--
2
CB
1.0
--
--
--
53
C--29
1 2 3
1 2 3
For model with cab. M
120 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
3
--
--
2
CB
1.0
--
--
--
C--29
1
For model with cab.
3
2
F
121 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
2
CB
1.0
C--29--A
1
2
For model with cab.
122 Col.
Sect.
1
R
0.5
3
LB
1.0
2
HL
1.0
4
N
1.0
For model with cab, version 3, 4 and 5.
SW--30
1
Pin
2
Sect.
3
Col.
4
Pin
123 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
3
LB
1.0
2
LN
1.0
--
--
--
C--31
2
2 3
1
1
For model with cab, version 3, 4 and 5.
3
54
124 Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
3
R
1.0
2
R
1.0
--
--
--
CB--31
2
2
1
1
3
3
For model with cab, version 3, 4 and 5.
125 Pin
Col.
Sect.
Pin
Col.
Sect.
1
ZB
0.5
2
RV
0.5
SW--32
1
1
2
2
For model with cab, version 3, 4 and 5. For model without cab.
126 1
C
0.5
3
B
0.5
2
GV
0.5
--
--
--
For model with cab, version 4 and 5. For model without cab, version 3.
SEN--33
1
Sect.
2
Col.
3
Pin
1
Sect.
2
Col.
3
Pin
127 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
MV
0.5
6
MV
0.5
3
MV
0.5
7
SN
0.5
4
S
0.5
8
--
--
For model with cab, version 3 and 5.
8
2
SW--34--A
7
--
6
Sect.
--
5
Col.
5
4
Pin
0.5
3
Sect.
BR
2
Col.
1
1
Pin
55
128 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
2
N
0.5
SW--34--B
For model with cab, version 3. 1
2
129 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
0.5
2
GN
0.5
SW--34--B
For model with cab, version 5. 1
2
130 Col.
Sect.
1
--
--
3
C
1.0
2
C
1.0
4
--
--
For model without cab, version 2.
SW--35--A
2
Pin
4
Sect.
1
Col.
3
Pin
131 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
0.5
3
C
0.5
2
C
0.5
4
CL
0.5
For model without cab, version 3.
SW--35--A
2
Sect.
CN
4
Col.
1
1
Pin
3
56
132 Col.
Sect.
3
C
1.0
2
CN
1.0
4
--
--
For model with cab, version 2 and 3.
SW--35--A
2
Pin
--
4
Sect.
--
1
Col.
1
3
Pin
133
C
0.5
6
--
--
3
C
0.5
7
--
--
4
CL
0.5
8
--
--
For model with cab, version 4 and 5.
8
2
SW--35--A
7
--
6
Sect.
--
5
Col.
5
4
Pin
0.5
3
Sect.
CN
2
Col.
1
1
Pin
134 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
2
N
0.5
SW--35--B
For model with cab, version 3, 4 and 5. 1
2
135 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
AR
1.0
6
--
--
3
Z
1.0
7
Z
1.0
4
RV
1.0
8
AR
1.0
For model with cab, version 3, 4 and 5. For model without cab.
8
2
SW--36--A
7
--
6
Sect.
--
5
Col.
5
4
Pin
--
3
Sect.
--
2
Col.
1
1
Pin
57
136 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
0.5
2
GN
0.5
SW--36--B
For model without cab, version 1 and 2. 1
2
137 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
2
N
0.5
For model with cab, version 3, 4 and 5. For model without cab, version 3.
SW--36--B
1
2
138 Pin
Col.
Sect.
Pin
Col.
Sect.
1
C
0.5
--
--
--
SW--37--1
For model with cab, version 3 and 5.
139 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
58 Pin
Col.
Sect.
Pin
Col.
Sect.
1
M
0.5
--
--
--
SW--37--2
For model with cab, version 3 and 5.
140 Pin
Col.
Sect.
Pin
Col.
Sect.
1
M
0.5
--
--
--
SW--37--3
For model with cab, version 3 and 5.
141 Pin
Col.
Sect.
Pin
Col.
Sect.
1
B
0.5
--
--
--
SW--37--4
For model with cab, version 3 and 5.
142 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
4
N
0.5
2
N
1.0
5
N
1.0
3
N
1.0
--
--
--
GND--38
For model without cab, version 1 and 3.
143 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
0.5
4
N
1.0
2
N
1.0
5
N
1.0
3
N
1.0
--
--
--
59
GND--38
For model without cab, version 2.
144 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
4
N
1.0
2
N
0.5
5
N
1.0
3
N
1.0
6
N
1.0
GND--38
For model with cab, version 1 and 4.
145 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
4
N
1.0
2
N
1.0
5
N
1.0
3
N
0.5
6
N
1.0
GND--38
For model with cab, version 2.
146 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
5
N
1.0
2
N
1.0
6
N
0.5
3
N
0.5
7
N
0.5
4
N
1.0
8
N
1.0
GND--38
For model with cab, version 3.
147 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
60 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
5
N
0.5
2
N
1.0
6
N
1.0
3
N
1.0
7
N
1.0
4
N
0.5
--
--
--
GND--38
For model with cab, version 5.
148 Pin
Col.
Sect.
Pin
Col.
Sect.
1
LB
1.0
2
B
1.0
SW--39
1
1
2
2
For model with cab, version 3, 4 and 5. For model without cab.
149 Sect.
Pin
Col.
Sect.
M
0.5
5
--
--
2
LG
0.5
6
N
0.5
3
AB
0.5
7
GN
0.5
4
VB
0.5
8
HL
0.5
MOD--40
For model with cab, version 3 and 5.
8 7 6 5
Col.
1
4 3 2 1
Pin
150 Pin
Col.
Sect.
Pin
Col.
Sect.
1
BL
1.0
2
N
1.0
C--41
1
2
For model with cab, version 1.
151 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
2
BL
1.0
61
C--41
1
2
For model with cab.
152 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
2
AB
1.0
M--42--A
1
2
For model with cab.
153 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
2
CL
1.0
M--42--B
1
2
For model with cab.
154 Sect.
Pin
Col.
Sect.
1
AB
0.5
5
AN
0.5
2
H
0.5
6
VB
0.5
3
HG
0.5
7
N
0.5
4
A
0.5
8
GN
0.5
For model with cab, version 3 and 5.
MOD--43
8 7 6 5
Col.
4 3 2 1
Pin
155 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
62 Pin
Col.
Sect.
Pin
Col.
Sect.
1
C
0.5
--
--
--
SW--44--1
For model with cab, version 3 and 5.
156 Pin
Col.
Sect.
Pin
Col.
Sect.
1
M
0.5
--
--
--
SW--44--2
For model with cab, version 3 and 5.
157 Pin
Col.
Sect.
Pin
Col.
Sect.
1
M
0.5
--
--
--
SW--44--3
For model with cab, version 3 and 5.
158 Pin
Col.
Sect.
Pin
Col.
Sect.
1
B
0.5
--
--
--
SW--44--4
For model with cab, version 3 and 5.
159 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Col.
Sect.
3
R
1.0
--
N
0.5
4
A
1.0
2
GN
0.5
--
--
--
For model without cab, ISO.
LMP--45
3
Pin
1.0
4
Sect.
N
1
Col.
1
2
Pin
63
160 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
3
A
1.0
2
N
1.0
4
R
1.0
LMP--45
1
3
2
4
For model with cab.
161 Pin
Col.
Sect.
Pin
Col.
Sect.
1
AB
1.0
2
N
1.0
C--46
1
2
For model without cab.
162 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
2
AB
1.0
C--46
1
2
For model with cab.
163 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
64 Pin
Col.
Sect.
Pin
Col.
Sect.
31
N
2.5
58L
N
2.5
54
M
2.5
58R
M
2.5
C--47
For NORTH AMERICAN model.
31
54
58R
58L
164 Col.
Sect.
3
R
1.0
--
N
0.5
4
AN
1.0
2
G
1.0
--
--
--
--
G
0.5
--
--
--
For model without cab, ISO.
LMP--48
3
Pin
1.0
4
Sect.
N
1
Col.
1
2
Pin
165 Pin
Col.
Sect.
Pin
Col.
Sect.
1
G
0.5
3
AN
1.0
2
N
1.0
4
R
1.0
LMP--48
1
3
2
4
For model with cab.
166 Pin
Col.
Sect.
Pin
Col.
Sect.
1
M
4.0
--
--
--
1
N
4.0
--
--
--
C--49
For model without cab, ISO.
167 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Col.
Sect.
3
--
--
2
AB
1.0
4
--
--
For model with cab.
SW--52--A
2
Pin
1.0
4
Sect.
A
1
Col.
1
3
Pin
65
168 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
2
GN
0.5
SW--52--B
For model with cab. 1
2
169
--
--
6
R
1.0
3
L
1.0
7
A,G
1.0
4
A
1.0
8
--
--
For model with cab.
8
2
SW--53--A
7
1.0
6
Sect.
V
5
Col.
5
4
Pin
--
3
Sect.
--
2
Col.
1
1
Pin
170 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
2
N
1.0
SW--53--B
For model with cab. 1
2
171 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
66 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
4
--
--
2
V
1.0
5
R
1.0
3
G
1.0
6
L
1.0
For model with cab.
M--54 3
6
2
5
1
4
172
--
--
6
VN
1.0
3
CL
1.0
7
CN
1.0
4
CN
1.0
8
VN
1.0
For model with cab.
8
2
SW--55--A
7
--
6
Sect.
--
5
Col.
5
4
Pin
--
3
Sect.
--
2
Col.
1
1
Pin
173 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
2
N
1.0
SW--55--B
For model with cab. 1
2
174 Pin
Col.
Sect.
Pin
Col.
Sect.
1
VN
1.0
2
N
1.0
M--56
1
2
For model with cab.
175 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin 1 2 3 4 5 7 8 9 10 11 12
Col. N N N N N N N N N N N
Sect. 1:00 1:00 1:00 1:00 1:00 1:00 4:00 0:05 1:00 1:00 1:00
Pin 13 14 15 16 17 18 19 20 21 22 23
Col. N N N N N N N N N N N
Sect. 1:00 1:00 0:05 0:05 0:05 0:05 1:00 1:00 1:00 1:00 1:00
67
GND--57
For model with cab.
176
1.0
4B
AN
1.0
5A
--
--
5B
G
1.0
6A
--
--
6B
GN
1.0
7A
VG
1.0
7B
--
--
8A
N
1.0
8B
--
--
7
GR
B 8
4A
7
1.0
A 8
--
A
5
--
3B
6
2B
--
5
--
--
6
--
3A
3
2A
MOD--58
4
--
3
Sect.
--
4
Col.
1B
1
Pin
--
2
Sect.
--
1
Col.
1A
2
Pin
For model with cab. 177 Pin
Col.
Sect.
Pin
Col.
Sect.
1
A
1.0
--
--
--
1
AN
1.0
--
--
--
AUD--60
For model with cab.
178 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
1.0
--
--
--
1
G
1.0
--
--
--
AUD--61
For model with cab.
179 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
4.0
3
GN
0.5
2
G
4.0
4
V
0.5
For model with cab.
C--62
1
Sect.
N
2
Col.
1
3
Pin
4
68
180 Col.
Sect.
3
--
--
--
CB
1.0
4
--
--
2
GR
1.0
--
--
--
SW--63--A
2
Pin
0.5
4
Sect.
CB
1
Col.
1
3
Pin
For model with cab.
181 Pin
Col.
Sect.
Pin
Col.
Sect.
1
CB
0.5
2
N
1.0
SW--63--B
For model with cab. 1
2
182
87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
B
0.5
18
--
--
69
2
--
--
19
--
--
3
MN
1.0
20
--
--
4
LB
0.5
21
BN
0.5
5
CB
1.0
22
V
1.0
1
9
6
--
--
23
--
--
10
17
7
--
--
24
H
0.5
18
25
0.5
26
34
8
MV
1.0
25
GV
9
SB
1.0
26
--
--
10
--
--
27
CL
1.0
11
--
--
28
--
--
12
G
0.75
29
N
1.0
13
V
0.75
30
VN
1.0
14
--
--
31
--
--
15
C
0.5
32
--
--
16
RN
0.5
33
CN
0.5
17
RG
0.5
34
CL
0.5
MOD--64
For model with cab, version 4 and 5. For model without cab, version 3.
183 Pin
Col.
Sect.
Pin
Col.
Sect.
1
VB
0.5
2
V
0.5
C--73
1
2
For model with cab.
184 --
5
--
--
2
--
--
6
GN
0.5
3
V
0.5
7
BG
0.5
4
GN
0.5
8
GN
0.5
For model with cab.
SW--74--A 8
--
7
1
6
Sect.
5
Col.
4
Pin
3
Sect.
2
Col.
1
Pin
185 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
70 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
2
N
1.0
SW--74--B
For model with cab. 1
2
186 Pin
Col.
Sect.
Pin
Col.
Sect.
1
R
1.0
8
AB
1.5
2
R
1.0
9
GR
1.5
12
11
10
3
R
1.0
10
L
2.5
F3
F2
F1
--
R
4.0
--
L
4.0
9
8
7
4
CN
1.0
11
L
1.5
5
A
1.0
--
L
2.5
6
5
4
F5
F4
2
1
MOD--75--A
6
G
4.0
12
L
1.5
F6
7
AN
1.5
--
--
--
3
For model with cab. 187
0.5
V
0.5
R1_87
AB
1.0
R3_87
L
1.0
R1_87A
--
--
R3_87A
--
--
R2_30
L
4.0
R4_30
AN
1.5
R2_85
N
0.5
R4_85
N
0.5
R2_86
BL
0.5
R4_86
VB
0.5
R2_87
R
4.0
R4_87
HN
1.5
R2_87A
--
--
R4_87A
--
--
R2
R4
85 87a 86
N
R3_86
85 87a 86
R3_85
0.5
87
0.5
BG
87
N
R1_86
30
R1_85
MOD--75--B
30
1.0
85 87a 86
Sect.
B
85 87a 86
Col.
R3_30
87
Pin
1.5
87
Sect.
AB
30
Col.
30
Pin R1_30
R1
R3
For model with cab.
188
Pin
Col.
Sect.
Pin
Col.
Sect.
A
HN
1.0
B
N
1.0
LMP--76
B
B
A
A
For model with cab.
189 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
A
HN
1.0
B
N
1.0
71
LMP--77
B
B
A
A
For model with cab.
190 Pin
Col.
Sect.
Pin
Col.
Sect.
A
AB
1.0
B
N
1.0
LMP--78
B
B
A
A
For model with cab.
191 Pin
Col.
Sect.
Pin
Col.
Sect.
A
AB
1.0
B
N
1.0
LMP--79
B
B
A
A
For model with cab.
192 Pin
Col.
Sect.
Pin
Col.
Sect.
1
RN
1.0
--
--
--
1
N
1.0
--
--
--
LMP--80
193 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
72 Pin
Col.
Sect.
Pin
Col.
Sect.
1
RN
1.0
--
--
--
1
N
1.0
--
--
--
LMP--81
For model with cab.
194 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GR
0.5
--
--
--
LMP--82--1
For model with cab.
195 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
0.5
--
--
--
LMP--82--2
For model with cab.
196 Pin
Col.
Sect.
Pin
Col.
Sect.
1
L
10
--
--
--
--
L
10
--
--
--
BAT--83--A
For model with cab.
197 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
R
10
--
--
--
73
BAT--83--B
For model without cab.
198 Pin
Col.
Sect.
Pin
Col.
Sect.
1
R
16.0
--
--
--
BAT--83--E
199 Pin
Col.
Sect.
Pin
Col.
Sect.
1
RV
1.0
--
--
--
ALT--84--B
200 Pin
Col.
Sect.
Pin
Col.
Sect.
1
R
16.0
--
--
--
ALT--84--C
201 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
74 Pin
Col.
Sect.
Pin
Col.
Sect.
30
R
16.0
--
--
--
M--85
202 Pin
Col.
Sect.
Pin
Col.
Sect.
50
RN
2.5
--
--
--
M--85
203 Pin
Col.
Sect.
Pin
Col.
Sect.
1
BR
1.0
--
--
--
1
LR
1.0
--
--
--
SEN--86
204 Pin
Col.
Sect.
Pin
Col.
Sect.
1
MV
1.0
--
--
--
1
N
1.0
--
--
--
SEN--87
205 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
2
GR
1.0
75
C--88--A
1
2
For model with cab.
206 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
--
--
--
--
GN
1.0
--
--
--
C--88--B
For model with cab.
207 Col.
Sect.
Pin
Col.
Sect.
1
MN
0.75
3
LR
1.0
2
ZB
1.0
--
--
--
2
2
3
3
1
For model with cab.
SEN--89
1
Pin
208 1
MN
1.0
3
LR
1.0
2
ZB
1.0
--
--
--
For model without cab.
SEN--89
1
Sect.
2
Col.
3
Pin
1
Sect.
2
Col.
3
Pin
209 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
76 Pin
Col.
Sect.
Pin
Col.
Sect.
1
L
1.0
2
N
1.0
M--90
1
1
2
2
For model with cab.
210 Pin
Col.
Sect.
Pin
Col.
Sect.
1
L
1.0
2
L
1.0
SEN--91
1
2
For model with cab.
211 Pin
Col.
Sect.
Pin
Col.
Sect.
1
HN
1.0
--
--
--
SEN--92
212 Col.
Sect.
Pin
Col.
Sect.
A
VN
1.0
C
ZB
1.0
B
HR
1.0
--
--
--
SEN--93
A
C
B
Pin
213 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
SG
1.0
--
--
--
--
SG
1.0
--
--
--
77
SOL--94
214 Pin
Col.
Sect.
Pin
Col.
Sect.
1
VN
1.0
--
--
--
SOL--95
For model with cab.
215 Pin
Col.
Sect.
Pin
Col.
Sect.
1
V
1.0
--
--
--
SOL--95
For model without cab.
216 Col.
Sect.
1
SG
1.0
2
V
1.0
SW--96
1
Pin
2
Sect.
1
Col.
2
Pin
217 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
0.5
2
ZN
1.0
6
M
1.0
3
BR
0.5
7
VB
1.0
4
VN
0.5
8
V
1.0
SW--97 1
Sect.
HN
2
Col.
5
4
Pin
1.0
5
Sect.
Z
6
Col.
1
1
Pin
2
3
3
7
For model with cab, version 3, 4 and 5. For model without cab.
8
78
218 Col.
Sect.
2
MV
1.0
SOL--99
1
Pin
1.0
2
Sect.
ZN
1
Col.
1
2
Pin
219 Col.
Sect.
2
BN
1.0
SOL--100
1
Pin
1.0
2
Sect.
MV
1
Col.
1
2
Pin
220 Sect.
Pin
Col.
Sect.
1
VB
1.0
3
AB
1.0
2
V
1.0
--
--
--
SEN--101
2
2
3
3
1
Col.
1
Pin
221 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Col.
Sect.
Pin
Col.
Sect.
1
AB
0.5
3
AR
0.5
2
VB
0.5
4
AG
0.5
MOD--102
4
3
2
1
Pin
79
222
MV
0.5
6
MV
0.5
3
MV
0.5
7
MV
0.5
4
C
0.5
8
L
0.5
8
2
SW--103
7
0.5
6
Sect.
L
5
Col.
5
4
Pin
0.5
3
Sect.
G
2
Col.
1
1
Pin
223 Sect.
Pin
Col.
Sect.
HV
1.0
3
N
1.0
2
LG
1.0
4
HB
1.0
SW--104
1
Col.
1
1
Pin
3
3
4
4
2
2
For model with cab, version 1, 2 and 3. For model without cab, version 1 and 2.
224 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
2
N
0.5
For model with cab, version 4 and 5. For model without cab, version 3.
SW--105
1
2
225 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
80 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
2
N
1.0
GND--106
226 Pin
Col.
Sect.
Pin
Col.
Sect.
1
AG
1.0
--
--
--
1
N
1.0
--
--
--
SEN--107
227 Pin
Col.
Sect.
Pin
Col.
Sect.
1
HL
1.0
--
--
--
1
HR
1.0
--
--
--
SEN--108
228 Pin
Col.
Sect.
Pin
Col.
Sect.
1
BR
1.0
--
--
--
1
BR
1.0
--
--
--
SOL--109
229 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
30
BR
1.0
87
HL
1.0
85
N
1.0
87A
--
--
86
B
0.5
--
--
--
81
RLY--110--A
30
86
87 87a 85
230 Pin
Col.
Sect.
Pin
Col.
Sect.
30
BR
1.0
87
HL
1.0
85
N
1.0
87A
--
--
86
HR
1.0
--
--
--
RLY--110--B
30
86
87 87a 85
231 Pin
Col.
Sect.
Pin
Col.
Sect.
30
B
0.5
87
B
0.5
85
N
1.0
87A
--
--
86
HL
1.0
--
--
--
RLY--110--C
30
86
87 87a 85
232 1.0
3
HL
1.0
2
HG
1.0
4
HV
1.0
SW--111
1
HB
2
1
3
Sect.
4
Col.
1
Pin
2
Sect.
3
Col.
4
Pin
233 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
82 Pin
Col.
Sect.
Pin
Col.
Sect.
1
HL
1.0
--
--
--
1
MB
1.0
--
--
--
SEN--112
234 Col.
Sect.
3
--
--
2
GN
0.5
4
--
--
For model with cab, version 4 and 5.
SW--113--A
2
Pin
0.5
4
Sect.
GR
1
Col.
1
3
Pin
235 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
2
N
0.5
SW--113--B
For model with cab, version 4 and 5. 1
2
236 Pin
Col.
Sect.
Pin
Col.
Sect.
1
R
1.0
2
H
1.0
SW--114
1
1
2
2
For version with splitter.
237 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
H
1.0
2
H
1.0
83
SW--114
1
1
2
2
For standard version.
238 Pin
Col.
Sect.
Pin
Col.
Sect.
1
R
1.0
2
H
1.0
SW--115
1
1
2
2
For version with splitter.
239 Sect.
Pin
Col.
Sect.
RG
1.0
3
--
--
2
--
--
4
HL
1.0
SW--116
1
Col.
1
3
3
4
4
2
2
1
Pin
240 Col.
Sect.
Pin
Col.
Sect.
1
AR
1.0
--
--
--
SOL--117
1
Pin
241 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
84 Pin
Col.
Sect.
Pin
Col.
Sect.
1
Z
1.0
--
--
--
1
N
1.0
--
--
--
AUD--118
242 Col.
Sect.
B
N
1.0
LMP--119
B
Pin
1.0
A
Sect.
B
B
Col.
A
A
Pin
243 Col.
Sect.
3
V
1.0
2
--
--
4
H
1.0
LMP--120
2
Pin
1.0
1
Sect.
N
4
Col.
1
3
Pin
244 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
3
V
1.0
2
--
--
4
H
1.0
LMP--120
For NORTH AMERICAN model. C
A B
245 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
3
V
1.0
2
--
--
4
H
1.0
85
LMP--121
4
2
3
1
For ISO version.
246 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
3
V
1.0
2
--
--
4
H
1.0
LMP--121
For NORTH AMERICAN model. C
A B
247 Col.
Sect.
B
N
1.0
LMP--122
B
Pin
1.0
A
Sect.
B
B
Col.
A
A
Pin
248 Col.
Sect.
1
S
1.0
2
ZB
1.0
SEN--123
1
Pin
2
Sect.
1
Col.
2
Pin
249 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
86 Pin
Col.
Sect.
Pin
Col.
Sect.
1
CN
1.0
--
--
--
1
N
1.0
--
--
--
SEN--124
For model with cab, version 4 and 5. For model without cab, version 3.
250 Pin
Col.
Sect.
Pin
Col.
Sect.
1
MV
1.0
2
N
1.0
SW--125
1
1
2
2
For model with cab, version 4 and 5. For model without cab, version 3.
251 Pin
Col.
Sect.
Pin
Col.
Sect.
1
C
1.0
2
SB
1.0
SEN--126
1
2
For model with cab, version 4 and 5. For model without cab, version 3.
252 1
C
1.0
3
B
1.0
2
VN
1.0
--
--
--
For model with cab, version 4 and 5. For model without cab, version 3.
SEN--127
1
Sect.
2
Col.
3
Pin
1
Sect.
2
Col.
3
Pin
253 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
C
1.0
3
B
1.0
2
V
1.0
--
--
--
87
SEN--128
2
2
3
3
1
1
For model with cab, version 4 and 5. For model without cab, version 3.
254 Pin
Col.
Sect.
Pin
Col.
Sect.
1
ZB
1.0
2
HB
1.0
SEN--129
1
2
For model with cab, version 1, 2 and 3. For model without cab, version 1 and 2.
255 Col.
Sect.
Pin
Col.
Sect.
1
ZB
1.0
2
BC
1.0
SEN--130
1
2
Pin
256 1
VB
1.0
3
AB
1.0
2
ZN
1.5
--
--
--
For model with cab, version 3 and 5.
SEN--131
1
Sect.
2
Col.
3
Pin
1
Sect.
2
Col.
3
Pin
257 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
Pin
Col.
Sect.
Pin
Col.
Sect.
1
AB
1.0
3
VB
1.0
2
VG
1.0
--
--
--
SEN--132
2
2 3
1
1
For model with cab, version 3 and 5.
3
88
258 Pin
Col.
Sect.
Pin
Col.
Sect.
1
RV
1.0
2
SG
1.0
SOL--133
1
2
For model with cab, version 3 and 5.
259 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GV
1.0
2
GR
1.0
SOL--134
1
2
For model with cab, version 3 and 5.
260 Pin
Col.
Sect.
Pin
Col.
Sect.
1
CL
1.0
2
CB
1.0
SOL--135
2
1
For model with cab, version 4 and 5. For model without cab, version 3.
261 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
C
1.0
2
RN
1.0
89
SW--136--A
1
1
2
2
For model with cab, version 3, 4 and 5. For model without cab.
262 Pin
Col.
Sect.
Pin
Col.
Sect.
1
Z
1.0
2
RG
1.0
SW--136--B
1
1
2
2
For model without cab.
263 Pin
Col.
Sect.
Pin
Col.
Sect.
1
C
1.0
2
RG
1.0
SW--136--B
1
1
2
2
For model with cab, version 3, 4 and 5.
264 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
1.0
2
GR
1.0
SOL--138
1
2
For version with dual command (2--speed power shift)
265 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
90 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
1.0
2
GR
1.0
SOL--138
1
1
2
2
For version with dual command (2--speed power shift), paddy field version
266 Pin
Col.
Sect.
Pin
Col.
Sect.
1
SG
1.0
2
SN
1.0
SOL--139
1
2
For version with dual command (2--speed power shift)
267 Pin
Col.
Sect.
Pin
Col.
Sect.
1
SG
1.0
2
SN
1.0
SOL--139
1
1
2
2
For version with dual command (2--speed power shift), paddy field version
268 Pin
Col.
Sect.
Pin
Col.
Sect.
1
ZN
1.0
2
ZB
1.0
SOL--140
1
2
For Power--Shuttle version.
269 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
AB
1.0
2
BG
1.0
91
SW--141
1
1
2
2
For Power--Shuttle version.
270 Pin
Col.
Sect.
Pin
Col.
Sect.
1
AB
1.0
2
GL
1.0
SW--142
1
1
2
2
For Power--Shuttle version.
271 Col.
Sect.
2
HG
1.0
For version with Dual Command (2 Speed Power Shift) and version with Dual Command (2 Speed Power Shift) , paddy field version
SW--143
1
Pin
1.0
2
Sect.
AB
1
Col.
1
2
Pin
272 Pin
Col.
Sect.
Pin
Col.
Sect.
A
AN
1.0
B
AR
1.0
SOL--146
For Power--Shuttle version.
273 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
92 Pin
Col.
Sect.
Pin
Col.
Sect.
A
AN
1.0
B
AR
1.0
SOL--146
1
1
2
2
For version with dual command (2--speed power shift), paddy field version
274 Pin
Col.
Sect.
Pin
Col.
Sect.
A
AN
1.0
B
AR
1.0
SOL--146--B
For version with dual command (2--speed power shift)
275 Pin
Col.
Sect.
Pin
Col.
Sect.
A
BR
1.0
B
BN
1.0
SOL--147
For Power--Shuttle version.
276 Pin
Col.
Sect.
Pin
Col.
Sect.
A
BR
1.0
B
BN
1.0
SOL--147
1
1
2
2
For version with dual command (2--speed power shift), paddy field version
277 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
A
BR
1.0
B
BN
1.0
93
SOL--147--B
For version with dual command (2--speed power shift)
278 Pin
Col.
Sect.
Pin
Col.
Sect.
A
VN
1.0
B
HM
1.0
SEN--148
For Power--Shuttle version.
279 Pin
Col.
Sect.
Pin
Col.
Sect.
1
VN
0.5
18
ZB
1.0
2
RN
0.5
19
B
0.5
3
MN
1.0
20
AV
1.0
4
LB
0.5
21
R
0.5
5
AN
1.0
22
AG
1.0
1
9
6
BR
1.0
23
SG
1.0
10
17
7
S
0.5
24
C
1.0
18
25
26
34
8
HM
1.0
25
--
--
9
AN
0.75
26
AR
1.0
10
BN
1.0
27
SN
1.0
11
AB
0.5
28
--
--
12
G
0.75
29
N
1.0
13
V
0.75
30
GN
1.0
14
MB
1.0
31
GR
1.0
15
A
0.75
32
HV
1.0
16
GL
1.0
33
--
--
17
BG
1.0
34
HG
1.0
MOD--150
For version with dual command (2--speed power shift)
280 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
94 Pin
Col.
Sect.
Pin
Col.
Sect.
1
VN
0.5
18
ZB
1.0
2
RN
0.5
19
B
0.5
3
MN
1.0
20
SN
1.0
4
LB
0.5
21
R
0.5
5
AN
1.0
22
--
--
1
9
6
BR
1.0
23
--
--
10
17
7
S
0.5
24
--
--
18
25
26
34
8
HM
1.0
25
--
--
9
AN
0.75
26
AR
1.0
10
BN
1.0
27
--
--
11
AB
0.5
28
--
--
12
G
0.75
29
N
1.0
13
V
0.75
30
--
--
14
--
--
31
--
--
15
A
0.75
32
--
--
16
GL
1.0
33
--
--
17
BG
1.0
34
--
--
MOD--150
For Power--Shuttle version.
281 Sect.
Pin
Col.
Sect.
1
B
0.5
3
RN
0.5
2
B
0.5
4
HV
1.0
SW--151
1
Col.
1
Pin
3
3
4
4
2
2
For Power--Shuttle version.
282 0.75
8
N
0.75
2
AN
0.75
9
--
--
3
A
0.75
10
--
--
SW--152
--
11
--
--
MV
1.0
12
--
--
6
Z
1.0
13
--
--
7
B
0.75
14
--
--
3
8
--
5
4
4
12 13
AB
10 11
1
9
Sect.
7
Col.
6
Pin
5
Sect.
2
Col.
1
Pin
For Power--Shuttle version. 283 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
AB
0.5
3
VN
0.5
2
S
0.5
--
--
--
95
SEN--153
2
2
3
3
1
1
For Power--Shuttle version.
284 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
0.75
3
N
1.0
2
N
1.0
4
N
1.0
GND--155
For version with dual command (2--speed power shift)
285 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
2
N
1.0
--
N
0.75
3
N
1.0
GND--155
For Power--Shuttle version.
286 Col.
Sect.
1
GR
1.0
6
AR
1.0
2
--
--
7
LR
1.0
3
AR
1.0
8
N
1.0
4
RV
1.0
9
--
--
5
RN
1.0
10
HR
1.0
MOD--156
6
Pin
10
Sect.
1
Col.
5
Pin
287 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
1.0
2
N
1.0
RLY--157
1
Sect.
AR
2
Col.
1
1
Pin
2
96
288 Pin
Col.
Sect.
Pin
Col.
Sect.
1
R
16.0
--
--
--
1
R
16.0
--
--
--
RLY--158
289 Pin
Col.
Sect.
Pin
Col.
Sect.
1
R
16.0
--
--
--
RES--159
290 Pin
Col.
Sect.
Pin
Col.
Sect.
1
R
16.0
--
--
--
1
R
16.0
--
--
--
F--160
291 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
MN
0.75
5
--
--
2
N
0.5
6
--
--
3
N
1.0
8
--
--
4
LN
0.75
--
--
--
8
1
SW--161--A
7
--
6
Sect.
--
5
Col.
7
4
Pin
1.0
3
Sect.
N
2
Col.
--
1
Pin
97
For model with cab, version 3.
292
N
1.0
6
--
--
3
N
1.0
7
--
--
4
LN
0.75
8
--
--
For model with cab, version 4 and 5.
8
2
SW--161--A
7
--
6
Sect.
--
5
Col.
5
4
Pin
0.75
3
Sect.
MN
2
Col.
1
1
Pin
293
N
1.0
6
--
--
3
N
1.0
7
--
--
4
LN
1.0
8
--
--
For model without cab, version 3.
8
2
SW--161--A
7
--
6
Sect.
--
5
Col.
5
4
Pin
1.0
3
Sect.
MN
2
Col.
1
1
Pin
294 1.0
5
--
--
2
N
0.5
6
--
--
--
N
0.5
7
--
--
3
N
0.5
8
--
--
4
LN
1.0
--
--
--
SW--161--A 8
MN
7
1
6
Sect.
5
Col.
4
Pin
3
Sect.
2
Col.
1
Pin
ON DIGITAL INSTRUMENT CABLE
295 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
98 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
2
N
0.5
--
--
--
--
N
1.0
For model with cab, version 3.
SW--161--B
1
2
296 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.75
2
N
1.0
SW--161--B
For model with cab, version 4 and 5. 1
2
297 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
2
N
1.0
SW--161--B
For model without cab, version 3. 1
2
298 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
2
N
0.5
--
GN
0.5
--
N
0.5
ON DIGITAL INSTRUMENT CABLE
SW--161--B
1
2
299 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
N
1.0
5
--
--
N
0.5
6
--
--
3
N
1.0
8
--
--
4
BN
0.75
--
--
--
8
-2
SW--162--A
7
--
6
Sect.
--
5
Col.
7
4
Pin
0.75
3
Sect.
SN
2
Col.
1
1
Pin
99
For model with cab, version 3.
300
N
1.0
6
--
--
3
N
1.0
7
--
--
4
BN
0.75
8
--
--
For model with cab, version 4 and 5.
8
2
SW--162--A
7
--
6
Sect.
--
5
Col.
5
4
Pin
0.75
3
Sect.
SN
2
Col.
1
1
Pin
301
N
1.0
6
--
--
3
N
1.0
7
--
--
4
BN
1.0
8
--
--
For model without cab, version 3.
8
2
SW--162--A
7
--
6
Sect.
--
5
Col.
5
4
Pin
1.0
3
Sect.
SN
2
Col.
1
1
Pin
302 0.5
4
BN
0.5
2
N
0.5
5
--
--
--
N
0.5
6
--
--
3
N
0.5
7
--
--
--
N
0.5
8
--
--
SW--162--A 8
SN
7
1
6
Sect.
5
Col.
4
Pin
3
Sect.
2
Col.
1
Pin
ON DIGITAL INSTRUMENT CABLE
303 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
100 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
2
N
0.5
SW--162--B
For model with cab, version 3. 1
2
304 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.75
2
N
1.0
SW--162--B
For model with cab, version 4 and 5. 1
2
305 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
2
N
0.5
--
--
--
--
N
1.0
For model without cab, version 3.
SW--162--B
1
2
306 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
0.5
2
GN
0.5
--
N
0.5
--
--
--
ON DIGITAL INSTRUMENT CABLE
SW--162--B
1
2
307 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Col.
Sect.
Pin
Col.
Sect.
1
RN
0.5
3
RG
1.0
2
C
0.5
--
--
--
C--166
3
2
1
Pin
101
308
G
0.75
4
--
--
For Power--Shuttle version.
4
2
C--167
3
0.75
2
Sect.
V
1
Col.
3
4
Pin
--
3
Sect.
--
2
Col.
1
1
Pin
M
309
G
0.75
4
--
--
For model with cab, version 2, 3, 4 and 5. For model without cab, version 2 and 3.
1
2
C--167
2
0.75
3
Sect.
V
4
Col.
3
1
Pin
--
2
Sect.
--
3
Col.
1
4
Pin
F
310 Pin
Col.
Sect.
Pin
Col.
Sect.
A
L
10
B
L
10
F--168
A
B
311 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
102 Pin
Col.
Sect.
Pin
Col.
Sect.
A
R
10
B
R
10
F--169
A
B
312
2
S
1.5
6
G
1.0
3
SN
1.5
7
N
1.5
4
N
1.5
8
--
--
C--170 1
1.0
2
Sect.
RV
4
Col.
5
5
Pin
1.5
6
Sect.
Z
1
Col.
1
2
Pin
3
8
3
7
For model with cab, version 3.
313 Col.
Sect.
3
--
--
2
M
2.5
4
--
--
For model with cab, version 3.
SW--171--A
2
Pin
2.5
4
Sect.
MN
1
Col.
1
3
Pin
314 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
2
N
0.5
SW--171--B
For model with cab, version 3. 1
2
315 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
C
1.0
3
N
1.0
2
CN
1.0
4
--
--
C--175
4
3
2
1
For model with cab, version 1, 2 and 3. For model without cab, version 1 and 2.
103
316 Col.
Sect.
Pin
Col.
Sect.
1
ZB
1.0
3
--
--
2
HV
1.0
--
--
--
SEN--176
2
2
3
3
1
1
Pin
317 1 11 21 31
10 20 30 40
NOTE: See connection MOD--11--B.
MOD--177
318 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
104 Pin
Col.
Sect.
Pin
Col.
Sect.
1
BV
1.0
--
--
--
1
N
1.0
--
--
--
LMP--178
For model without cab.
319 Pin
Col.
Sect.
Pin
Col.
Sect.
1
RN
1.0
2
RG
1.0
C--179
2
2
1
1
For model without cab, NORTH AMERICAN.
M
320 Pin
Col.
Sect.
Pin
Col.
Sect.
1
BN
1.0
2
H
1.0
C--179
1
1
For model without cab, ISO.
2
2
F
321 N
1.0
4
R
1.0
2
GN
0.5
5
AN
1.0
3
A
1.0
6
G
1.0
2
2
1
1
3
For model without cab, ISO.
C--180 6
1
5
Sect.
4
Col.
3
Pin
6
Sect.
5
Col.
4
Pin
M
322 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
2
GN
0.5
5
AN
1.0
3
A
1.0
6
G
1.0
5
5
6
6
4
For model without cab, version 1 and 2.
C--180 1
1.0
2
Sect.
R
3
Col.
4
4
Pin
1.0
1
Sect.
N
2
Col.
1
3
Pin
105
F
323
2
GN
1.0
5
AN
1.0
3
A
1.0
6
G
1.0
5
5
6
6
4
For model without cab, version 3.
C--180 1
1.0
2
Sect.
R
3
Col.
4
4
Pin
1.0
1
Sect.
N
2
Col.
1
3
Pin
F
324 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
--
--
--
GND--181
325 Pin
Col.
Sect.
Pin
Col.
Sect.
1
SN
1.0
--
--
--
1
AB
1.0
--
--
--
SEN--182
For Power--Shuttle version.
326 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
1.0
2
C
1.0
4
AG
1.0
SW--183
1
Sect.
MB
2
For version with Dual Command (2 Speed Power Shift) and version with Dual Command (2 Speed Power Shift) , paddy field version
2
Col.
3
3
Pin
1.0
4
Sect.
AV
1
Col.
1
3
Pin
4
106
327 Pin
Col.
Sect.
Pin
Col.
Sect.
1
RN
1.0
2
N
1.0
C--184
2 1
For model with cab.
328 Pin
Col.
Sect.
Pin
Col.
Sect.
1
RG
1.0
2
N
1.0
C--185
2 1
For model with cab.
329 1
AB
1.0
3
VN
1.0
2
HV
1.0
--
--
--
For version with Dual Command (2 Speed Power Shift) and version with Dual Command (2 Speed Power Shift) , paddy field version
SEN--203
1
Sect.
2
Col.
3
Pin
1
Sect.
2
Col.
3
Pin
330 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
107
Pin
Col.
Sect.
Pin
Col.
Sect.
1
AB
0.5
14
--
--
2
A
1.0
15
--
--
3
AG
0.5
16
HV
0.5
4
BN
1.0
17
R
0.5
26
20
5
ZN
1.0
18
--
--
19
14
6
--
--
19
BR
1.0
13
8
7
7
AN
1.0
20
--
--
8
MV
1.0
21
AR
0.5
9
C
0.5
22
ZB
1.0
10
L
0.5
23
BG
1.0
11
G
0.5
24
V
1.0
12
--
--
25
--
--
13
--
--
26
VB
0.5
Pin
Col.
Sect.
Pin
Col.
Sect.
1
ZB
1.0
3
--
--
2
MV
1.0
--
--
--
Pin
Col.
Sect.
Pin
Col.
Sect.
1
MV
1.0
3
--
--
2
BG
1.0
--
--
--
25
Amps
21
1 5
3
MOD--204
331
2
2
3
3
1
1
SW--205
332
2 3
1
2 3
1
SW--206
333 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Col.
Sect.
Pin
Col.
Sect.
1
VB
1.0
3
A
1.0
2
BR
1.0
4
AN
1.0
SOL--208
3
3
4
4
2
2
1
Pin
1
108
334 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
--
--
--
1
G
1.0
--
--
--
LMP--210
For ISO model.
335 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
0.5
--
--
--
LMP--212--A
For model without cab, ISO.
336 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
--
--
--
LMP--212--B
For model without cab, ISO.
337 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
0.5
--
--
--
109
LMP--212--C
For model without cab, ISO.
338 Pin
Col.
Sect.
Pin
Col.
Sect.
1
G
0.5
--
--
--
LMP--212--D
For model without cab, ISO.
339 Pin
Col.
Sect.
Pin
Col.
Sect.
1
R
1.0
4
RG
1.0
2
GN
1.0
5
N
1.0
3
A
1.0
--
--
--
LMP--213
5
4
For model without cab, NORTH AMERICAN. 3
2 1
340 Pin
Col.
Sect.
Pin
Col.
Sect.
1
R
1.0
4
RN
1.0
2
G
1.0
5
N
1.0
3
AN
1.0
--
--
--
LMP--214
5
4
For model without cab, NORTH AMERICAN. 3
2 1
341 87666787A - 11 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
110 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
4.0
--
--
--
GND--215
For model without cab, ISO.
342 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
2.5
--
--
--
GND--215
For model without cab, NORTH AMERICAN.
343
87666787A - 11 - 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
1
SECTION 55 − ELECTRICAL SYSTEM Chapter 9 − FAULT CODES INDEX Section
Meaning
Page
List of fault codes for EDC electronically controlled rear hydraulic lift (SA) . . . . . . . . . . . . . 2 List of transmission fault codes (SB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 List of four−wheel drive fault codes (SC, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 List of front PTO fault codes (SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Front electronic lift error code list (SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 List of electric fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 List of ADIC control panel fault codes (ZA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Diagnosis of fault codes for EDC electronic lift (SA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Diagnosis of transmission fault codes (SB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Diagnosis of four−wheel drive codes (SC, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Front PTO error code troubleshooting (SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Front electronic lift troubleshooting (SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Diagnosis of electric codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Diagnosis of ADIC control panel codes (ZA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
2
ELECTRONICALLY CONTROLLED REAR HYDRAULIC LIFT (EDC) FAULT CODES 1008
Fast up/down switch failure (page 7).
1009
Both external switches operated at same time (page 8).
1010
Voltage too low on the maximum arms raise potentiometer (page 9).
1011
Voltage too high on the maximum arms raise potentiometer (page 10).
1012
Voltage too low on the lowering speed potentiometer (page 11).
1013
Voltage too high on the lowering speed potentiometer (page 12).
1021
Voltage too low on the position/draft control potentiometer (page 13).
1022
Voltage too high on the position/draft control potentiometer (page 14).
1023
Rear lift control panel disconnected (page 15).
1024
Calibrate the arms (page 16).
1025
Voltage too low on the working depth control potentiometer (page 17).
1026
Voltage too high on the working depth control potentiometer (page 18).
1027
Voltage too low on the lift arms position potentiometer (page 19).
1028
Voltage too high on the lift arms position potentiometer (page 20).
1029
Lift solenoid valves disconnected (page 21).
1031
Chassis harness disconnected (page 22).
1032
Short circuit to +12 V on the draft sensor (page 23).
1033
Open circuit on the draft sensor (page 24).
1040
Lift not calibrated (page 25).
1042
Lowering limit potentiometer not set on maximum value (page 26).
1043
Lowering speed potentiometer not set on maximum value (page 27).
1044
Set position/draft control potentiometer not in position (page 28).
1063
Open circuit on the lowering control solenoid valve (page 29).
1064
Open circuit on the lifting control solenoid valve (page 30).
1065
Lowering control solenoid valve shorted (page 31).
1066
Lifting control solenoid valve shorted (page 32).
1068
Max. raise limit potentiometer not set on maximum value (page 33).
1080
Voltage too low on the lowering limit potentiometer (page 34).
1081
Voltage too high on the lowering limit potentiometer (page 35).
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
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TRANSMISSION FAULT CODES 2011
Clutch pedal potentiometer signal too low (page 36).
2012
Clutch pedal potentiometer signal too high (page 37).
2013
HI and LO pushbuttons pressed at the same time (page 38).
2021
Transmission harness disconnected (page 39).
2024
All clutches not calibrated (page 40).
2026
Engine speed too high (page 41).
2035
The solenoid of the dump valve shorted to + 12 V (page 42).
2036
The solenoid of the dump valve in open circuit or shorted to ground (page 43).
2037
Clutch pedal switch circuit open (page 44).
2047
Clutch pedal switch set too high (page 45).
2048
Clutch pedal switch set too low (page 46).
2051
Open circuit on the transmission oil temperature sensor (page 47).
2052
Short circuit to ground on the transmission oil temperature sensor (page 48).
2059
Shuttle lever switches disagree (page 49).
2061
Shuttle/HI−LO synchro potentiometer signal too high (page 50).
2062
Shuttle/HI−LO synchro potentiometer signal too low (page 51).
2063
Synchro not moving to shuttle position (page 52).
2064
Synchro not moving to HI−LO position (page 53).
2070
Voltage from forward speed switch of the shuttle lever too high (page 54).
2071
Voltage from forward speed switch of the shuttle lever too low (page 55).
2072
Voltage from reverse speed switch of the shuttle lever too high (page 56).
2073
Voltage from reverse speed switch of the shuttle lever too low (page 57).
2085
Open circuit at the shuttle position synchronizer solenoid valve (page 58).
2086
Open circuit at the HI−LO position synchronizer solenoid valve (page 59).
2087
Short circuit to + 12 V at the shuttle position synchronizer solenoid valve (page 60).
2088
Short circuit to + 12 V at the HI−LO position synchronizer solenoid valve (page 61).
2199
Creeper unit option not enabled (page 62).
2311
HI speed switch input voltage too high (page 63).
2312
LO speed switch input voltage too high (page 64).
2342
Clutch A solenoid shorted to ground or circuit open (page 65).
2343
Clutch B solenoid shorted to ground or circuit open (page 66).
2352
The solenoid of clutch A is shorted to + 12 V (page 67).
2353
The solenoid of clutch B is shorted to + 12 V (page 68).
2362
Clutch A not calibrated (page 69).
2363
Clutch B not calibrated (page 70).
2400
Dual Command (2 Speed Power Shift)/SHUTTLE synchronizer not calibrated or badly calibrated (page 71).
2411
Synchronizer does not move during start−up procedure (page 72).
2413
Synchronizer disengaged without control module control (page 73). 87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
4 2421
Voltage from range lever switch too low (page 74).
2422
Voltage from range lever switch too high (page 75).
2425
Voltage from gear lever switch too low (page 76).
2426
Voltage from gear lever switch too high (page 77).
2427
Error on gear lever button common (page 78).
2428
Dump switch voltage too high (page 79).
2429
Dump switch jammed on (page 80)
2430
Low creeper switch voltage (page 81).
2431
High creeper switch voltage (page 82).
2432
Oil pressure switch jammed off (page 83).
2433
Oil pressure switch jammed on (page 84).
4WD FAULT CODES 6011
Permanent four−wheel drive switches and sensors supply fuse error (page 85).
6014
Short circuit between the terminals of the four−wheel drive solenoid valve (page 86).
6020
Automatic/manual four−wheel drive selector switch faulty (page 87).
6021
Four−wheel drive solenoid stuck off (page 88).
6023
Four−wheel drive solenoid circuit open (page 89).
6031
Voltage from the front shaft speed sensor (VAA) too low (page 90).
6032
Voltage from the front shaft speed sensor (VAA) too high (page 91).
6033
Voltage from the rear shaft speed sensor (VAP) too low (page 92).
6034
Voltage from the rear shaft speed sensor (VAP) too high (page 93).
6035
Frequency from the front shaft speed sensor (VAA) too high (page 94).
6036
Frequency from the rear shaft speed sensor (VAP) too high (page 95).
6037
Inconsistent sensors (VAA) and (VAP) (page 96).
6038
Voltage from tilt sensor too low (page 97).
6039
Voltage from tilt sensor too high (page 98).
6041
Voltage from steering angle sensor too high (page 99).
6042
Voltage from steering angle sensor too low (page 100).
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
5
FRONT PTO FAULT CODES 8007
Short circuit to +12 V on electromagnetic clutch (page 101).
8008
Short circuit to ground or open circuit on electromagnetic clutch (page 102).
8017
Short circuit between terminals of electromagnetic clutch slip detector (page 103).
8032
Short circuit to +12 V or open circuit on electromagnetic clutch slip detector (page 104).
8033
Open circuit on front PTO NC switch (page 105).
8037
Short circuit to front PTO NO switch (page 106).
FRONT ELECTRONIC LIFT ERROR CODES 9001
Open circuit in the front lift link position potentiometer (page 107).
9002
Short circuit to positive in the front lift link position potentiometer (page 108).
9011
Open circuit in the front lift upper limit potentiometer (page 109).
9012
Short circuit to positive in the front lift link upper limit potentiometer (page 110).
9013
Open circuit in the front lift working depth potentiometer (page 111).
9014
Short circuit to positive in the front lift working depth potentiometer (page 112).
9019
Engine rpm too low for calibration (page 113).
9024
Lift calibration (page 114).
9041
Upper limit potentiometer not set correctly for the calibration procedure (page 115).
9063
Open circuit in the lowering solenoid valve (page 116).
9064
Open circuit in the lifting solenoid valve (page 117).
9065
Short circuit to positive in the lowering solenoid valve (page 118).
9066
Short circuit to positive in the lifting solenoid valve (page 119).
ELECTRIC CODES 13011
SA (EDC control unit) +12VF too high (page 120).
13012 SB (power shuttle control unit) +12VF too high (page 121). 13013 SC/SD (control unit of four−wheel drive, lift and front power take−off)+12VF too high (page 122). 13021 SA (EDC control unit) +12VF too low (page 123). 13022 SB (power shuttle control unit) +12VF too low (page 124). 13023 SC/SD (control unit of four−wheel drive, lift and front power take−off)+12VF too low (page 125). 13031 SA (EDC control unit) error on +8V reference voltage (page 126). 13032 SB (power shuttle control unit) error on +5V reference voltage (page 127). 13033 SC/SD (ECU for 4WD, front PTO and lift) error on +5 V reference voltage (page 128). 13102 SB (power shuttle control unit) data not recorded correctly when switching off (page 129).
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
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CONTROL PANEL (ADIC) FAULT CODES 14001 Rear power take−off sensor shorted to + 12 V (page 130). 14002 Rear PTO sensor shorted to ground (page 131). 14011
Engine speed sensor shorted to positive or circuit open (page 132).
14012 Engine speed sensor shorted to ground (page 133). 14021 Cranking line sensing shorted to + 12 V (page 134). 14022 Cranking line sensing shorted to ground (page135). 14041 Engine coolant temperature sensor shorted to positive or circuit open (page 136). 14042 Engine coolant temperature sensor shorted to ground (page 137). 14051 Fuel level sensor shorted to positive or circuit open (page 138). 14052 Fuel level sensor shorted to ground (page 139). 14058 Seat switch on for longer than 25 hours (page 140). 14091 Transmission output speed shorted to + 12 V (page 141). 14092 Transmission output speed shorted to ground (page 142). 14093 Seat switch shorted to positive or circuit open (page 143). 14094 Seat switch shorted to ground (page 144). 14101 Sediment unit filter sensor not connected (page 145). 14106 Front PTO fitted but not configured (page 146). 14107 Front lift fitted but not configured (page 147). 14108 Rear PTO rpm sensor present yet not configured (page 148). 14201 Steering sensor shorted to positive or circuit open (page 149). 14900 No SB (page 150). 14901 No SA (page 151). 14913 No SC/SD (page 152).
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
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ELECTRONICALLY CONTROLLED REAR HYDRAULIC LIFT (EDC) FAULT CODES 1008 − FAST UP/DOWN SWITCH FAILURE Control module: Rear electronic lift control unit. NOTE: Lift disabled. Possible fault modes: 5. Faulty connector 6. Switch faulty 7. Wiring fault 8. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the operation of the button in H5. A. Enter the HH programs, select the control unit CA and the program H5. The display will show d0 that will change into d6 by pressing the switch at the bottom (float), unstable, and in d3 by pressing it at the top, stable. If the values displayed are not okay, continue to step 2. B. If the values displayed are okay, while still in H5, wiggle the harness and the connector of the switch SW−34 and that of the control unit MOD−27 to check for an intermittent circuit. The values displayed will change if an intermittent circuit is indicated; repair or replace as necessary. 2. Check the connector of the switch SW−34, the connector of the control unit MOD−27. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check switch operation. A. Disconnect connector SW−34. Test the continuity between: SW−34 pin 1 and pin 2 continuity by pressing the button on the unstable portion SW−34 pin 3 and pin 4 continuity by pressing the button on lifting SW−34 pin 6 and pin 7 continuity by pressing the button on lowering. If the switch does not have these characteristics, change the push−button. B. If the button is okay, continue to step 4. 4. Check for a short circuit between the lines carrying the signals to the control unit. A. Disconnect the connector of the control unit MOD−27. Test the continuity between: SW−34 pin 1 wire (BR) and pin 4 wire (S) SW−34 pin 1 wire (BR) and pin 7 wire (SN) SW−34 pin 4 wire (S) and pin 7 wire (SN) If there is a short circuit, repair or replace the wiring harness as required. B. If the wiring harness is okay, continue to step 5. 5. Check for a short circuit to positive. A. Turn the ignition key ON and measure the voltage between: SW−34 pin 1 wire (BR) and ground SW−34 pin 7 wire (SN) and ground SW−34 pin 4 wire (S) and ground if there is a short circuit to positive, repair or replace the wiring harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors MOD−27 and SW−34 sect. 55, chap. 8, fig. 117 and fig. 128), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339). 87666787A2 − 06 − 2009
8
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
1009 − BOTH EXTERNAL SWITCHES OPERATED AT SAME TIME. Control module: Rear electronic lift control unit. NOTE: Lift disabled. Possible fault modes: 1. Faulty connector 2. HPL fender switch(es) sticking 3. Faulty HPL fender switch 4. Wiring harness faulty 5. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the operation of the push−buttons in H5. A. Enter the HH programs, select the control unit CA and the program H5. The display will show d0 that will change into d1 by pressing the switch at the bottom lowering portion, and in d2 by pressing it at the top, lifting. If the values displayed, for each switch, are not okay, continue to step 2. B. If the values displayed are okay, while still in H5, wiggle the harness and the connectors of the external switches SW−37 left−hand, SW−44 right−hand and that of the control unit MOD−27 to check for an intermittent circuit. The values displayed will change if an intermittent circuit is indicated; repair or replace as necessary. 2. Check the connector SW−37, the connector SW−44 and the connector MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check the operation of the switches. A. Disconnect the connectors SW−37 and SW−44 then measure the continuity, on each switch, between: SW−37/44 pin 1 and pin 2 continuity by pressing on lowering SW−37/44 pin 3 and pin 4 continuity by pressing on lifting, if the switches do not have these characteristics then replace them. B. If they are okay, continue to step 4. 4. Check for a short circuit with positive voltage. A. Disconnect the connector of the control unit MOD−27. Turn the key start ON. Measure the voltage between connector: SW−37 pin 1 wire (C) and ground SW−37 pin 4 wire (B) and ground SW−44 pin 1 wire (C) and ground SW−44 pin 4 wire (B) and ground If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated continue to step 5. 5. Check for a short circuit between the signals of the two switches. A. Measure the continuity between: MOD−27 pin 19 wire (C) and MOD−27 pin 14 wire (B) If a short circuit is indicated, repair or replace harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors MOD−27, SW−37 and SW−44 sect. 55, chap. 8, fig. 117, fig. 139÷142 and fig. 156÷159), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339). 87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
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1010 − VOLTAGE TOO LOW ON THE MAXIMUM ARMS RAISE POTENTIOMETER. Control module: Rear electronic lift control unit. NOTE: Both the lifting limit and the lifting function are disabled; this function is only available with the external push−buttons. Possible fault modes: 1. Faulty connector 2. Faulty height limit control potentiometer 3. Wiring harness faulty 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the height limit control potentiometer in H9, ch 35. A. Turn the height limit control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 900 and 100, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 35 wiggle the harness and the connector MOD−43 of the EDC control panel, the connector MOD−27 of the wiring harness of the controller to check for an intermittent circuit. The values of ch 35 will change if an intermittent circuit is indicated; repair or replace as necessary. 2. Check the connector MOD−43 of the EDC control panel and the connector MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check the height limit control potentiometer. A. Remove the EDC control panel and disconnect the connector MOD−43. While turning the height limit control knob fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel side between: MOD−43 pin 4 and MOD−43 pin 1 MOD−43 pin 4 and MOD−43 pin 6 If the resistances indicated are not between approximately a minimum of 170÷190 and a maximum 400÷420 Ω, replace the control panel. B. If the EDC control panel is okay, continue to step 4. 4. Check for a short to ground. A. Check between: MOD−43 pin 4 wire (A) and ground MOD−43 pin 1 wire (AB) and ground If a short a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5. 5. Check for an open circuit. A. Disconnect the connectors MOD−27 of the controller. Check between: MOD−27 pin 11 wire (AB) and MOD−43 pin 1 wire (AB) MOD−27 pin 8 wire (A) and MOD−43 pin 4 wire (A) MOD−27 pin 1 wire (VB) and MOD−43 pin 6 wire (VB) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors MOD−27, MOD−43 sect. 55, chap. 8, fig. 117, fig. 155), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339). 87666787A2 − 06 − 2009
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
1011 − VOLTAGE TOO HIGH ON THE MAXIMUM ARMS RAISE POTENTIOMETER. Control module: Rear electronic lift control unit. NOTE: Both the lifting limit and the lifting function are disabled; this function is only available with the external push−buttons. Possible fault modes: 1. Faulty connector 2. Faulty height limit control potentiometer 3. Wiring harness faulty 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the height limit control potentiometer in H9, ch 35. A. Turn the height limit control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 900 and 100, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 35 wiggle the harness and the connector MOD−43 of the EDC control panel, the connector MOD−27 of the wiring harness of the controller to check for an intermittent circuit. The values of ch 35 will change if an intermittent circuit is indicated; repair or replace as necessary. 2. Check the connector MOD−43 of the EDC control panel and the connector MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check the height limit control potentiometer. A. Remove the EDC control panel and disconnect the connector MOD−43. While turning the height limit control knob fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel side between: MOD−43 pin 4 and MOD−53 pin 1 MOD−43 pin 4 and MOD−53 pin 6 If the resistances indicated are not between approximately a minimum of 170÷190 and a maximum 400÷420 Ω, replace the control panel. B. If the EDC control panel is okay, continue to step 4. 4. Check for a short to +12 V. A. Turn the key start ON. Measure the voltage, with the panel disconnected, between the connector MOD−43 pin 1 wire (AB) and ground. If the voltage indicated is greater than +8 V, repair or replace the harness as required. B. If the voltage indicated is approximately +8 V, continue to step 5. 5. Check for a short circuit with positive voltage. A. Disconnect connector MOD−27, turn the key start ON. Measure the voltage between the connector. MOD−43 pin 8 wire (A) and ground. If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors MOD−27, MOD−43 sect. 55, chap. 8, fig. 117, fig. 155), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339).
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
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1012 − VOLTAGE TOO LOW ON THE LOWERING SPEED POTENTIOMETER. Control module: Rear electronic lift control unit. NOTE: The set down speed is maintained and when there is a fault it is considered the top speed. Possible fault modes: 1. Faulty connector 2. Lowering speed control potentiometer faulty 3. Wiring harness faulty 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the drop rate control potentiometer in H9, ch 34. A. Turn the drop rate control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 900 and 100, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 34 wiggle the harness and the connector MOD−43 of the EDC control panel, the connector MOD−27 of the wiring harness of the controller to check for an intermittent circuit. The values of ch 34 will change if an intermittent circuit is indicated; repair or replace as necessary. 2. Check the connector MOD−43 of the EDC control panel and the connector MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check the drop rate control potentiometer. A. Remove the EDC control panel and disconnect the connector MOD−43. While turning the drop rate control knob fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel between: MOD−43 pin 2 and MOD−53 pin 1 MOD−43 pin 2 and MOD−53 pin 6 If the resistances indicated are not between approximately a minimum of 170÷190 and a maximum 400÷420 Ω, replace the control panel. B. If the EDC control panel is okay, continue to step 4. 4. Check for a short to ground. A. Check between: MOD−43 pin 1 wire (AB) and ground MOD−43 pin 2 wire (H) and ground If a short a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5. 5. Check for an open circuit. A. Disconnect the connectors MOD−27 of the controller. Check between: MOD−27 pin 11 wire (AB) and MOD−43 pin 1 wire (AB) MOD−27 pin 31 wire (H) and MOD−43 pin 2 wire (H) MOD−27 pin 1 wire (VB) and MOD−43 pin 6 wire (VB) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors MOD−27, MOD−43 sect. 55, chap. 8, fig. 117, fig. 155), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339). 87666787A2 − 06 − 2009
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
1013 − VOLTAGE TOO HIGH ON THE LOWERING SPEED POTENTIOMETER. Control module: Rear electronic lift control unit. NOTE: The set down speed is maintained and when there is a fault it is considered the top speed. Possible fault modes: 1. Faulty connector 2. Lowering speed control potentiometer faulty 3. Wiring harness faulty 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the drop rate control potentiometer in H9, ch 34. A. Turn the drop rate control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 900 and 100, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 34 wiggle the harness and the connector MOD−43 of the EDC control panel, the connector MOD−27 of the wiring harness of the controller to check for an intermittent circuit. The values of ch 34 will change if an intermittent circuit is indicated; repair or replace as necessary. 2. Check the connector MOD−43 of the EDC control panel and the connector MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check the drop rate control potentiometer. A. Remove the EDC control panel and disconnect the connector MOD−43. While turning the drop rate control knob fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel between: MOD−43 pin 2 and MOD−53 pin 1 MOD−43 pin 2 and MOD−53 pin 6 If the resistances indicated are not between approximately a minimum of 170÷190 and a maximum 400÷420 Ω, replace the control panel. B. If the EDC control panel is okay, continue to step 4. 4. Check for a short to +12 V. A. Turn the key start ON. Measure the voltage, with the panel disconnected, between the connector MOD−43 pin 1 wire (AB) and ground. If the voltage indicated is greater than +8 V, repair or replace the harness as required. B. If the voltage indicated is approximately +8 V, continue to step 5. 5. Disconnect connector MOD−27, turn the key start ON. Check for a short circuit with positive voltage. A. Measure the voltage between the connector: MOD−43 pin 2 wire (H) and ground. If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors MOD−27, MOD−43 sect. 55, chap. 8, fig. 117, fig. 155), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339).
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
13
1021 − VOLTAGE TOO LOW ON THE POSITION/DRAFT CONTROL POTENTIOMETER. Control module: Rear electronic lift control unit. NOTE: The draft control is disabled and only the position control is enabled. Possible fault modes: 1. Faulty connector 2. Position / draft control potentiometer faulty 3. Wiring harness faulty 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the position / draft control potentiometer in H9, ch 40. A. Turn the draft / position control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 900 and 100, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 40 wiggle the wiring harness and the connector MOD−43 of the EDC control panel, the connector MOD−27 of the wiring harness of the controller to check for an intermittent circuit. The values of ch 40 will change if an intermittent circuit is indicated; repair or replace as necessary. 2. Check the connector MOD−43 of the EDC control panel and the connector MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check the position / draft control potentiometer. A. Remove the EDC control panel and disconnect the connector MOD−43. While turning the position / draft control knob fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel between: MOD−43 pin 3 and MOD−53 pin 1 MOD−43 pin 3 and MOD−53 pin 6 If the resistances indicated are not between approximately a minimum of 170÷190 and a maximum 400÷420 Ω, replace the control panel. B. If the EDC control panel is okay, continue to step 4. 4. Check for a short to ground. A. Check between: MOD−43 pin 1 wire (AB) and ground MOD−43 pin 3 wire (HG) and ground If a short a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5. 5. Check for an open circuit. A. Disconnect the connectors MOD−27 of the controller. Check between: MOD−27 pin 11 wire (AB) and MOD−43 pin 1 wire (AB) MOD−27 pin 21 wire (HG) and MOD−43 pin 3 wire (HG) MOD−27 pin 1 wire (VB) and MOD−43 pin 6 wire (VB) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors MOD−27, MOD−43 sect. 55, chap. 8, fig. 117, fig. 155), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339). 87666787A2 − 06 − 2009
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
1022 − VOLTAGE TOO HIGH ON THE POSITION/DRAFT CONTROL POTENTIOMETER. Control module: Rear electronic lift control unit. NOTE: The draft control is disabled and only the position control is enabled. Possible fault modes: 1. Faulty connector 2. Position / draft control potentiometer faulty 3. Wiring harness faulty 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the position / draft control potentiometer in H9, ch 40. A. Turn the draft / position control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 900 and 100, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 40 wiggle the wiring harness and the connector MOD−43 of the EDC control panel, the connector MOD−27 of the wiring harness of the controller to check for an intermittent circuit. The values of ch 40 will change if an intermittent circuit is indicated; repair or replace as necessary. 2. Check the connector MOD−43 of the EDC control panel and the connector MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check the position / draft control potentiometer. A. Remove the EDC control panel and disconnect the connector MOD−43. While turning the position / draft control knob fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel between: MOD−43 pin 3 and MOD−53 pin 1 MOD−43 pin 3 and MOD−53 pin 6 If the resistances indicated are not between approximately a minimum of 170÷190 and a maximum 400÷420 Ω, replace the control panel. B. If the EDC control panel is okay, continue to step 4. 4. Check for a short to +12 V. A. Turn the key start ON. Measure the voltage, with the panel disconnected, between the connector: MOD−43 pin 1 wire (AB) and ground If the voltage indicated is greater than +8 V, repair or replace the harness as required. B. If the voltage indicated is approximately +8 V, continue to step 4. 5. Check for a short circuit with positive voltage. A. Disconnect connector MOD−27, turn the key start ON. Check for a short circuit with positive voltage: MOD−43 pin 3 wire (HG) and ground. If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors MOD−27, MOD−43 sect. 55, chap. 8, fig. 117, fig. 155), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339).
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1023 − REAR LIFT CONTROL PANEL DISCONNECTED. Control module: Rear electronic lift control unit. NOTE: The lift is disabled, it is possible to move the lift only with the external buttons. Possible fault modes: 1. Faulty connector 2. Lift control panel faulty 3. Wiring harness faulty Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the connector MOD−43 of the EDC potentiometer panel, the connectors MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2. 2. Visually check the harness to the potentiometer panel for any damage. A. If the harness is damaged, repair or replace as required. B. If the harness is not damaged, continue to step 3. 3. Check for an open circuit. A. Disconnect the connectors MOD−43 and MOD−27. Measure the continuity between: MOD−27 pin 11 wire (AB) and MOD−43 pin 1 wire (AB) if there is an open circuit, repair or replace the harness as required. B. If the supply is okay, continue to step 4. 4. Check all harness connectors are connected. A. If any connectors are disconnected, connect the connectors as required. B. If the harness is okay, remove and replace the EDC control panel. For the connectors, components and wiring diagrams affected, see (Connectors MOD−27, MOD−43 sect. 55, chap. 8, fig. 117, fig. 155), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339).
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
1024 − CALIBRATE THE ARMS. Control module: Rear electronic lift control unit. NOTE: The lift works, there may be problems with the height of the arms. Possible fault modes: 1. Arms position potentiometer replacement Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the codes appearing simultaneously with this. A. Simultaneously with this code, the following codes may appear: 1042 − Lowering limit potentiometer not set on maximum value 1043 − Lowering speed potentiometer not set on maximum value 1044 − Set position/draft control potentiometer not in position 1068 − Max. raise limit potentiometer not set on maximum value resolve these codes by carrying out the relevant operations. B. If no other code appears, continue with operation 2. 2. Arms lift potentiometer calibration. A. With engine running at a speed of 1200 ÷ 1300 rpm, without any tool on the arms (only a weight of approximately 100 ÷ 200 kg, to prevent the arms locking), taking special care the arms are able to make their full travel; using the work depth knob, capture the lift and take it to its full height. With the arms fully up (you should hear, for a moment, the activation of the pressure relief valve), wait for the indicator light next to the knob to come on, move the arms fully down, after the indicator light comes on showing that the arms have reached their minimum height, switch off the machine and the potentiometer calibration is concluded. NOTE: It is very straightforward to calibrate the solenoid valves and potentiometer by entering the HH programs (see code 1040 − Lift not calibrated) and afterwards run both calibration procedures simultaneously, first calibrating the potentiometer and then calibrating the solenoid valves. Refer to the HH diagnosis program, section 55, chapter 10 in this manual.
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1025 − VOLTAGE TOO LOW ON THE WORKING DEPTH CONTROL POTENTIOMETER. Control module: Rear electronic lift control unit. NOTE: The lift is disabled, it is possible to move the lift only with the external buttons. Possible fault modes: 1. Faulty connector 2. Working depth control potentiometer faulty 3. Wiring harness faulty 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the working depth control potentiometer in H9, ch 33. A. Turn the working depth control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 900 and 100, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 33 wiggle the harness and the connector MOD−40 of the EDC working depth control panel, the connector MOD−27 of the wiring harness of the controller to check for an intermittent circuit. The values of ch 33 will change if an intermittent circuit is indicated; repair or replace as necessary. 2. Check the connector MOD−40 of the EDC working depth control panel and the connector MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check the working depth control potentiometer. A. Remove the EDC working depth control panel and disconnect the connector MOD−40. While turning the working depth control knob fully clockwise and then fully counter clockwise, measure the resistance on the panel between: MOD−40 pin 8 and MOD−40 pin 3 MOD−40 pin 8 and MOD−40 pin 4 If the resistances indicated are not between approximately a minimum of 200 and a maximum of 1200 Ω, replace the working depth control panel. B. If the EDC working depth control panel is okay, continue to step 4. 4. Check for a short to ground. A. Check between: MOD−40 pin 8 wire (HL) and ground MOD−40 pin 3 wire (AB) and ground If a short a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5. 5. Check for an open circuit. A. Disconnect the connectors MOD−27 of the controller. Check between: MOD−27 pin 11 wire (AB) and MOD−40 pin 3 wire (AB) MOD−27 pin 28 wire (HL) and MOD−40 pin 8 wire (HL) MOD−27 pin 1 wire (VB) and MOD−40 pin 4 wire (VB) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors MOD−27, MOD−40 sect. 55, chap. 8, fig. 117, fig. 150), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339). 87666787A2 − 06 − 2009
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
1026 − VOLTAGE TOO HIGH ON THE WORKING DEPTH CONTROL POTENTIOMETER. Control module: Rear electronic lift control unit. NOTE: The lift is disabled, it is possible to move the lift only with the external buttons. Possible fault modes: 1. Faulty connector 2. Working depth control potentiometer faulty 3. Wiring harness faulty 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the working depth control potentiometer in H9, ch 33. A. Turn the draft / position control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 900 and 100, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 33 wiggle the harness and the connector MOD−40 of the EDC working depth control panel, the connector MOD−27 of the wiring harness of the controller to check for an intermittent circuit. The values of ch 33 will change if an intermittent circuit is indicated; repair or replace as necessary. 2. Check the connector MOD−40 of the EDC working depth control panel and the connector MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check the working depth control potentiometer. A. Remove the EDC working depth control panel and disconnect the connector MOD−40. While turning the working depth control knob fully clockwise and then fully counter clockwise, measure the resistance on the panel between: MOD−40 pin 8 and MOD−40 pin 3 MOD−40 pin 8 and MOD−40 pin 4 If the resistances indicated are not between approximately a minimum of 200 and a maximum of 1200 Ω, replace the working depth control panel. B. If the EDC working depth control panel is okay, continue to step 4. 4. Check for a short to +12 V. A. Turn the key start ON. Measure the voltage, with the panel disconnected, between the connector: MOD−40 pin 3 wire (AB) and ground If the voltage indicated is greater than +8 V, repair or replace the harness as required. B. If the voltage indicated is approximately +8 V, continue to step 4. 5. Check for a short circuit with positive voltage. A. Disconnect connector MOD−27, turn the key start ON. Check for a short circuit with positive voltage: MOD−40 pin 8 wire (HL) and ground If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors MOD−27, MOD−40 sect. 55, chap. 8, fig. 117, fig. 150), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339).
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1027 − VOLTAGE TOO LOW ON THE LIFT ARMS POSITION POTENTIOMETER. Control module: Rear electronic lift control unit. NOTE: Lift controls disabled, it is possible to move the arms only with the external buttons. Possible fault modes: 1. Faulty connector 2. Arms position control potentiometer faulty 3. Wiring harness faulty 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the arms position control potentiometer in H9, ch 32. A. Move the lift arms to their full travel. If the values displayed are not between 900 and 100, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 32 wiggle the harness and the connector SEN−132 of the arms position control potentiometer, the main connector C−18 and the connector MOD−27 of the wiring harness of the controller to check for an intermittent circuit. The values of ch 32 will change if an intermittent circuit is indicated; repair or replace as necessary. 2. Check the connector SEN−132 of the arms position control potentiometer, the main connector C−18 and the connector MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check the arms position control potentiometer. A. Remove the arms position control potentiometer and disconnect the connector SEN−132. While turning the arms position control potentiometer fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel side between: SEN−132 pin 1 and SEN−132 pin 2 SEN−132 pin 3 and SEN−132 pin 2 If the resistances indicated are not between approximately 0.4 and 3.7 kΩ, replace the working depth control panel. B. If the arms position control potentiometer is okay, continue to step 4. 4. Check for a short to ground. A. Check between: SEN−132 pin 1 wire (AB) and ground SEN−132 pin 2 wire (VG) and ground If a short a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5. 5. Check for an open circuit. A. Disconnect connector MOD−27 of the controller. Check between: SEN−132 pin 1 wire (AB) and MOD−27 pin 11 wire (AB) SEN−132 pin 2 wire (VG) and MOD−27 pin 25 wire (VG) SEN−132 pin 3 wire (VB) and MOD−27 pin 1 wire (VB) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors C−18, MOD−27, SEN−132 sect. 55, chap. 8, fig. 72, fig. 117, fig. 258), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339). 87666787A2 − 06 − 2009
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
1028 − VOLTAGE TOO HIGH ON THE LIFT ARMS POSITION POTENTIOMETER. Control module: Rear electronic lift control unit. NOTE: Lift controls disabled, it is possible to move the arms only with the external buttons. Possible fault modes: 1. Faulty connector 2. Arms position control potentiometer faulty 3. Wiring harness faulty 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the arms position control potentiometer in H9, ch 32. A. Move the lift arms to their full travel. If the values displayed are not between 900 and 100, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 32 wiggle the harness and the connector SEN−132 of the arms position control potentiometer, the main connector C−18 and the connector MOD−27 of the wiring harness of the controller to check for an intermittent circuit. The values of ch 32 will change if an intermittent circuit is indicated; repair or replace as necessary. 2. Check the connector SEN−132 of the arms position control potentiometer, the main connector C−18 and the connector MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check the arms position control potentiometer. A. Remove the arms position control potentiometer and disconnect the connector SEN−132. While turning the arms position control potentiometer fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel side between: SEN−132 pin 1 and SEN−132 pin 2 SEN−132 pin 3 and SEN−132 pin 2 If the resistances indicated are not between approximately 0.4 and 3.7 kΩ, replace the working depth control panel. B. If the arms position control potentiometer is okay, continue to step 4. 4. Check for a short to +12 V. A. Turn the key start ON. Measure the voltage between: SEN−132 pin 3 wire (AB) and ground If the voltage indicated is greater than +8 V, repair or replace the harness as required. B. If the voltage indicated is approximately +8 V, continue to step 4. 5. Check for a short circuit with positive voltage. A. Disconnect connector MOD−27, turn the key start ON. Check for a short circuit with positive voltage: SEN−132 pin 2 wire (VG) and ground If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors C−18, MOD−27, SEN−132 sect. 55, chap. 8, fig. 72, fig. 117, fig. 258), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339).
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1029 − LIFT SOLENOID VALVES DISCONNECTED. Control module: Rear electronic lift control unit. NOTE: Electronic lift disabled. Possible fault modes: 1. Faulty connector 2. Wiring harness faulty 3. Hydraulic control solenoid valves defective 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check for other fault codes being displayed. A. If any other error code is displayed, continue to these tests. B. If no other error code is displayed, continue to step 2. 2. Check connectors SOL−133 and SOL−134 of the control solenoid valve, the main connector C−18 and the connectors MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Visibly check the harness any damage. A. Check the wiring harness of the connector MOD−27 of the controller, of the connectors SOL−133 and SOL−134 of the control solenoid valve and the main connector C−18 for any damage. If damage to the harness is indicated, repair or replace the harness as required. B. If the harness seems okay, continue to step 4. 4. Check for an open circuit. A. Disconnect the connectors SOL−133, SOL−134 and MOD−27. Measure the continuity between: SOL−133 pin 1 wire (RV) MOD−27 pin 30 wire (RV) SOL−133 pin 2 wire (SG) MOD−27 pin 6 wire (SG) SOL−134 pin 1 wire (GV) MOD−27 pin 18 wire (GV) SOL−134 pin 2 wire (GR) MOD−27 pin 5 wire (GR) if any open circuits are indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors C−18, MOD−27, SOL−133, SOL−134 sect. 55, chap. 8, fig. 72, fig. 117, fig. 259, fig. 260), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339).
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
1031 − CHASSIS HARNESS DISCONNECTED. Control module: Rear electronic lift control unit. NOTE: Electronic lift disabled. Possible fault modes: 1. Faulty connector 2. Wiring harness faulty 3. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check connectors C−18 of the chassis frame wiring. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the chassis harness connectors are okay, continue to step 2. 2. Visually check the chassis harness for any damage. A. If the harness is damaged, repair or replace as required. B. If harness okay, continue to step 3. 3. Check for other fault codes being displayed. A. If any other error code is displayed, continue to these tests. B. If no other error codes are displayed, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors C−18 sect. 55, chap. 8, fig. 72), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339).
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1032 − SHORT CIRCUIT TO +12 V ON THE DRAFT SENSOR. Control module: Rear electronic lift control unit. NOTE: Electronic lift unit operates only in position. Possible fault modes: 1. Faulty connector 2. Faulty draft control sensor 3. Wiring harness faulty 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Test the draft sensor in H9 at channel ch38. A. If the display does not show a number ranging from approximately 300÷400 with no load on the arms, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 38 wiggle the harness and the connector SEN−131 of the draft control sensor, the main connector C−18 and the connector MOD−27 of the wiring harness of the controller to check for an intermittent circuit. The values of ch 38 will change if an intermittent circuit is indicated; repair or replace as necessary. 2. Check connectors SEN−131 of the draft control sensor, the main connector C−18 and the connectors MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Test the draft sensor. A. Remove the draft sensor, disconnect the connector SEN−131 try to make two bridges with loose wires between pin 3 of the sensor and connector and pin 1 of the sensor and connector. Using a tester, measure the voltage on the sensor between: SEN−131 pin 3 and pin 2 pressing and releasing the end of the sensor if the voltage to measure goes no further than 2 V (25% of 8 V of the supply) at 6 V (75% of 8 V of the supply) change the sensor. B. If the sensor is okay, continue to step 4. 4. Check for a short to +12 V. A. Turn the key start ON. Measure the voltage between: SEN−131 pin 3 wire (AB) and ground If the voltage indicated is greater than +8 V, repair or replace the harness as required. B. If the voltage indicated is approximately +8 V, continue to step 5. 5. Check for a short circuit with positive voltage. A. Disconnect connector MOD−27, turn the key start ON. Check for a short circuit with positive voltage: SEN−131 pin 2 wire (ZN) and ground If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors C−18, MOD−27, SEN−131 sect. 55, chap. 8, fig. 72, fig. 117, fig. 257), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339).
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1033 − OPEN CIRCUIT ON THE DRAFT SENSOR. Control module: Rear electronic lift control unit. NOTE: Electronic lift unit operates only in position. Possible fault modes: 1. Faulty connector 2. Faulty draft control sensor 3. Wiring harness faulty 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Test the draft sensor in H9 at channel ch38. A. If the display does not show a number ranging from approximately 300÷400 with no load on the arms, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 38 wiggle the harness and the connector SEN−131 of the draft control sensor, the main connector C−18 and the connector MOD−27 of the wiring harness of the controller to check for an intermittent circuit. The values of ch 38 will change if an intermittent circuit is indicated; repair or replace as necessary. 2. Check connectors SEN−131 of the draft control sensor, the main connector C−18 and the connectors MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Test the draft sensor. A. Remove the draft sensor, disconnect the connector SEN−131 try to make two bridges with loose wires between pin 3 of the sensor and connector and pin 1 of the sensor and connector. Using a tester, measure the voltage on the sensor between: SEN−131 pin 3 and pin 2 pressing and releasing the end of the sensor if the voltage to measure goes no further than 2 V (25% of 8 V of the supply) at 6 V (75% of 8 V of the supply) change the sensor. B. If the sensor is okay, continue to step 4. 4. Check for a short to ground. A. Disconnect connector SEN−121. Check between: SEN−131 pin 2 wire (ZN) and ground SEN−131 pin 3 wire (AB) and ground If a short a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5. 5. Check for an open circuit. A. Disconnect connector MOD−27 of the controller. Check between: SEN−131 pin 1 wire (VB) and MOD−27 pin 1 wire (VB) SEN−131 pin 2 wire (ZN) and MOD−27 pin 7 wire (ZN) SEN−131 pin 3 wire (AB) and MOD−27 pin 11 wire (AB) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors C−18, MOD−27, SEN−131 sect. 55, chap. 8, fig. 72, fig. 117, fig. 257), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339). 87666787A2 − 06 − 2009
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1040 − LIFT NOT CALIBRATED. Control module: Rear electronic lift control unit. NOTE: The lift is not disabled. Possible fault modes: 1. Replace arm lift potentiometer 2. Replace solenoid valve 3. Replace control unit 4. After deleting the memory in H8 Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check whether the lift has been calibrated. A. If the lift has not been calibrated, after replacing the control unit or after using H8 (deleting EEPROM memory) run the lift calibration procedure. Enter the menu HH, select the program H1 then proceed with calibration; without tool 380000843, to access calibration, press and hold down push−button Lifting/work/rapid ground entry SW−34 in rapid ground entry while starting the machine, release it after starting. B. If the transmission has been calibrated, download the correct level of the software and run the calibration procedure again. If the error is repeated, remove and replace the control unit.
NOTE: for a description of the HH menus, refer to section 55 chapter 10.
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
1042 − LOWERING LIMIT POTENTIOMETER NOT SET ON MAXIMUM VALUE. Control module: Rear electronic lift control unit. NOTE: The lift works. Possible fault modes: 1. With code 1024 − Calibrate the arms. Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the lowering limit potentiometer positioning. A. Set the potentiometer on the maximum lower limit, turned fully clockwise. NOTE: When there is code 1024 − Calibrate the arms, the control unit also observes the position of the potentiometers of the lift control panel MOD−43 and codes: 1043 − Lowering speed potentiometer not set on maximum value 1044 − Set position/draft control potentiometer not in position 1068 − Max. raise limit potentiometer not set on maximum value if the various potentiometers are not in the right position to calibrate the lift arms potentiometer. See code 1024.
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1043 − LOWERING SPEED POTENTIOMETER NOT SET ON MAXIMUM VALUE. Control module: Rear electronic lift control unit. NOTE: The lift works. Possible fault modes: 1. With code 1024 − Calibrate the arms. Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the drop rate potentiometer positioning. A. Set the potentiometer on the maximum limit (on the hare), turned fully clockwise. NOTE: When there is code 1024 − Calibrate the arms, the control unit also observes the position of the potentiometers of the lift control panel MOD−43 and codes: 1042 − Lowering limit potentiometer not set on maximum value 1044 − Set position/draft control potentiometer not in position 1068 − Max. raise limit potentiometer not set on maximum value if the various potentiometers are not in the right position to calibrate the lift arms potentiometer. See code 1024.
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1044 − SET POSITION/DRAFT CONTROL POTENTIOMETER NOT IN POSITION. Control module: Rear electronic lift control unit. NOTE: The lift works. Possible fault modes: 1. With code 1024 − Calibrate the arms. Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the position/draft potentiometer positioning. A. Set the potentiometer on the position, turned fully counter clockwise. NOTE: When there is code 1024 − Calibrate the arms, the control unit also observes the position of the potentiometers of the lift control panel MOD−43 and codes: 1042 − Lowering limit potentiometer not set on maximum value 1043 − Lowering speed potentiometer not set on maximum value 1068 − Max. raise limit potentiometer not set on maximum value if the various potentiometers are not in the right position to calibrate the lift arms potentiometer. See code 1024.
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1063 − OPEN CIRCUIT ON THE LOWERING CONTROL SOLENOID VALVE. Control module: Rear electronic lift control unit. NOTE: The lift is disabled. Possible fault modes: 1. Faulty connector 2. Faulty EDC lowering solenoid valve 3. Wiring harness faulty 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the lowering solenoid valve in H9 at channel ch31. A. Activate the solenoid valve if the display does not show a number ranging from approximately 0÷10 with solenoid valve not activated 550÷700 with solenoid valve activated, continue to phase 2. B. If the values displayed are okay, while still in H9, ch31 wiggle the harness and the connector SOL−133 of the lowering solenoid valve, the main connector C−18 and the connector MOD−27 of the wiring harness of the controller to check for an intermittent circuit. The values of ch 31 will change if an intermittent circuit is indicated; repair or replace as necessary. 2. Check the connector SOL−133 of the EDC lowering solenoid valve, the main connector C−18 and the connector MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check the EDC lowering solenoid valve. A. Disconnect connector SOL−133 of the EDC lowering solenoid valve. Measure the resistance between the terminals of the solenoid valve. SOL−133 pin 1 and pin 2 if the resistance indicated is not approximately 7.5 Ω, remove and replace the EDC lowering solenoid valve. B. If the solenoid is okay, continue to step 4. 4. Check for a short to ground. A. Disconnect connector MOD−27 of the controller. Check between the connector: SOL−133 pin 1 wire (RV) and ground SOL−133 pin 2 wire (SG) and ground If a short a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5. 5. Check for an open circuit. A. Disconnect connector MOD−27 of the controller. Check between: SOL−133 pin 2 wire (SG) and MOD−27 pin 6 wire (SG) SOL−133 pin 1 wire (RV) and MOD−27 pin 30 wire (RV) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors C−18, MOD−27, SOL−133 sect. 55, chap. 8, fig. 72, fig. 117, fig. 259), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339).
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
1064 − OPEN CIRCUIT ON THE LIFTING CONTROL SOLENOID VALVE. Control module: Rear electronic lift control unit. NOTE: The lift is disabled. Possible fault modes: 1. Faulty connector 2. EDC lifting solenoid valve faulty 3. Wiring harness faulty 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the lifting solenoid valve in H9 at channel ch30. A. Activate the solenoid valve if the display does not show a number ranging from approximately 0÷10 with solenoid valve not activated 550÷700 with solenoid valve activated, continue to phase 2. B. If the values displayed are okay, while still in H9, ch31 wiggle the harness and the connector SOL−134 of the lifting solenoid valve, the main connector C−18 and the connector MOD−27 of the wiring harness of the controller to check for an intermittent circuit. The values of ch 30 will change if an intermittent circuit is indicated; repair or replace as necessary. 2. Check the connector SOL−134 of the EDC lifting solenoid valve, the main connector C−18 and the connector MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check the EDC lifting solenoid valve. A. Disconnect connector SOL−134 of the EDC lifting solenoid valve. Measure the resistance between the terminals of the solenoid valve. SOL−134 pin 1 and pin 2 if the resistance indicated is not approximately 7.5 Ω, remove and replace the EDC lifting solenoid valve. B. If the solenoid is okay, continue to step 4. 4. Check for a short to ground. A. Disconnect connector MOD−27 of the controller. Check between the connector: SOL−134 pin 1 wire (GV) and ground SOL−134 pin 2 wire (GR) and ground If a short a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5. 5. Check for an open circuit. A. Check between: SOL−134 pin 2 wire (GR) and MOD−27 pin 5 wire (GR) SOL−134 pin 1 wire (GV) and MOD−27 pin 18 wire (GV) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors C−18, MOD−27, SOL−134 sect. 55, chap. 8, fig. 72, fig. 117, fig. 260), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339).
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1065 − LOWERING CONTROL SOLENOID VALVE SHORTED. Control module: Rear electronic lift control unit. NOTE: The lift is disabled. Possible fault modes: 1. Faulty connector 2. Faulty EDC lowering solenoid valve 3. Wiring harness faulty 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the lowering solenoid valve in H9 at channel ch31. A. Activate the solenoid valve if the display does not show a number ranging from approximately 0÷10 with solenoid valve not activated 550÷700 with solenoid valve activated, continue to phase 2. B. If the values displayed are okay, while still in H9, ch31 wiggle the harness and the connector SOL−133 of the lowering solenoid valve, the main connector C−18 and the connector MOD−27 of the wiring harness of the controller to check for an intermittent circuit. The values of ch 31 will change if an intermittent circuit is indicated; repair or replace as necessary. 2. Check the connector SOL−133 of the EDC lowering solenoid valve, the main connector C−18 and the connector MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check the EDC lowering solenoid valve. A. Disconnect connector SOL−133 of the EDC lowering solenoid valve. Measure the resistance between the terminals of the solenoid valve. SOL−133 pin 1 and pin 2 if the resistance indicated is not approximately 7.5 Ω, remove and replace the EDC lowering solenoid valve. B. If the solenoid is okay, continue to step 4. 4. Check for a short circuit. A. Disconnect connector MOD−27 of the controller. Check between: SOL−133 pin 2 wire (SG) and SOL−133 pin 1 wire (RV) If a short circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors C−18, MOD−27, SOL−133 sect. 55, chap. 8, fig. 72, fig. 117, fig. 259), (Components, diagram 5÷8. sect 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339).
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1066 − LIFTING CONTROL SOLENOID VALVE SHORTED. Control module: Rear electronic lift control unit. NOTE: The lift is disabled. Possible fault modes: 1. Faulty connector 2. EDC lifting solenoid valve faulty 3. Wiring harness faulty 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the lifting solenoid valve in H9 at channel ch30. A. Activate the solenoid valve if the display does not show a number ranging from approximately 0÷10 with solenoid valve not activated 550÷700 with solenoid valve activated, continue to phase 2. B. If the values displayed are okay, while still in H9, ch30 wiggle the harness and the connector SOL−134 of the lifting solenoid valve, the main connector C−18 and the connector MOD−27 of the wiring harness of the controller to check for an intermittent circuit. The values of ch 30 will change if an intermittent circuit is indicated; repair or replace as necessary. 2. Check the connector SOL−134 of the EDC lifting solenoid valve, the main connector C−18 and the connector MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3. 3. Check the EDC lifting solenoid valve. A. Disconnect connector SOL−134 of the EDC lifting solenoid valve. Measure the resistance between the terminals of the solenoid valve. SOL−134 pin 1 and pin 2 if the resistance indicated is not approximately 7.5 Ω, remove and replace the EDC lifting solenoid valve. B. If the solenoid is okay, continue to step 4. 4. Check for a short circuit. A. Disconnect connector MOD−27 of the controller. Check between: SOL−134 pin 2 wire (GR) and SOL−134 pin 1 wire (GV) If a short circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors C−18, MOD−27, SOL−134 sect. 55, chap. 8, fig. 72, fig. 117, fig. 260), (Components, diagram 5÷8. sect. 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339).
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1068 − MAX. RAISE LIMIT POTENTIOMETER NOT SET ON MAXIMUM VALUE. Control module: Rear electronic lift control unit. NOTE: The lift works. Possible fault modes: 1. With code 1024 − Calibrate the arms. Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the lifting limit potentiometer positioning. A. Set the potentiometer on the fully raised position, turned fully clockwise. NOTE: When there is code 1024 − Calibrate the arms, the control unit also observes the position of the potentiometers of the lift control panel MOD−43 and codes: 1042 − Lowering limit potentiometer not set on maximum value 1043 − Lowering speed potentiometer not set on maximum value 1044 − Set position/draft control potentiometer not in position if the various potentiometers are not in the right position to calibrate the lift arms potentiometer. See code 1024.
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1080 − VOLTAGE TOO LOW ON THE LOWERING LIMIT POTENTIOMETER. Control module: Rear electronic lift control unit. NOTE: The lower limit set when the fault code appears is considered the maximum lower limit. Possible fault modes: 1. Faulty connector 2. Faulty lower limit control potentiometer 3. Wiring harness faulty 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the lower limit control potentiometer in H9, ch 36. A. Turn the lower limit control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 900 and 100, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 36 wiggle the harness and the connector MOD−43 of the EDC control panel, the connector MOD−27 of the wiring harness of the controller to check for an intermittent circuit. The values of ch 36 will change if an intermittent circuit is indicated; Repair or replace as necessary. 2. Check the connector MOD−43 of the EDC control panel and the connector MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the lower limit control potentiometer. A. Remove the EDC control panel and disconnect the connector MOD−43. While turning the lower limit control knob fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel between: MOD−43 pin 5 and MOD−43 pin 1 MOD−43 pin 5 and MOD−43 pin 6 If the resistances indicated are not between approximately a minimum of 170÷190 and a maximum 400÷420 Ω, replace the control panel. B. If the EDC control panel is okay, continue to step 4. 4. Check for a short to ground. A. Check between: MOD−43 pin 5 wire (AN) and ground MOD−43 pin 1 wire (AB) and ground If a short a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5. 5. Check for an open circuit. A. Disconnect the connectors MOD−27 of the controller. Check between: MOD−27 pin 1 wire (VB) and MOD−43 pin 6 wire (VB) MOD−27 pin 11 wire (AB) and MOD−43 pin 1 wire (AB) MOD−27 pin 24 wire (AN) and MOD−43 pin 5 wire (AN) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors MOD−27, MOD−43 sect. 55, chap. 8, fig. 117, fig. 155), (Components, diagram 5÷8. sect. 55, chap. 6, page 337), (Diagram 5, sect. 55, chap.6, page 339). 87666787A2 − 06 − 2009
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1081 − VOLTAGE TOO HIGH ON THE LOWERING LIMIT POTENTIOMETER. Control module: Rear electronic lift control unit. NOTE: The lower limit set when the fault code appears is considered the maximum lower limit. Possible fault modes: 1. Faulty connector 2. Faulty lower limit control potentiometer 3. Wiring harness faulty 4. Faulty controller Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the lower limit control potentiometer in H9, ch 36. A. Turn the lower limit control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 900 and 100, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 36 wiggle the harness and the connector MOD−43 of the EDC control panel, the connector MOD−27 of the wiring harness of the controller to check for an intermittent circuit. The values of ch 36 will change if an intermittent circuit is indicated; Repair or replace as necessary. 2. Check the connector MOD−43 of the EDC control panel and the connector MOD−27 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the lower limit control potentiometer. A. Remove the EDC control panel and disconnect the connector MOD−43. While turning the lower limit control knob fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel between: MOD−43 pin 5 and MOD−43 pin 1 MOD−43 pin 5 and MOD−43 pin 6 If the resistances indicated are not between approximately a minimum of 170÷190 and a maximum 400÷420 Ω, replace the control panel. B. If the EDC control panel is okay, continue to step 4. 4. Check for a short to +12 V. A. Turn the key start ON. Measure the voltage, with the panel disconnected, between the connector MOD−43 pin 1 wire (AB) and ground If the voltage indicated is greater than +8 V, repair or replace the harness as required. B. If the voltage indicated is approximately +8 V, continue to step 5. 5. Check for a short circuit with positive voltage. A. Disconnect connector MOD−27, turn the key start ON. Measure the voltage between the connector. MOD−43 pin 5 wire (AN) and ground If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re−occurs, remove and replace the controller. For the connectors, components and wiring diagrams affected, see (Connectors MOD−27, MOD−43 sect. 55, chap. 8, fig. 117, fig. 155), (Components, diagram 5÷8. sect. 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339).
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TRANSMISSION FAULT CODES 2011 − CLUTCH PEDAL POTENTIOMETER SIGNAL TOO LOW. Control module: Power Shuttle control unit NOTE: The tractor can be moved using the Shuttle control lever. Possible fault modes: 1. 2. 3. 4.
Faulty connector Clutch pedal potentiometer fault Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the clutch pedal potentiometer in H9, channel ch1. A. Cycle clutch pedal. If the values displayed do not change continuously between 200÷300 (pedal pressed) and 800÷950 (pedal released), continue to phase 2. B. If the values displayed are okay, while still in H9 channel ch1, wiggle the harness, the clutch pedal potentiometer connector SEN−153 and the connectors of the control unit MOD−150 to check for an intermittent circuit. The values of channel ch1 will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check connectors SEN−153 and MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the clutch pedal potentiometer. A. Disconnect connector SEN−153. While operating the clutch pedal, measure the resistance between the component side of connector: SEN−153 pin 2 and SEN−153 pin 3 must indicate approximately between 1.0÷0.9 kΩ and 3.5÷4.0 kΩ SEN−153 pin 2 and SEN−153 pin 1 must indicate approximately between 0.2÷0.4 kΩ and 3.0−3.5 kΩ If the indicated resistances are not okay, remove and replace the clutch pedal potentiometer. B. If the clutch pedal potentiometer is okay, continue to step 4. 4. Check for an open circuit. A. Disconnect the connector of the control unit MOD−150. Check between: SEN−153 pin 1, wire (AB) and MOD−150 pin 11, wire (AB) SEN−153 pin 2, wire (S) and MOD−150 pin 7, wire (S) SEN−153 pin 3, wire (VN) and MOD−150 pin 1, wire (VN) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue with step 5. 5. Check for a short to ground. A. Check between the connector: SEN−153 pin 2, wire (S) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors MOD−150 and SEN−153, sect. 55, chap. 8, figs. 280−281 and fig. 284), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 24−26, sect. 55, chap. 6, pages 385−389). 87666787A2 − 06 − 2009
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2012 − CLUTCH PEDAL POTENTIOMETER SIGNAL TOO HIGH. Control module: Power Shuttle control unit NOTE: The tractor can be moved using the Shuttle control lever. Possible fault modes: 1. 2. 3. 4.
Faulty connector Clutch pedal potentiometer fault Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the clutch pedal potentiometer in H9, channel ch1. A. Cycle clutch pedal. If the values displayed do not change continuously between 200÷300 (pedal pressed) and 800÷950 (pedal released), continue to phase 2. B. If the values displayed are okay, while still in H9 channel ch1, wiggle the harness, the clutch pedal potentiometer connector SEN−153 and the connectors of the control unit MOD−150 to check for an intermittent circuit. The values of channel ch1 will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check connectors MOD−150 and SEN−153. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the clutch pedal potentiometer. A. Disconnect connector SEN−153. While operating the clutch pedal, measure the resistance between the component side of connector: SEN−153 pin 2 and SEN−153 pin 3 must indicate approximately between 1.0÷0.9 kΩ and 3.5÷4.0 kΩ SEN−153 pin 2 and SEN−153 pin 1 must indicate approximately between 0.2÷0.4 kΩ and 3.0−3.5 kΩ If the indicated resistances are not okay, remove and replace the clutch pedal potentiometer. B. If the clutch pedal potentiometer is okay, continue to step 4. 4. Check for short to a positive voltage. A. Turn the ignition key switch to ON position. Measure the voltage between connector: SEN−153 pin 2, wire (S) and ground If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated, continue to step 5. 5. Check for a short to + 8 or + 12 V. A. With the keystart ON. Measure the voltage between the connector: SEN−153 pin 1, wire (AB) and and ground If the indicated voltage is not approximately + 5 V, repair or replace the harness as required. B. If the voltage indicated is approximately +5 V, download the correct software release. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors MOD−150 and SEN−153, sect. 55, chap. 8, figs. 280−281 and fig. 284), (Components, diagram 24÷28, sect. 55, chap. 6, page 383), (Diagram 24−26, sect. 55, chap. 6, pages 385−389).
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2013 − HI AND LO BUTTONS PRESSED AT THE SAME TIME. Control module: Power Shuttle control unit NOTE: With this fault the HIGH and LOW functions cannot be selected, but the transmission remains operative. Possible fault modes: 1. 2. 3. 4.
Faulty connector Switches faulty Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the switches in H5. A. Press first the LO switch then the HI switch and the display will show respectively d17 and d18, otherwise continue to phase 2. B. If the values displayed are okay, while still in H5, wiggle the harness, the gear lever connector SW−183, the main connector C−9 and the connector of the control unit MOD−150 to check for an intermittent circuit. The values displayed in H5 will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check connectors MOD−150 and SW−183. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the HI and LO buttons. A. Disconnect connector SW−183. Measure continuity with a tester between: SW−183 pin 3 and pin 1 for the LO button SW−183 pin 3 and pin 2 for the HI button with the buttons pressed there will be continuity, on releasing the button it will be broken off. If this is not the case, repair or replace the lever as required. B. If the button operation is okay, continue to step 4 4. Check for a short circuit between the outputs of the switches on the gear lever. A. Check on the connector SEN−183: SW−183 pin 1 and pin 2 if a short circuit is indicated, repair or replace the lever as required. B. If there is no short circuit, continue to step 5. 5. Check for a short circuit on the wiring harness. A. Disconnect connector MOD−150. Check between: MOD−150 pin 14 wire (MB) and pin 24 wire (C) MOD−150 pin 14 wire (MB) and pin 20 wire (AV) MOD−150 pin 24 wire (C) and pin 20 wire (AV) if a short circuit is indicated, repair or replace harness as required B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, MOD−150 and SW−183, sect. 55, chap. 8, fig. 42, fig. 280 and fig. 327), (Components, diagram 24÷28, sect. 55, chap. 6, page 383), (Diagram 27, sect. 55, chap. 6, page 391).
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2021 − TRANSMISSION HARNESS DISCONNECTED. Control module: Power Shuttle control unit NOTE: The tractor is not operative. Possible fault modes: 1. Faulty connectors 2. Wiring fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the transmission harness connector C−9. A.Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. For the connectors, components and wiring diagrams affected, see (Connectors C−9, sect. 55, chap. 8, figs. 42−44), (Components, diagram 24÷28, sect. 55, chap. 6, page 383), (Diagram 25−27, sect. 55, chap. 6, pages 387−391).
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
2024 − ALL CLUTCHES NOT CALIBRATED. Control module: Power Shuttle control unit NOTE: The tractor runs, but movement is abrupt. Possible fault modes: 1. Transmission not calibrated 2. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check whether the transmission has been calibrated. A. If the transmission has not been calibrated since replacing the control unit or since using H8 (deleting EEPROM memory) run the transmission calibration procedure. Enter the menu HH, select the program H1 then proceed with calibration; without tool 380000843, to access calibration, press and hold down push−button HOME on the dashboard while starting the machine. B. If the transmission has been calibrated, download the correct level of the software and run the calibration procedure again. If the error is repeated, remove and replace the control unit.
NOTE: for a description of the HH menus, refer to section 55 chapter 10.
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2026 − ENGINE SPEED TOO HIGH. Control module: Power Shuttle control unit NOTE: The transmission control unit, via CAN, has seen the engine speed reach too high values for a few seconds. Possible fault modes: 1. Engine overrevving 2. Sensor faulty Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. With the generation of this code, by the transmission control unit, there will be other codes on the control panel, so resolve these and as a result this will disappear as well. NOTE: The control unit of the power shuttle, via CAN bus through the ADIC dashboard, probably sees engine overrevving, so it sets in motion a clutch protection sequence, once the speed returns to normal values the code will disappear.
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2035 − THE SOLENOID OF THE DUMP VALVE SHORTED TO + 12 V. Control module: Power Shuttle control unit NOTE: The tractor is not operative. Possible fault modes: 1. Wiring fault 2. ECU fault 3. Solenoid valve faulty Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the connector of the dump solenoid valve SOL−140, the main connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check for a short to + 12 V. A. Disconnect connector SOL−140. Turn the ignition key ON. Measure the voltage between connector: SOL−140 pin 1, wire (ZN) and ground SOL−140 pin 2, wire (ZB) and ground If a voltage is indicated, turn the key−start OFF. Disconnect the control unit connector MOD−150. Turn the ignition key ON. If a voltage is still indicated, repair or replace the harness as required. B. If no voltage is indicated, download the correct level of software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, SOL−140 and MOD−150 sect. 55, chap. 8, figs. 42−44, fig. 269 and figs. 280−281), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 25−27, sect. 55, chap 6, pages 387−391).
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2036 − THE SOLENOID OF THE DUMP VALVE HAS OPEN CIRCUIT OR IS SHORTED TO GROUND. Control module: Power Shuttle control unit NOTE: The tractor runs normally but the hydraulic safety, provided by the dump solenoid valve when the clutch pedal is pressed, is no longer present. Possible fault modes: 1. Solenoid valve faulty 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the connector of the dump solenoid valve SOL−140, the main connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check the dump solenoid valve. A. Disconnect connector SOL−140. Measure the resistance in the solenoid valve: SOL−140 between pins 1 and 2 If the resistance indicated is not approximately 7.5 Ω, remove and replace the dump solenoid valve. B. If the resistance is okay, continue to step 3. 3. Check the dump solenoid vale for a short to ground. A. Check between the component side of connector: SOL−140 pin 1 and ground SOL−140 pin 2 and ground If a short to ground is indicated, remove and replace the dump solenoid valve. B. If a short to ground is not indicated, continue to step 4. 4. Check for a short to ground. A. Disconnect the connectors MOD−150. Check between: SOL−140 pin 2, wire (ZB) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5. 5. Check for an open circuit. A. Check between: SOL−140 pin 1, wire (ZN) and ground SOL−140 pin 2, wire (ZB) and MOD−150 pin 18, wire (ZB) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, SOL−140 and MOD−150 sect. 55, chap. 8, figs. 42−44, fig. 269 and figs. 280−281), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 25−27, sect. 55, chap 6, pages 387−391).
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2037 − CLUTCH PEDAL SWITCH CIRCUIT OPEN. Control module: Power Shuttle control unit NOTE: The tractor is not operative. Possible fault modes: 1. 2. 3. 4. 5.
Faulty connector Incorrect clutch disconnect switch adjustment Clutch disconnect switch faulty Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the clutch disconnect switch in H7 channel ch1. A. Position the forward/reverse shuttle lever into gear. Operate the clutch pedal from fully depressed to fully released. The display should indicate the switch is closed before 15%. If the switch is turned on much after 15% of pedal travel, adjust the switch as required. If the display does not indicate the switch has closed, continue to step 2. B. If the switch is adjusted correctly, while in H7 Channel 1 wiggle the harness, the disconnect switch connector SW−151 and the connectors of the control unit MOD−150 to check for an intermittent circuit. Channel 1 values will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check the clutch disconnect switch connector SW−151, the shuttle lever assembly connector SW−152, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the clutch disconnect switch. A. Disconnect connector SW−151. Check between the component side of connector: SW−151 pin 2 and pin 3 should indicate a closed circuit with the pedal released and an open circuit with the pedal depressed. SW−151 pin 1 and pin 4 should indicate an open circuit with the pedal released and a closed circuit with the pedal depressed. If the switch is not okay, remove and replace the clutch disconnect switch. B. If the switch is okay, continue to step 4. 4. Check for an open circuit. A. Turn ignition switch to OFF position. Disconnect the connectors MOD−150, SW−152. Check between: SW−151 pin 1, wire (B) and MOD−150 pin 19, wire (B) SW−151 pin 2, wire (B) and MOD−150 pin 19, wire (B) SW−151 pin 3, wire (RN) and MOD−150 pin 2, wire (RN) SW−151 pin 2, wire (B) and SW−152 pin 7, wire (B) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors MOD−150, SW−151 and SW−152 sect. 55, chap. 8, figs. 280−281, fig. 282 and fig. 283), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 24−26, sect. 55, chap. 6, pages 385−389).
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2047 − CLUTCH PEDAL SWITCH TOO HIGH. Control module: Power Shuttle control unit NOTE: The tractor starting movement may be abrupt. Possible fault modes: 1. Incorrect switch calibration 2. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Calibrate the clutch pedal. Enter the HH diagnostics program using tool 380000843. Select the control unit SB, enter the diagnostics program H7 at channel ch1. A. Position the shuttle lever not on neutral (either forward or reverse gear), slowly pressing the clutch pedal, observe the behaviour of the clutch pedal switch on the display: − pressing the pedal the switch status must change above 5%. From the ON status it must move onto OFF (the display, with the shuttle lever not on neutral, will show the switch status, otherwise with the lever on neutral you need to pay more attention to hear the noise of the change in switch status). − releasing the pedal the switch status must change under 15%. From the OFF status it must move onto ON. If the situation is not respected, make the due adjustments with the switch retaining screws. B. If the adjustment is okay, continue to operation 2. 2. Check the clutch disconnect switch connector SW−151, the shuttle lever assembly connector SW−152, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the shuttle lever supply. Disconnect connector SW−152. Turn the ignition key onto ON and test between: SW−152 pin 5 wire (MV) and ground there should be a voltage of approximately 12 V, otherwise replace the wiring harness or repair as required. B. If the voltage is okay, continue to operation 4. 4. Check for an open circuit on the +12 VD line (clutch A and B supply). A. Disconnect the connectors MOD−150 and, SW−151. Check between the pins of the connectors: SW−152 pin 7 wire (B) and SW−151 pin 2 wire (B) SW151 pin 3 wire (RN) and MOD−150 pin 2 wire (RN) if there are any open circuits replace the wiring harness or repair as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors MOD−150, SW−151 and SW−152 sect. 55, chap. 8, figs. 280−281, fig. 282 and fig. 283), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 24−26, sect. 55, chap. 6, pages 385−389). NOTE: for a description of the HH menus, refer to section 55 chapter 10.
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2048 − CLUTCH PEDAL SWITCH SET TOO LOW. Control module: Power Shuttle control unit NOTE: The tractor starting movement may be abrupt. Possible fault modes: 1. Incorrect switch calibration 2. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Calibrate the clutch pedal. Enter the HH diagnostics program using tool 380000843. Select the control unit SB, enter the diagnostics program H7 at channel ch1. A. Position the shuttle lever not on neutral (either forward or reverse gear), slowly pressing the clutch pedal, observe the behaviour of the clutch pedal switch on the display: − pressing the pedal the switch status must change above 5%. From the ON status it must move onto OFF (the display, with the shuttle lever not on neutral, will show the switch status, otherwise with the lever on neutral you need to pay more attention to hear the noise of the change in switch status). − releasing the pedal the switch status must change under 15%. From the OFF status it must move onto ON. If the situation is not respected, make the due adjustments with the switch retaining screws. B. If the adjustment is okay, continue to operation 2. 2. Check the clutch disconnect switch connector SW−151, the shuttle lever assembly connector SW−152, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check for a short to +12 VF (on the clutch A and B supply, +12 VD). A. Disconnect the connectors MOD−150, SW−152 and, SW−151 and turn the ignition switch ON. Check between the pins of the connectors: SW−151 pin 2 wire (RN) and ground if there is a short to positive, replace the wiring harness or repair as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors MOD−150, SW−151 and SW−152 sect. 55, chap. 8, figs. 280−281, fig. 282 and fig. 283), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 24−26, sect. 55, chap. 6, pages 385−389). NOTE: for a description of the HH menus, refer to section 55 chapter 10.
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2051 − OPEN CIRCUIT ON THE TRANSMISSION OIL TEMPERATURE SENSOR. Control module: Power Shuttle control unit NOTE: The tractor is in working order, but it may behave jerkily, inching (press and release the clutch pedal to set off) could require a higher pedal position than under normal working conditions for the machine. Possible fault modes: 1. 2. 3. 4.
ECU fault Oil temperature sensor faulty Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the transmission oil temperature sensor in H9, channel ch2. A. The value will change dependant on temperature, at approximately 20 C the value displayed will be approximately 500, if the reading is not correct, proceed to phase 2. B. If the values displayed are okay, while still in H9, channel ch2, wiggle the harness, the transmission oil temperature sensor connector SEN−148, the connectors of the control unit MOD−150 and the main connector C−9 to check for an intermittent circuit. The values of channel ch2 will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check the temperature sensor connector SEN−148, the connectors of the control unit MOD−150 and the main connector C−9. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the temperature sensor. A. Disconnect connector SEN−148. Measure the resistance between the temperature sensor terminals. If the resistance indicated is not 460 ÷ 540 Ω at 25 C, remove and replace the temperature sensor. B. If the temperature sensor is okay, continue to step 4. 4. Check for an open circuit. A. Disconnect the connectors MOD−150 of the control unit. Check between: SEN−148 pin B, wire (HM) and MOD−150 pin 8, wire (HM) SEN−148 pin A, wire (VN) and MOD−150 pin 1, wire (VN) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue with step 5. 5. Check for short to a positive voltage. A. Turn the ignition key ON. Measure the voltage between the connector: SEN−148 pin B, wire (HM) and ground If a short to a positive voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, SEN−148 and MOD−150, sect. 55, chap. 8, figs. 42−44, fig. 279 and figs. 280−281), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 25−27, sect. 55, chap. 6, pages 387−391).
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2052 − SHORT CIRCUIT TO GROUND ON THE TRANSMISSION OIL TEMPERATURE SENSOR. Control module: Power Shuttle control unit NOTE: The tractor is in working order, but it may behave jerkily, inching (press and release the clutch pedal to set off) could require a higher pedal position than under normal working conditions for the machine. Possible fault modes: 1. 2. 3. 4. 5.
Oil temperature ECU fault Oil temperature sensor shorted Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the transmission oil temperature sensor in H9, channel ch2. A. The value will change dependant on temperature, at approximately 20 C the value displayed will be approximately 500, if the reading is not correct, proceed to phase 2. B. If the values displayed are okay, while still in H9, channel ch2, wiggle the harness, the transmission oil temperature sensor connector SEN−148, the connectors of the control unit MOD−150 and the main connector C−9 to check for an intermittent circuit. The values of channel ch2 will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check the temperature sensor connector SEN−148, the connectors of the control unit MOD−150 and the main connector C−9. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the temperature sensor. A. Disconnect connector SEN−148. Measure the resistance between the temperature sensor terminals. If the resistance indicated is not 460 ÷ 540 Ω at 25 C, remove and replace the temperature sensor. B. If the temperature sensor is okay, continue to step 4. 4. Check the temperature sensor for a short to ground. A. Check between the component side of connector: SEN−148 pin A and ground SEN−148 pin B and ground If short to ground is indicated, remove and replace the temperature sensor. B. If the temperature sensor is okay, continue to step 5. 5. Check for a short to ground. A. Disconnect the connectors MOD−150 of the control unit. Check between the connector: SEN−148 pin B, wire (HM) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, SEN−148 and MOD−150, sect. 55, chap. 8, figs. 42−44, fig. 279 and figs. 280−281), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 25−27, sect. 55, chap. 6, pages 387−391).
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2059 − SHUTTLE LEVER SWITCHES DISAGREE. Control module: Power Shuttle control unit NOTE: Open circuit between the neutral switch and the control unit, or the shuttle lever assembly is faulty. The control unit gives code N (put the shuttle lever into neutral) and transmission disabled. Possible fault modes: 1. 2. 3. 4.
Faulty connector Faulty shuttle lever assembly Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the other error codes. A. If error codes 2070, 2071, 2072 or 2073 are displayed, continue to these tests. B. If no other error code is displayed, continue to step 2. 2. Check the shuttle lever connector SW−152 and the connector of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the shuttle lever forward switch. A. Disconnect the shuttle lever connector SW−152. Move the shuttle lever onto forward gear and measure the resistance in the connector: SW−152 between pin 1 and pin 2 if the resistance indicated is not approximately 0.56 kΩ, and then in neutral approximately 2.76 kΩ, remove and replace the shuttle lever assembly. B. If the shuttle lever switch is okay, continue to step 4. 4. Check the shuttle lever reverse gear switch. A. Move the shuttle lever to reverse and measure the resistance in the connector: SW−152 between pin 1 and pin 2 if the resistance indicated is not approximately 0.56 kΩ, and then in neutral approximately 2.76 kΩ, remove and replace the shuttle lever assembly. B. If the shuttle lever switch is okay, continue to step 5. 5. Check for a short between the wires carrying the forward and reverse gear switch signal to the control unit. A. Disconnect the connector of the control unit MOD−150. Check for a short on the connector between: MOD−150 pin 9 wire (AN) and MOD−150 pin 15 wire (A) if there is continuity, repair or replace the harness as required. B. If the harness is okay, remove and replace the shuttle lever assembly. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors MOD−150, SW−152 sect. 55, chap. 8, figs. 280−281 and fig. 283), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 25−27 sect. 55, chap. 6, pages 387−391).
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2061 − SHUTTLE/HI−LO SYNCHRO POTENTIOMETER SIGNAL TOO HIGH. Control module: Power Shuttle control unit NOTE: The tractor only runs in LO forward gear and reverse. Possible fault modes: 1. 2. 3. 4.
Faulty connector Potentiometer faulty Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the potentiometer in H9. A. Enter the HH diagnostics programs in H9 channel ch72. The display will show a number, depending on the position of the synchronizer, ranging from 700÷900 with synchronizer on reverse drive and 250÷300 with synchronizer on forward drive. B. If the values displayed are okay, while still in H9, wiggle the harness, the potentiometer connector SEN−203, the main cable connector C−9, and the connector of the control unit MOD−150 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the potentiometer connector SEN−203, the main cable connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the potentiometer. A. Disconnect connector SEN−203, then remove it. Measure the resistance between: SEN−203 pin 1 and pin 2 SEN−203 pin 3 and pin 2 If, on turning the potentiometer, the indicated resistance varies from a minimum of approximately 400 W to a maximum of approximately 3700 W otherwise replace the potentiometer. B. If the potentiometer is okay, continue to step 4. 4. Check for short to a positive voltage. A. Turn the ignition key ON. Measure the voltage between the connector: SEN−203 pin 2, wire (HV) and ground If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated, continue to step 5. 5. Check for a short to + 8 or + 12 V. A. With the keystart ON. Measure the voltage between the connector: SEN−203 pin 1, wire (AB) and ground If the indicated voltage is not approximately + 5 V, repair or replace the harness as required. B. If the voltage is approximately +5 V, download the correct software release. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, MOD−150, and SEN−203 sect. 55, chap. 8, fig. 42, fig. 280 and fig. 330), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 27, sect. 55, chap. 6, page 391).
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2062 − SHUTTLE/HI−LO SYNCHRO POTENTIOMETER SIGNAL TOO LOW. Control module: Power Shuttle control unit NOTE: The tractor only runs in LO forward gear and reverse. Possible fault modes: 1. 2. 3. 4.
Faulty connector Potentiometer faulty Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the potentiometer in H9. A. Enter the HH diagnostics programs in H9 channel ch72. The display will show a number, depending on the position of the synchronizer, ranging from 700÷900 with synchronizer on reverse drive and 250÷300 with synchronizer on forward drive. B. If the values displayed are okay, while still in H9, wiggle the harness, the potentiometer connector SEN−203, the main cable connector C−9, and the connector of the control unit MOD−150 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the potentiometer connector SEN−203, the main cable connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the potentiometer. A. Disconnect connector SEN−203, then remove it. Measure the resistance between: SEN−203 pin 1 and pin 2. SEN−203 pin 3 and pin 2. If, on turning the potentiometer, the indicated resistance varies from a minimum of 400 W to a maximum of 3700 W otherwise replace the potentiometer. B. If the potentiometer is okay, continue to step 4. 4. Check for a voltage of + 5 V. A. Turn the ignition key ON. Measure the voltage between the connector: SEN−203 pin 1, wire (AB) and ground If the indicated voltage is not approximately + 5 V, repair or replace the harness as required. B. If the voltage indicated is approximately + 5 V, continue to step 5. 5. Check for an open circuit. A. Disconnect the connector of the control unit MOD−150. Check in the connector: MOD−150 between pin 32, wire (HV) and SEN−203 pin 2, wire (HV) MOD−150 between pin 1, wire (VN) and SEN−203 pin 3, wire (VN) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue with step 6. 6. Check for a short to ground. A. Measure on the control unit connector between: MOD−150 pin 32 wire (HV) and ground if a short to ground is indicated, repair or replace harness as required. B. If the voltage is approximately +5 V, download the correct software release. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, MOD−150, and SEN−203 sect. 55, chap. 8, fig. 42, fig. 280 and fig. 330), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 27, sect. 55, chap. 6, page 391). 87666787A2 − 06 − 2009
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2063 − SYNCHRO NOT MOVING TO SHUTTLE POSITION. Control module: Power Shuttle control unit NOTE: The control unit, via the potentiometer, has not seen the synchronizer move. The tractor only runs in forward gears (HI or LO), this depends on where the synchro stopped, if it does not engage with the rear gear the transmission will not move. Possible fault modes: 1. Solenoid valves faulty 2. Potentiometer faulty 3. Synchro sticking Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check whether the code is accompanied by other codes related to trouble with the potentiometer SEN−203, of the Dual Command (2 Speed Power Shift) solenoid valves SOL−138 and shuttle SOL−139 for moving the synchronizer. A. Make the due repairs related to the other fault codes. B. If there are no other error codes, continue to step 2. 2. Check all the pressures of the synchronizer movement assembly. A. If the pressure indicated is approximately 16 bar, possible mechanical fault (synchronizer sticking) in the transmission. If the pressure does not correspond to approximately 16 bar, continue with the hydraulic troubleshooting procedures. B. If the pressures are okay, continue to step 3. 3. Attempting movement of the synchronizer via the diagnostics program H7. A. Enter the program H7 of the control unit SB, with the engine running and the gear lever in neutral, select the channel ch2. Press the push−button HI, on the gear lever, the synchronizer is moved in Dual Command (2 Speed Power Shift) mode. Press the push−button LO, on the gear lever, the synchronizer is moved in shuttle mode. The display will show the status of the synchro. B. If the synchronizer does not move and the error is repeated, there should be a mechanical fault so open the gearbox and make the mechanical repairs. For the connectors, components and wiring diagrams affected, see (Connectors SOL−138, SOL−139, and SEN−203 sect. 55, chap. 8, fig. 265, fig. 267 and fig. 330), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 27, sect. 55, chap. 6, page 391). NOTE: for a description of the HH menus, refer to section 55 chapter 10.
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2064 − SYNCHRO NOT MOVING TO HI−LO POSITION. Control module: Power Shuttle control unit NOTE: The control unit, via the potentiometer, has not seen the synchronizer move. The tractor only runs in forward and reverse gears, this depends on where the synchro stopped, if it does not engage with the front gear the transmission will not move. Possible fault modes: 1. Solenoid valves faulty 2. Potentiometer faulty 3. Synchro sticking Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check whether the code is accompanied by other codes related to trouble with the potentiometer SEN−203, of the Dual Command (2 Speed Power Shift) solenoid valves SOL−138 and shuttle SOL−139 for moving the synchronizer. A. Make the due repairs related to the other fault codes. B. If there are no other error codes, continue to step 2. 2. Check all the pressures of the synchronizer movement assembly. A. If the pressure indicated is approximately 16 bar, possible mechanical fault (synchronizer sticking) in the transmission. If the pressure does not correspond to approximately 16 bar, continue with the hydraulic troubleshooting procedures. B. If the pressures are okay, continue to step 3. 3. Attempting movement of the synchronizer via the diagnostics program H7. A. Enter the program H7 of the control unit SB, with the engine running and the gear lever in neutral, select the channel ch2. Press the push−button HI, on the gear lever, the synchronizer is moved in Dual Command (2 Speed Power Shift) mode. Press the push−button LO, on the gear lever, the synchronizer is moved in shuttle mode. The display will show the status of the synchro. B. If the synchronizer does not move and the error is repeated, there should be a mechanical fault so open the gearbox and make the mechanical repairs. For the connectors, components and wiring diagrams affected, see (Connectors SOL−138, SOL−139, and SEN−203 sect. 55, chap. 8, fig. 265, fig. 267 and fig. 330), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 27, sect. 55, chap. 6, page 391). NOTE: for a description of the HH menus, refer to section 55 chapter 10.
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2070 − VOLTAGE FROM FORWARD SPEED SWITCH OF THE SHUTTLE LEVER TOO HIGH. Control module: Power Shuttle control unit NOTE: The tractor only runs in reverse gear. Possible fault modes: 1. 2. 3. 4.
Faulty connector Faulty shuttle lever assembly Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the shuttle lever forward switch in H5. A. Access the HH diagnostics programs, select H5. Move the shuttle lever into forward. If the display does not show d15, continue to step 2. B. If the display does change to d15, while still in H5 wiggle the harness and the connectors to check for an intermittent circuit. The display will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check the shuttle lever forward switch. A. Disconnect the shuttle lever connector SW−152. Move the shuttle lever onto forward gear and measure the resistance in the connector: SW−152 between pin 1 and pin 2 if the resistance indicated is not approximately 0.56 kΩ, and then in neutral approximately 2.76 kΩ, remove and replace the shuttle lever assembly. B. If the shuttle lever switch is okay, continue to step 3. 3. Check for a short to + 8 or +12 V. A. Turn the ignition key ON. Measure the voltage between the connector: SW−152 pin 1, wire (AB) and ground If the indicated voltage is greater than + 5 V, repair or replace the harness as required. B. If the voltage indicated is approximately + 5 V, continue to step 4. 4. Check for short to a positive voltage. A. Turn the ignition key ON. Measure the voltage between the connector: SW−152 pin 2, wire (AN) and ground If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors SW−152 sect. 55, chap. 8, fig. 283), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 24−26 sect. 55, chap. 6, pages 385−389).
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2071 − VOLTAGE FROM FORWARD SPEED SWITCH OF THE SHUTTLE LEVER TOO LOW. Control module: Power Shuttle control unit NOTE: The tractor only runs in reverse gear. Possible fault modes: 1. 2. 3. 4.
Faulty connector Faulty shuttle lever assembly Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the shuttle lever forward switch in H5. A. Access the HH diagnostics programs, select H5. Move the shuttle lever into forward. If the display does not show d15, continue to step 2. B. If the display does change to d15, while still in H5 wiggle the harness and the connectors to check for an intermittent circuit. The display will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check the shuttle lever forward switch. A. Disconnect the shuttle lever connector SW−152. Move the shuttle lever onto forward gear and measure the resistance between the connector: SW−152 pin 1 and pin 2 if the resistance indicated is not approximately 0.56 kΩ and in neutral approximately 2.76 kΩ, remove and replace the shuttle lever assembly. B. If the shuttle lever switch is okay, continue to step 3. 3. Check for a voltage of + 5 V. A. Turn the ignition key ON. Measure the voltage between the connector: SW−152 pin 1, wire (AB) and ground If the indicated voltage is not approximately + 5 V, repair or replace the harness as required. B. If the voltage indicated is approximately + 5 V, continue to step 4. 4. Check for an open circuit. A. Turn ignition switch to OFF position. Disconnect the connector of the control unit MOD−150. Check in the connector: MOD−150 between pin 9, wire (AN) and SW−152 pin 2, wire (AN) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue with step 5. 5. Check for a short to ground. A. Check between the connector: MOD−150 between pin 9, wire (AN) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors MOD−150 and SW−152 sect. 55, chap. 8, figs. 280−281 e fig. 283), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 24−26 sect. 55, chap. 6, pages 385−389).
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2072 − VOLTAGE FROM REVERSE SPEED SWITCH OF THE SHUTTLE LEVER TOO HIGH. Control module: Power Shuttle control unit NOTE: The tractor only runs in forward gear. Possible fault modes: 1. 2. 3. 4.
Faulty connector Faulty shuttle lever assembly Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the shuttle lever reverse switch in H5. A. Access the HH diagnostics programs, select H5. Move the shuttle lever into reverse. If the display does not show d16, continue to step 2. B. If the display does change to d16, while still in H5 wiggle the harness and the connectors to check for an intermittent circuit. The display will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check the shuttle lever forward switch. A. Disconnect the shuttle lever connector SW−152. Move the shuttle lever to reverse and measure the resistance in the connector: SW−152 between pin 1 and pin 3 if the resistance indicated is not approximately 0.56 kΩ, and then in neutral approximately 2.76 kΩ, remove and replace the shuttle lever assembly. B. If the shuttle lever switch is okay, continue to step 3. 3. Check for a short to + 8 or +12 V. A. Turn the ignition key ON. Measure the voltage between the connector: SW−152 pin 1, wire (AB) and ground If the indicated voltage is greater than + 5 V, repair or replace the harness as required. B. If the voltage indicated is approximately + 5 V, continue to step 4. 4. Check for short to a positive voltage. A. Turn the ignition key ON. Measure the voltage between the connector: SW−152 pin 3, wire (A) and ground If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors SW−152 sect. 55, chap. 8, fig. 283), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 24−26 sect. 55, chap. 6, pages 385−389).
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2073 − VOLTAGE FROM REVERSE SPEED SWITCH OF THE SHUTTLE LEVER TOO LOW. Control module: Power Shuttle control unit NOTE: The tractor only runs in forward gear. Possible fault modes: 1. 2. 3. 4.
Faulty connector Faulty shuttle lever assembly Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the shuttle lever forward switch in H5. A. Access the HH diagnostics programs, select H5. Move the shuttle lever into reverse. If the display does not show d16, continue to step 2. B. If the display does change to d16, while still in H5 wiggle the harness and the connectors to check for an intermittent circuit. The display will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check the shuttle lever reverse switch. A. Disconnect the shuttle lever connector SW−152. Move the shuttle lever to reverse and measure the resistance between the connector: SW−152 pin 1 and pin 3 if the resistance indicated is not approximately 0.56 kΩ and in neutral approximately 2.76 kΩ, remove and replace the shuttle lever assembly. B. If the shuttle lever switch is okay, continue to step 3. 3. Check for a voltage of + 5 V. A. Turn the ignition key ON. Measure the voltage between the connector: SW−152 pin 1, wire (AB) and ground If the indicated voltage is not approximately + 5 V, repair or replace the harness as required. B. If the voltage indicated is approximately + 5 V, continue to step 4. 4. Check for an open circuit. A. Turn ignition switch to OFF position. Disconnect the connector of the control unit MOD−150. Check in the connector: MOD−150 between pin 15, wire (A) and SW−152 pin 3, wire (A) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue with step 5. 5. Check for a short to ground. A. Check between the connector: MOD−150 between pin 15, wire (A) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors MOD−150 and SW−152 sect. 55, chap. 8, figs. 280−281 e fig. 283), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 24−26 sect. 55, chap. 6, pages 385−389).
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2085 − OPEN CIRCUIT AT THE SHUTTLE POSITION SYNCHRONIZER SOLENOID VALVE. Control module: Power Shuttle control unit NOTE: The tractor only runs in HI and LO forward gears. Possible fault modes: 1. Faulty connector 2. Solenoid valve faulty 3. Wiring fault 4. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the solenoid valve with HH diagnostic programs. A. Enter the program H9 of the control unit SB, select the channel ch59. With the engine running in forward drive with HI engaged (hare on) put the shuttle lever into reverse, the display will show a number that from 0 reaches up to approximately 700÷900 then goes back to 0 (energizing solenoid valve for moving synchro in shuttle position). B. If nothing appears on the display and the drive is not reversed, continue to phase 2 2. Check the connector of the solenoid valve SOL−139, the main cable connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the shuttle position synchronizer solenoid valve. A. Disconnect connector SOL−139. Measure the resistance in the connector: SOL−139 between pins 1 and 2 If the resistance indicated is not approximately 7.5 Ω, remove and replace the solenoid valve. B. If the resistance is okay, continue to step 4. 4. Check the solenoid valve for a short to ground. A. Check between the component side of connector: SOL−139 pin 1, and ground SOL−139 pin 2, and ground If a short to ground is indicated, remove and replace the solenoid. B. If a short to ground is not indicated, continue to step 4. 5. Check for a short to ground. A. Check between: SOL−139 pin 1, wire (SG) and ground SOL−139 pin 2, wire (SN) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5. 6. Check for an open circuit. A. Disconnect the control unit connector MOD−150. Check between: SOL−139 pin 1, wire (SG) and MOD−150 pin 23, wire (SG) SOL−139 pin 2, wire (SN) and MOD−150 pin 27, wire (SN) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, SOL−139 and MOD−150 sect. 55, chap. 8, fig. 42, fig. 267 and fig. 280), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 27, sect. 55, chap. 6, page 391). 87666787A2 − 06 − 2009
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2086 − OPEN CIRCUIT AT THE HI−LO POSITION SYNCHRONIZER SOLENOID VALVE. Control module: Power Shuttle control unit NOTE: The tractor only runs in LO forward and reverse gears. Possible fault modes: 1. 2. 3. 4.
Faulty connector Solenoid valve faulty Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the solenoid valve with HH diagnostic programs. A. Enter the program H9 of the control unit SB, select the channel ch58. With the engine running in forward drive with LO engaged (hare off) press the HI button on the gear lever, the display will show a number that from 0 reaches up to approximately 700÷900 then goes back to 0 (energizing solenoid valve for moving synchro in HI−LO position). B. If nothing appears on the display and the drive is not reversed, continue to step 2. 2. Check the connector of the solenoid valve SOL−138, the main cable connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the shuttle position synchronizer solenoid valve. A. Disconnect connector SOL−138. Measure the resistance in the connector: SOL−138 between pins 1 and 2 If the resistance indicated is not approximately 7.5 Ω, remove and replace the solenoid valve. B. If the resistance is okay, continue to step 4. 4. Check the solenoid valve for a short to ground. A. Check between the component side of connector: SOL−138 pin 1, and ground SOL−138 pin 2, and ground If a short to ground is indicated, remove and replace the solenoid. B. If a short to ground is not indicated, continue to step 4. 5. Check for a short to ground. A. Check between: SOL−138 pin 1, wire (GN) and ground SOL−138 pin 2, wire (GR) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5. 6. Check for an open circuit. A. Disconnect the control unit connector MOD−150. Check between: SOL−138 pin 1, wire (GN) and MOD−150 pin 30, wire (GN) SOL−138 pin 2, wire (GR) and MOD−150 pin 31, wire (GR) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, SOL−138 and MOD−150 sect. 55, chap. 8, fig. 42, fig. 266 and fig. 280), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 27, sect. 55, chap. 6, page 391). 87666787A2 − 06 − 2009
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2087 − SHORT CIRCUIT TO + 12 V AT THE SHUTTLE POSITION SYNCHRONIZER SOLENOID VALVE. Control module: Power Shuttle control unit NOTE: The tractor only runs in HI and LO forward gears. Possible fault modes: 1. Faulty connector 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the solenoid valve with HH diagnostic programs. A. Enter the program H9 of the control unit SB, select the channel ch59. With the engine running in forward drive with HI engaged (hare on) put the shuttle lever into reverse, the display will show a number that from 0 reaches up to approximately 700÷900 then goes back to 0 (energizing solenoid valve for moving synchro in shuttle position). B. If nothing appears on the display and the drive is not reversed, continue to phase 2 2. Check the connector of the solenoid valve SOL−139, the main connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check for a short to + 12 V. A. Disconnect connector SOL−139. Turn the ignition key ON. Measure the voltage between connector: SOL−139 pin 1, wire (SG) and ground SOL−139 pin 2, wire (SN) and ground If a voltage is indicated, turn the key−start OFF. Disconnect the control unit connector MOD−150. Turn the ignition key ON. If a voltage is still indicated, repair or replace the harness as required. B. If no voltage is indicated, download the correct level of software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, SOL−139 and MOD−150 sect. 55, chap. 8, fig. 42, fig. 267 and fig. 280), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 27, sect. 55, chap. 6, page 391).
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2088 − SHORT CIRCUIT TO + 12 V AT THE HI−LO POSITION SYNCHRONIZER SOLENOID VALVE. Control module: Power Shuttle control unit NOTE: The tractor only runs in LO forward and reverse gears. Possible fault modes: 1. Faulty connector 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the solenoid valve with HH diagnostic programs. A. Enter the program H9 of the control unit SB, select the channel ch58. With the engine running in forward drive with LO engaged (hare off) press the HI button on the gear lever, the display will show a number that from 0 reaches up to approximately 700÷900 then goes back to 0 (energizing solenoid valve for moving synchro in HI−LO position). B. If nothing appears on the display and the drive is not reversed, continue to phase 2 2. Check the connector of the solenoid valve SOL−138, the main connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 3. Check for a short to + 12 V. A. Disconnect connector SOL−139. Turn the ignition key ON. Measure the voltage between connector: SOL−138 pin 1, wire (GN) and ground SOL−138 pin 2, wire (GR) and ground If a voltage is indicated, turn the key−start OFF. Disconnect the control unit connector MOD−150. Turn the ignition key ON. If a voltage is still indicated, repair or replace the harness as required. 4. B. If no voltage is indicated, download the correct level of software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, SOL−138 and MOD−150 sect. 55, chap. 8, fig. 42, fig. 266 and fig. 280), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 27, sect. 55, chap. 6, page 391).
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2199 − CREEPER UNIT OPTION NOT ENABLED. Control module: Power Shuttle control unit NOTE: The control unit receives the signal from the creeper unit position switch, but it has not been configured in H3 channel 2 of the SB transmission control unit. Possible fault modes: 1. Configuration error Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Configure the creeper unit option. A. Enter the diagnostics programs HH with tool 380000843 select the control unit SB enter in H7 and, at channel 2 select option “Present” press ENTER for 1 second to record the option. NOTE: for a description of the HH menus, refer to section 55 chapter 10.
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2311 − HI SPEED SWITCH INPUT VOLTAGE TOO HIGH. Control module: Power Shuttle control unit NOTE: The tractor runs, but pressing the HI button has no effect. Possible fault modes: 1. 2. 3. 4.
Faulty connector Faulty shuttle lever assembly Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the gear lever with the HH diagnostics programs. A. Enter the program H5 of the control unit SB, press the HI button on the gear lever, the display will not show the code related to the button ch18 continue to step 2 B. If the values displayed are okay, while in H5, wiggle the harness, the gear lever switch connector SW−183, the main cable connector C−9, and the connector of the control unit MOD−150 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the HI switch on the gear lever SW−183, the main cable C−9 and the cable of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 3. Check for short to a positive voltage. A. Disconnect connector SW−183 and MOD−150. Turn the ignition key ON. Measure the voltage between the connector: SW−183 pin 2, wire (C) and ground If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, MOD−150 and SW−183 sect. 55, chap. 8, fig. 42, fig. 280 and fig. 327), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 27, sect. 55, chap. 6, page 391).
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2312 − LO SPEED SWITCH INPUT VOLTAGE TOO HIGH. Control module: Power Shuttle control unit NOTE: The tractor runs, but pressing the LO button has no effect. Possible fault modes: 1. Faulty connector 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the gear lever with the HH diagnostics programs. A. Enter the program H5 of the control unit SB, press the LO button on the gear lever, the display will not show the code related to the button ch17 continue to phase 2 B. If the values displayed are okay, while in H5, wiggle the harness, the gear lever switch connector SW−183, the main cable connector C−9, and the connector of the control unit MOD−150 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the LO switch on the gear lever SW−183, the main cable C−9 and the cable of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check for short to a positive voltage. A. Disconnect connector SW−183 and MOD−150. Turn the ignition key ON. Measure the voltage between the connector: SW−183 pin 1, wire (AV) and ground If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, MOD−150 and SW−183 sect. 55, chap. 8, fig. 42, fig. 280 and fig. 327), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 27, sect. 55, chap. 6, page 391).
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2342 − CLUTCH A SOLENOID SHORTED TO GROUND OR CIRCUIT OPEN. Control module: Power Shuttle control unit NOTE: The tractor only runs in reverse gear. Possible fault modes: 1. Solenoid valve faulty 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the solenoid valve with HH diagnostic programs. A. Enter the program H9 of the control unit SB, select the channel ch43 or ch53. With the engine running, put the shuttle lever into forward drive, if the display does not show a number that from approximately 0, with the clutch pedal pressed, reaches up to approximately 300÷400, with clutch pedal released, continue to phase 2. B. If the values displayed are okay, while still in H9, wiggle the harness, the solenoid valve connector SOL−146, the main cable connector C−9, and the connector of the control unit MOD−150 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the clutch A solenoid valve connector SOL−146, the main connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the clutch A solenoid valve. A. Disconnect connector SOL−146. Measure the resistance in the connector: SOL−146 between pins A and B If the resistance indicated is not approximately 10 Ω, remove and replace the clutch A solenoid valve. B. If the resistance is okay, continue to step 4. 4. Check the clutch A solenoid for a short to ground. A. Check between the component side of connector: SOL−146 pin A and ground SOL−146 pin B and ground If a short to ground is indicated, remove and replace the clutch solenoid valve. B. If no short to ground is indicated, continue to step 5. 5. Check for a short to ground. A. Disconnect the connectors MOD−150. Check between: SOL−146 pin A, wire (AN) and ground SOL−146 pin B, wire (AR) and ground If a short to ground is indicated, repair or replace the harness as required. B. If no short to ground is indicated, continue to step 6. 6. Check for an open circuit. A. Check between: SOL−146 pin A, wire (AN) and MOD−150 pin 5, wire (AN) SOL−146 pin B, wire (AR) and MOD−150 pin 26, wire (AR) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, SOL−146 and MOD−150 sect. 55, chap. 8, figs. 42−44, figs. 276−277 and figs. 280−281), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 25−27 sect. 55, chap. 6, pages 387−391). 87666787A2 − 06 − 2009
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2343 − CLUTCH B SOLENOID SHORTED TO GROUND OR CIRCUIT OPEN. Control module: Power Shuttle control unit NOTE: The tractor only runs in forward gear. Possible fault modes: 1. Solenoid valve faulty 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the solenoid valve with HH diagnostic programs. A. Enter the program H9 of the control unit SB, select the channel ch44 or ch54. With the engine running, put the shuttle lever into reverse drive, if the display does not show a number that from approximately 0, with the clutch pedal pressed, reaches up to approximately 300÷400, with clutch pedal released, continue to phase 2. B. If the values displayed are okay, while still in H9, wiggle the harness, the solenoid valve connector SOL−147, the main cable connector C−9, and the connector of the control unit MOD−150 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the clutch B solenoid valve connector SOL−147, the main connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check clutch B solenoid valve. A. Disconnect connector SOL−147. Measure the resistance in the connector: SOL−147 between pins A and B If the resistance indicated is not approximately 10 Ω, remove and replace the clutch B solenoid valve. B. If the resistance is okay, continue to step 4. 4. Check the clutch B solenoid for a short to ground. A. Check between the component side of connector: SOL−147 pin A and ground SOL−147 pin B and ground If a short to ground is indicated, remove and replace the clutch solenoid valve. B. If no short to ground is indicated, continue to step 5. 5. Check for a short to ground. A. Disconnect the connectors MOD−150. Check between: SOL−147 pin A, wire (BR) and ground SOL−147 pin B, wire (BN) and ground If a short to ground is indicated, repair or replace the harness as required. B. If no short to ground is indicated, continue to step 6. 6. Check for an open circuit. A. Check between: SOL−147 pin A, wire (BR) and MOD−150 pin 6, wire (BR) SOL−147 pin B, wire (BN) and MOD−150 pin 10, wire (BN) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, SOL−147 and MOD−150 sect. 55, chap. 8, figs. 42−44, figs. 273−274 and figs. 280−281), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 25−27 sect. 55, chap. 6, pages 387−391). 87666787A2 − 06 − 2009
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2352 − CLUTCH A SOLENOID SHORTED TO + 12 V. Control module: Power Shuttle control unit NOTE: The tractor only runs in reverse gear. Possible fault modes: 1. Wiring fault 2. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the solenoid valve with HH diagnostic programs. A. Enter the program H9 of the control unit SB, select the channel ch43 or ch53. With the engine running, put the shuttle lever into forward drive, if the display does not show a number that from approximately 0, with the clutch pedal pressed, reaches up to approximately 300÷400, with clutch pedal released, continue to phase 2. B. If the values displayed are okay, while still in H9, wiggle the harness, the solenoid valve connector SOL−146, the main cable connector C−9, and the connector of the control unit MOD−150 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the clutch A solenoid valve connector SOL−146, the main connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check for a short to + 12 V. A. Disconnect the connector SOL−146. Turn the ignition key ON. Measure the voltage between connector: SOL−146 pin A, wire (AN) and ground SOL−146 pin B, wire (AR) and ground If a voltage is indicated, turn the key−start OFF. Disconnect the control unit connector MOD−150. Turn the ignition key ON. If a voltage is still indicated, repair or replace the harness as required. B. If no voltage is indicated, download the correct level of software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, SOL−146 and MOD−150 sect. 55, chap. 8, figs. 42−44, figs. 274−275 and figs. 280−281), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 25−27 sect. 55, chap. 6, pages 387−391).
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2353 − CLUTCH B SOLENOID SHORTED TO + 12 V. Control module: Power Shuttle control unit NOTE: The tractor only runs forwards. Possible fault modes: 1. Wiring fault 2. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the solenoid valve with HH diagnostic programs. A. Enter the program H9 of the control unit SB, select the channel ch44 or ch54. With the engine running, put the shuttle lever into reverse drive, if the display does not show a number that from approximately 0, with the clutch pedal pressed, reaches up to approximately 300÷400, with clutch pedal released, continue to phase 2. B. If the values displayed are okay, while still in H9, wiggle the harness, the solenoid valve connector SOL−147, the main cable connector C−9, and the connector of the control unit MOD−150 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the clutch B solenoid valve connector SOL−147, the main connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check for a short to + 12 V. A. Disconnect connector SOL−147. Turn the ignition key ON. Measure the voltage between connector: SOL−147 pin A, wire (BR) and ground SOL−147 pin B, wire (BN) and ground If a voltage is indicated, turn the key−start OFF. Disconnect the control unit connector MOD−150. Turn the ignition key ON. If a voltage is still indicated, repair or replace the harness as required. B. If no voltage is indicated, download the correct level of software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, SOL−147 and MOD−150 sect. 55, chap. 8, figs. 42−44, figs. 276−277 and figs. 280−281), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 25−27 sect. 55, chap. 6, pages 387−391).
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2362 − CLUTCH A NOT CALIBRATED. Control module: Power Shuttle control unit NOTE: Poor performance of the uncalibrated clutch. The tractor goes forwards, but the movement could be jerky. Possible fault modes: 1. 2. 3. 4. 5.
Transmission not calibrated Clutch A solenoid valve trouble Hydraulic circuit trouble Mechanical failure ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check whether the transmission has been calibrated. A. If the transmission has not been calibrated since replacing the control unit or since using H8 (deleting EEPROM memory) run the transmission calibration procedure. Enter the HH menu, select the program H1 then proceed with calibration; without tool 380000843, to access calibration, press and hold down HOME on the dashboard while starting the machine. B. If the transmission has been calibrated, download the correct level of the software and run the calibration procedure again. If the fault re−occurs again, continue to step 2. 2. Check for other error codes being displayed. A. If other error codes are displayed, continue with these tests. B. If no other error code is displayed, continue to step 3. 3. Check the solenoid valve of the broken clutch. A. Remove the solenoid, clean or replace as required. B. If the error code is still displayed, continue to step 4. 4. Check the clutch pack pressures. A. If the pressures indicated are approximately 16 bar, possible mechanical fault within the transmission. If the pressures of all the clutches are low, continue to hydraulic troubleshooting procedures. B. If the pressures indicated are not approximately 16 bar on one or more of the clutches there may be an internal leak in the transmission. NOTE: for a description of the HH menus, refer to section 55 chapter 10.
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2363 − CLUTCH B NOT CALIBRATED. Control module: Power Shuttle control unit NOTE: Poor performance of the uncalibrated clutch. The tractor goes in reverse, but the movement could be jerky. Possible fault modes: 1. 2. 3. 4. 5.
Transmission not calibrated Clutch B solenoid valve trouble Hydraulic circuit trouble Mechanical failure ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check whether the transmission has been calibrated. A. If the transmission has not been calibrated since replacing the control unit or since using H8 (deleting EEPROM memory) run the transmission calibration procedure. Enter the HH menu, select the program H1 then proceed with calibration; without tool 380000843, to access calibration, press and hold down HOME on the dashboard while starting the machine. B. If the transmission has been calibrated, download the correct level of the software and run the calibration procedure again. If the fault re−occurs again, continue to step 2. 2. Check for other error codes being displayed. A. If other error codes are displayed, continue with these tests. B. If no other error code is displayed, continue to step 3. 3. Check the solenoid valve of the broken clutch. A. Remove the solenoid, clean or replace as required. B. If the error code is still displayed, continue to step 4. 4. Check the clutch pack pressures. A. If the pressures indicated are approximately 16 bar, possible mechanical fault within the transmission. If the pressures of all the clutches are low, continue to hydraulic troubleshooting procedures. B. If the pressures indicated are not approximately 16 bar on one or more of the clutches there may be an internal leak in the transmission. NOTE: for a description of the HH menus, refer to section 55 chapter 10.
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2400 − HI−LO/SHUTTLE SYNCHRONIZER NOT CALIBRATED OR CALIBRATION INCORRECT. Control module: Power Shuttle control unit NOTE: The synchronizer is calibrated during clutch calibration. The control unit receives information on the position of the synchronizer from the potentiometer. The machine can run, it depends on the position of the synchro. The control unit memory has two bands (one, comprising the front initial portion of the travel, for the synchro in the shuttle position and another one, comprising the rear final portion, for the synchro in the HI−LO position) where it accepts the positioning of the synchro without emitting the code, but when the code is present the machine might work all the same. Perhaps the synchro has slightly stopped on a value within the two bands. Possible fault modes: 1. Mechanical trouble with the synchro 2. Incomplete calibration 3. Trouble with the synchronizer movement solenoid valves Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Calibrate the transmission again. A. If the code disappears OK. B. If the code is repeated, continue to phase 2. 2. Check for other error codes being displayed. A. If other error codes are displayed, continue with these tests. B. If no other error code is displayed, continue to step 3. 3. Attempting movement of the synchronizer via the diagnostics program H7. A. Enter the program H7 of the control unit SB, with the engine running and the gear lever in neutral, select the channel ch2. Press the push−button HI, on the gear lever, the synchronizer is moved in Dual Command (2 Speed Power Shift) mode. Press the push−button LO, on the gear lever, the synchronizer is moved in shuttle mode. The display will show the status of the synchro. B. If the synchronizer moves and the error is repeated, there should be a mechanical fault so if the machine does not work, open the gearbox and make any necessary mechanical repairs. NOTE: for a description of the HH menus, refer to section 55 chapter 10.
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2411 − SYNCHRONIZER DOES NOT MOVE DURING START−UP PROCEDURE. Control module: Power Shuttle control unit NOTE: In the starting phase the control unit moves the synchro into the opposite position to the one where it is. The movement of the machine depends on the position where the synchro is coupled. Possible fault modes: 1. Mechanical trouble with the synchro 2. Solenoid valves disconnected 3. Trouble with the synchronizer movement solenoid valves Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check whether the code is accompanied by other codes related to trouble with the potentiometer SEN−203, to the HI−LO mode solenoid valves. SOL−138 and shuttle mode SOL−139. A. Make the due repairs related to the other fault codes. B. If there are no other error codes, continue to step 2. 2. Check all the pressures of the synchronizer movement assembly. A. If the pressures indicated are approximately 16 bar, possible mechanical fault (synchronizer sticking) within the transmission. If the pressures of all the clutches are low, continue to hydraulic troubleshooting procedures. B. If the pressures are okay, continue to step 3. 3. Attempting movement of the synchronizer via the diagnostics program H7. A. Enter the program H7 of the control unit SB, with the engine running and the gear lever in neutral, select the channel ch2. Press the push−button HI, on the gear lever, the synchronizer is moved in Dual Command (2 Speed Power Shift) mode. Press the push−button LO, on the gear lever, the synchronizer is moved in shuttle mode. The display will show the status of the synchro. B. If the synchronizer does not move and the error is repeated, there should be a mechanical fault so open the gearbox and make the mechanical repairs. For the connectors, components and wiring diagrams affected, see (Connectors SOL−138, SOL−139 and SEN−203 sect. 55, chap. 8, fig. 265, fig. 267 and fig. 330), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 27, sect. 55, chap. 6, page 391). NOTE: for a description of the HH menus, refer to section 55 chapter 10.
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2413 − SYNCHRONIZER DISENGAGED WITHOUT CONTROL MODULE CONTROL. Control module: Power Shuttle control unit NOTE: The control unit sees a synchronizer movement with no control by the control module. Possible fault modes: 1. Mechanical fault, probable synchro trouble with subsequent disengagement of its mobile part. Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check for other error codes being displayed. A. If other error codes are displayed, continue with these tests. B. If no other error code is displayed, continue to step 2. 2. Attempting re−engagement of the synchronizer via the diagnostics program H7. A. Enter the program H7 of the control unit SB, with the engine running and the gear lever in neutral, select the channel ch2. Press the push−button HI, on the gear lever, the synchronizer is moved in Dual Command (2 Speed Power Shift) mode. Press the push−button LO, on the gear lever, the synchronizer is moved in shuttle mode. The display will show the status of the synchro. B. If the synchronizer re−engages and the error is not repeated, there should be a mechanical fault so if the problem is repeated on the machine, open the gearbox and make any necessary mechanical repairs or replace the synchro. NOTE: for a description of the HH menus, refer to section 55 chapter 10.
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2421 − VOLTAGE FROM RANGE LEVER SWITCH TOO LOW. Control module: Power Shuttle control unit NOTE: The tractor runs normally, but with low gears engaged it may not function. In this event, use the tractor in a higher gear. Possible fault modes: 1. 2. 3. 4.
Faulty connector Range switch faulty Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the range position switch in H5. A. Operate the range lever. moving it from engaged into the neutral position, the display will show d0 and d19 with the lever in neutral; if this does not happen, continue to phase 2. B. If the values displayed are okay, while in H5, with the lever in neutral, wiggle the harness, the range switch connector SW−141, the main cable connector C−9, and the connector of the control unit MOD−150 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the range switch connector SW−141, the main cable connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the range switch. A. Disconnect connector SW−141. Measure the resistance between: 70 pin 1 and pin 2. With the range lever in neutral (button pressed), it should indicate 0.560 kΩ. With the range lever engaged (button released), it should indicate 2.76 kΩ. If the resistances indicated are not okay, remove and replace the range switch. B. If the range position switch is okay, continue to step 4. 4. Check for an open circuit. A. Disconnect connector MOD−150. Check between: SW−141 pin 1, wire (AB) and MOD−150 pin 11, wire (AB) SW−141 pin 2, wire (BG) and MOD−150 pin 17, wire (BG) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue with step 5. 5. Check for a short to ground. A. Check between the connector: MOD−150 pin 17, wire (BG) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, SW−141 and MOD−150 sect. 55, chap. 8, figs. 42−44, fig. 270 and figs. 280−281), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 25−27 sect. 55, chap. 6, pages 387−391).
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2422 − VOLTAGE FROM RANGE LEVER SWITCH TOO HIGH. Control module: Power Shuttle control unit NOTE: The tractor runs normally, but with low gears engaged it may not function. In this event, use the tractor in a higher gear. Possible fault modes: 1. 2. 3. 4.
Faulty connector Range switch faulty Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the range position switch in H5. A. Operate the range lever. moving it from engaged into the neutral position, the display will show d0 and d19 with the lever in neutral; if this does not happen, continue to phase 2. B. If the values displayed are okay, while in H5, with the lever in neutral, wiggle the harness, the range switch connector SW−141, the main cable connector C−9, and the connector of the control unit MOD−150 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the range switch connector SW−141, the main cable connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the range switch. A. Disconnect connector SW−141. Measure the resistance between: SW−141 pin 1 and pin 2. With the range lever in neutral (button pressed), it should indicate 0.560 kΩ. With the range lever engaged (button released), it should indicate 2.76 kΩ. If the resistances indicated are not okay, remove and replace the range switch. B. If the range position switch is okay, continue to step 4. 4. Check for short to a positive voltage. A. Turn the ignition key ON. Measure the voltage between the connector: SW−141 pin 2, wire (BG) and ground If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated, continue to step 4. 5. Check for a short to + 8 or + 12 V. A. With the keystart ON. Measure the voltage between the connector: SW−141 pin 1, wire (AB) and ground If the indicated voltage is not approximately + 5 V, repair or replace the harness as required. B. If the voltage is approximately +5 V, download the correct software release. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, SW−141 and MOD−150 sect. 55, chap. 8, figs. 42−44, fig. 270 and figs. 280−281), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 25−27 sect. 55, chap. 6, pages 387−391).
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2425 − VOLTAGE FROM GEAR LEVER SWITCH TOO LOW. Control module: Power Shuttle control unit NOTE: The tractor runs normally, but with low gears engaged it may not function. In this event, use the tractor in a higher gear. Possible fault modes: 1. 2. 3. 4.
Faulty connector Gear switch faulty Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the gear position switch in H5. A. Operate the gear lever. moving it from engaged into the neutral position, the display will show d0 and d156, if this does not happen, continue to phase 2. B. If the values displayed are okay, while in H5, with the lever in neutral, wiggle the harness, the range switch connector SW−142, the main cable connector C−9, and the connector of the control unit MOD−150 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the gear switch connector SW−142, the main cable connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the range switch. A. Disconnect connector SW−142. Measure the resistance between: SW−142 pin 1 and pin 2. With the gear lever in neutral (button pressed), it should indicate 0.560 kΩ. With the gear lever engaged (button released), it should indicate 2.76 kΩ. If the resistances indicated are not okay, remove and replace the range switch. B. If the gear position switch is okay, continue to step 4. 4. Check for an open circuit. A. Disconnect connector MOD−150. Check between: SW−142 pin 1, wire (AB) and MOD−150 pin 11, wire (AB) SW−142 pin 2, wire (GL) and MOD−150 pin 16, wire (GL) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue with step 5. 5. Check for a short to ground. A. Check between the connector: MOD−150 pin 16, wire (GL) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, SW−142 and MOD−150 sect. 55, chap. 8, figs. 42−44, fig. 271 and figs. 280−281), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 25−27 sect. 55, chap. 6, pages 387−391).
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2426 − VOLTAGE FROM GEAR LEVER SWITCH TOO HIGH. Control module: Power Shuttle control unit NOTE: The tractor runs normally, but with low gears engaged it may not function. In this event, use the tractor in a higher gear. Possible fault modes: 1. 2. 3. 4.
Faulty connector Gear switch faulty Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the gear position switch in H5. A. Operate the gear lever. moving it from engaged into the neutral position, the display will show d0 and d156, if this does not happen, continue to phase 2. B. If the values displayed are okay, while in H5, with the lever in neutral, wiggle the harness, the range switch connector SW−142, the main cable connector C−9, and the connector of the control unit MOD−150 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the gear switch connector SW−142, the main cable connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the range switch. A. Disconnect connector SW−142. Measure the resistance between: SW−142 pin 1 and pin 2. With the gear lever in neutral (button pressed), it should indicate 0.560 kΩ. With the gear lever engaged (button released), it should indicate 2.76 kΩ. If the resistances indicated are not okay, remove and replace the range switch. B. If the gear position switch is okay, continue to step 4. 4. Check for short to a positive voltage. A. Turn the ignition key ON. Measure the voltage between the connector: SW−142 pin 2, wire (GL) and ground If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated, continue to step 4. 5. Check for a short to + 8 or + 12 V. A. With the keystart ON. Measure the voltage between the connector: SW−142 pin 1, wire (AB) and ground If the indicated voltage is not approximately + 5 V, repair or replace the harness as required. B. If the voltage is approximately +5 V, download the correct software release. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, SW−142 and MOD−150 sect. 55, chap. 8, figs. 42−44, fig. 271 and figs. 280−281), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 25−27 sect. 55, chap. 6, pages 387−391).
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2427 − ERROR ON GEAR LEVER BUTTON COMMON. Control module: Power Shuttle control unit NOTE: The tractor runs normally, but the buttons on the gear lever (HI, LO and Dump) cannot be used. Possible fault modes: 1. Faulty connector 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the gear lever in H5. A. On the gear lever press respectively button HI then LO and Dump, the display will show d0 (no button pressed), d18 (HI button), d17 (LO button) and d22 (Dump button), if this does not happen, continue to phase 2. B. If the values displayed are okay, while still in H5, wiggle the harness, the gear lever connector SW−183, the main cable connector C−9, and the connector of the control unit MOD−150 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the connector of the gear lever SW−183, the main cable connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check for a short to ground of the gear lever button supply. A. Disconnect the gear lever connections SW−183 and control unit MOD−150. Check between SW−183 pin 3 wire (MB) and ground if a short to ground is indicated, repair or replace the wiring harnesses as required. B. If no short to ground is indicated, continue to step 4. 4. Check for a short circuit to positive. A. Turn the key ON, measure between: SW−183 pin 3 wire (MB) and ground If a short to positive is indicated repair or replace the wiring harness as required. B. If the harness is okay, download the correct software release. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, MOD−150 and SW−183 sect. 55, chap. 8, fig. 42, fig. 280 and fig. 327), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 27, sect. 55, chap. 6, page 391).
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2428 − DUMP SWITCH VOLTAGE TOO HIGH. Control module: Power Shuttle control unit NOTE: The tractor runs normally, but the dump button cannot be used. Possible fault modes: 1. Faulty connector 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the dump switch in H5. A. Operate the dump button, the display will show d22, if this does not happen, continue to phase 2. B. If the values displayed are okay, while in H5, with the lever in neutral, wiggle the harness, the range switch connector SW−183, the main cable connector C−9, and the connector of the control unit MOD−150 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the connector of the gear lever SW−183, the main cable connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check for a short circuit to positive. A. Disconnect the gear lever connections SW−183 and control unit MOD−150. Turn the key ON, measure between: SW−183 pin 4 wire (AG) and ground If a short to positive is indicated repair or replace the wiring harness as required. B. If the harness is okay, download the correct software release. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, MOD−150 and SW−183 sect. 55, chap. 8, fig. 42, fig. 280 and fig. 327), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 27, sect. 55, chap. 6, page 391).
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2429 − DUMP SWITCH JAMMED ON. Control module: Power Shuttle control unit NOTE: The tractor runs normally, but the dump button cannot be used. Possible fault modes: 1. 2. 3. 4.
Faulty connector Switch faulty Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the dump switch in H5. A. Operate the dump button, the display will show d22, if this does not happen, continue to phase 2. B. If the values displayed are okay, while in H5, with the lever in neutral, wiggle the harness, the range switch connector SW−183, the main cable connector C−9, and the connector of the control unit MOD−150 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the connector of the gear lever SW−183, the main cable connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the operation of the dump button. A. Disconnect the gear lever connections SW−183. Measure the continuity between: SW−183 pin 4 and pin 3 If continuity is not indicated on pressing the button and releasing it the continuity ceases, replace the button. B. If the button is okay, continue to step 4. 4. Check for a short circuit between the supply and the signal. A. Disconnect the connector of the control unit MOD−150. Measure the continuity between: MOD−150 pin 14 wire (MB) and pin 22 wire (AG) if a short circuit is indicated, repair or replace the wiring harness as required. B. If the harness is okay, download the correct software release. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, MOD−150 and SW−183 sect. 55, chap. 8, fig. 42, fig. 280 and fig. 327), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 27, sect. 55, chap. 6, page 391).
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2430 − LOW CREEPER SWITCH INPUT. Control module: Power Shuttle control unit NOTE: The creeper unit is presumed to be engaged, the HI function disabled. Possible fault modes: 1. 2. 3. 4.
Faulty connector Creeper status switch faulty Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the creeper status switch in H5. A. Operate the creeper status switch. passing from creeper unit engaged to the neutral position and vice versa, the display will show d0 then d158, if this does not happen, continue to phase 2. B. If the values displayed are okay, while still in H5, with the lever in neutral, wiggle the harness, the creeper unit status switch connector SW−143, the main cable connector C−9, and the connector of the control unit MOD−150 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the creeper status switch connector SW−143, the main cable connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the creeper status switch. A. Disconnect connector SW−143. Measure the resistance between: SW−143 pin 1 and pin 2. With the creeper unit in neutral (button pressed), it should indicate 0.560 kΩ. With the creeper unit engaged (button released), it should indicate 2.76 kΩ. If the resistances indicated are not okay, remove and replace the creeper unit switch. B. If the creeper unit switch is okay, continue to step 4. 4. Check for a short to ground. A. Disconnect connector MOD−150. Check between the connector: MOD−150 pin 34, wire (HG) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, SW−143 and MOD−150 sect. 55, chap. 8, fig. 42, fig. 272 and fig. 280), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 27, sect. 55, chap. 6, page 391).
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2431 − HIGH CREEPER SWITCH VOLTAGE. Control module: Power Shuttle control unit NOTE: The creeper unit is presumed to be engaged, the HI function disabled. Possible fault modes: 1. 2. 3. 4.
Faulty connector Creeper switch faulty Wiring fault ECU fault
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the creeper status switch in H5. A. Operate the creeper status switch. passing from creeper unit engaged to the neutral position and vice versa, the display will show d0 then d158, if this does not happen, continue to phase 2. B. If the values displayed are okay, while still in H5, with the lever in neutral, wiggle the harness, the creeper unit status switch connector SW−143, the main cable connector C−9, and the connector of the control unit MOD−150 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the creeper status switch connector SW−143, the main cable connector C−9, and the connectors of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the creeper switch. A. Disconnect connector SW−143. Measure the resistance between: SW−143 pin 1 and pin 2 With the creeper unit in neutral (button pressed), it should indicate 0.560 kΩ. With the creeper unit engaged (button released), it should indicate 2.76 kΩ. If the resistances indicated are not okay, remove and replace the creeper unit switch. B. If the creeper unit switch is okay, continue to step 4. 4. Check for short to a positive voltage. A. Turn the ignition key ON. Measure the voltage between the connector: SW−143 pin 2, wire (HG) and ground If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated continue to step 5. 5. Check for a short to + 8 or + 12 V. A. With the keystart ON. Measure the voltage between the connector: SW−143 pin 1, wire (AB) and ground If the indicated voltage is not approximately + 5 V, repair or replace the harness as required. B. If the voltage is approximately +5 V, download the correct software release. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, SW−143 and MOD−150 sect. 55, chap. 8, fig. 42, fig. 272 and fig. 280), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 27, sect. 55, chap. 6, page 391).
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2432 − OIL PRESSURE SWITCH JAMMED OFF. Control module: Power Shuttle control unit NOTE: Fault that the control unit highlights a few seconds after the end of the start procedure, the tractor works (during the start procedure the tractor does not work). Possible fault modes: 1. Switch faulty 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the pressure switch connector SEN−182, the main connector C−9 and the connector of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check the transmission pressure switch. A. Disconnect the switch connector SEN−182. Check continuity with a tester between: SEN−182 pin 1 and pin 2 As it is a normally closed switch, with a lack of pressure there should be continuity. If there is no continuity, replace the switch. B. If the switch is okay, continue to step 3. 3. Check for an open circuit. A. Disconnect the connector of the control unit 85, test the continuity between: MOD−150 pin 20, wire (SN) and SEN−182 pin 1, wire (SN) if an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, MOD−150 and SEN−182 sect. 55, chap. 8, fig. 44, fig. 281 and fig. 326), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 25, sect. 55, chap. 6, page 387).
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2433 − OIL PRESSURE SWITCH JAMMED ON. Control module: Power Shuttle control unit NOTE: Fault that the control unit highlights a few seconds after the end of the start procedure, the tractor works (during the start procedure the tractor does not work). Possible fault modes: 1. Switch faulty 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the pressure switch connector SEN−182, the main connector C−9 and the connector of the control unit MOD−150. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check for a short to +5 V. A. Disconnect the connector 73. With the ignition key ON, measure the voltage between. SEN−182 pin 1, wire (SN) and ground if there is a voltage of +5 V (short between the two wires of the switch harness) replace or repair the wiring harness as required. B. If the harness is okay, remove and replace the switch. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−9, MOD−150 and SEN−182 sect. 55, chap. 8, fig. 44, fig. 281 and fig. 326), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 25, sect. 55, chap. 6, page 387).
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4WD FAULT CODES 6011 − PERMANENT FOUR−WHEEL DRIVE SWITCHES AND SENSORS SUPPLY FUSE ERROR. Control module: Four−wheel drive control unit NOTE: Four−wheel drive is always engaged, release is disabled. Possible fault modes: 1. Burned out fuse 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the supply of the sensors/switches in H9. A. Enter the HH menu select H9 of the control unit SC. Select channel ch 7. The display will show a value from 700 to a maximum of 900, if the value displayed remains very low continue to phase 3. B. If the display shows a correct value, while still in H9, wiggle the harness and the connector of the control unit MOD−64 to check for an intermittent circuit. The display will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check fuse F4 (10A). A. Check it is not blown and is well positioned; replace it if blown. B. If the fuse is okay, continue to step 3. 3. Check the connector of the control unit MOD−64 and the connectors behind the fuse box MOD−25−A pin 4. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 4. 4. Check for an open circuit. A. Disconnect the connector of the control unit MOD−64. Measure the continuity between: MOD−64 pin 15 wire (C) and MOD−25−A pin 4 wire (C) if an open circuit is indicated, repair or replace the harness as required. B. If the wiring harness is okay, continue to step 5. 5. Check for a short to ground. A. Measure the continuity between: MOD−64 pin 15 wire (C) and ground if a short to ground is indicated, repair or replace the wiring harness as required. B. If the wiring harness is okay and the error is repeated, download the correct software release, if the error occurs again then remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors MOD−25−A and MOD−64 sect. 55, chap. 8, fig. 95, fig. 183), (Components, diagram 1÷4. sect. 55, chap. 6, page 337), (Diagram 1, sect. 55, chap. 6, page 329).
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6014 − SHORT CIRCUIT BETWEEN THE TERMINALS OF THE FOUR−WHEEL DRIVE SOLENOID VALVE. Control module: Four−wheel drive control unit NOTE: Four−wheel drive is always engaged, release is disabled. Possible fault modes: 1. Solenoid valve faulty 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the four wheel drive solenoid valve in H9 channel ch130. A. Enter the HH menu select H9 of the control unit SC. Press the manual four−wheel drive engagement switch, the display will show a number ranging from approximately 500P600, if this does not happen, continue to phase 2. B. If the values displayed are okay, while still in H9, wiggle the harness, the four−wheel drive solenoid valve connector SOL−135, main connector C−6 and the connector of the control unit MOD−64 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the connector of the control unit MOD−64 and the main connector C−6 and the four−wheel drive solenoid valve connector SOL−135. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check for a short circuit between the terminals of the solenoid valve. A. Disconnect the connector of the control unit MOD−64 and the connector of the solenoid valve SOL−134. Measure the continuity between: MOD−64 pin 27 wire (CL) and MOD−64 pin 5 wire (CB) if a short circuit is indicated, repair or replace the wiring harness as required. B. If the wiring harness is okay and the error is repeated, download the correct software release, if the error occurs again then remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−6, MOD−64 and SOL−135 sect. 55, chap. 8, fig. 30, fig. 183, fig. 261), (Components, diagram 1÷4. sect. 55, chap. 6, page 327), (Diagram 1, sect. 55, chap. 6, page 329).
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6020 − AUTOMATIC/MANUAL FOUR−WHEEL DRIVE SELECTOR SWITCH FAULTY. Control module: Four−wheel drive control unit NOTE: Four−wheel drive is engaged automatically. Possible fault modes: 1. Switch faulty 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the four wheel drive switch in H5. A. Enter the HH menu select H5 of the control unit SC. Press the switch first in manual and then in automatic mode the display will show respectively d41 then d42, if this does not happen, continue to phase 2. B. If the values displayed are okay, while still in H5, wiggle the harness, the four−wheel drive switch connector SW−35 and the connector of the control unit MOD−64 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the connector of the control unit MOD−64 and the four−wheel drive switch connector SW−35. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the four−wheel drive engagement switch. A. Disconnect the switch connector SW−35. Measure on the switch between SW−35 pin 1 and pin 2 pressing the switch on the manual portion there is continuity SW−35 pin 3 and pin 4 pressing the switch on the automatic portion there is continuity SW−35 pin 1 and pin 4 there will be no continuity in any case, if the switch does not have these characteristics, replace it. B. If the switch is okay, continue to step 4. 4. Check for a short circuit in the wiring harness. A. Disconnect the control unit connector MOD−64. Measure the continuity between: SW−35 pin 1 wire (GN) and pin 2 wire (C) SW−35 pin 1 wire (GN) and pin 4 wire (CL) SW−35 pin 4 wire (CL) and pin 2 wire (C) if there is a short circuit, repair or replace the wiring harness as required. B. If the wiring harness is okay, continue to step 5. 5. Check for a short circuit to positive. A. With the keystart ON. Check on the connector MOD−64 between: MOD−64 pin 33 wire (CN) and ground MOD−64 pin 34 wire (Cl) and ground if there is a short circuit to positive, repair or replace the wiring harness as required. B. If the wiring harness is okay and the error is repeated, download the latest software release, if the error occurs again then remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors SW−35 and MOD−64 sect. 55, chap. 8, fig. 134 and fig. 183), (Components, diagram 1÷4. sect. 55, chap. 6, page 327), (Diagram 1, sect. 55, chap. 6, page 329).
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6021 − FOUR−WHEEL DRIVE SOLENOID STUCK OFF. Control module: Four−wheel drive control unit NOTE: Four−wheel drive is always engaged, release is disabled. Possible fault modes: 1. Solenoid faulty 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the four wheel drive solenoid valve in H9 channel ch130. A. Enter the HH menu select H9 of the control unit SC. Press the manual four−wheel drive engagement switch, the display will show a number ranging from approximately 500P600, if this does not happen, continue to phase 2. B. If the values displayed are okay, while still in H9, wiggle the harness, the four−wheel drive solenoid valve connector SOL−135, the main connector C−6 and the connector of the control unit MOD−64 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the connector of the control unit MOD−64, the main connector C−6 and the four−wheel drive solenoid valve connector SOL−135. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the solenoid valve wiring harness for a short to positive. A. Disconnect the connectors MOD−64 and SOL−135, turn the ignition switch ON. Measure between: SOL−135 pin 1 wire (CL) and ground SOL−135 pin 2 wire (CB) and ground if a short to + 12 V is indicated, repair or replace the wiring harness as required. B. If the wiring harness is okay and the error is repeated, download the latest software release, if the error occurs again then remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−6, MOD−64 and SOL−135 sect. 55, chap. 8, fig. 30, fig. 183, fig. 261), (Components, diagram 1÷4. sect. 55, chap. 6, page 327), (Diagram 1, sect. 55, chap. 6, page 329).
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6023 − FOUR−WHEEL DRIVE SOLENOID CIRCUIT OPEN. Control module: Four−wheel drive control unit NOTE: Four−wheel drive is always engaged, release is disabled. Possible fault modes: 1. Solenoid faulty 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the four wheel drive solenoid valve in H9 channel ch130. A. Enter the HH menu select H9 of the control unit SC. Press the manual four−wheel drive engagement switch, the display will show a number ranging from approximately 500P600, if this does not happen, continue to phase 2. B. If the values displayed are okay, while still in H9, wiggle the harness, the four−wheel drive solenoid valve connector SOL−135, the main connector C−6 and the connector of the control unit MOD−64 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the connector of the control unit MOD−64, the main connector C−6 and the four−wheel drive solenoid valve connector SOL−135. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the four−wheel drive engagement solenoid SOL−135. A. Disconnect connector SOL−135. Measure between: SOL−135 pin 1 and pin 2 If the resistance indicated is not approximately 7.5 Ω replace the solenoid valve. B. If the solenoid valve is okay, continue to step 4. 4. Check for a short circuit to ground. A. Disconnect the connector of the control unit MOD−64 and check between: MOD−64 pin 27 wire (CL) and ground MOD−64 pin 5 wire (CB) and ground if there is a short circuit to ground, repair or replace the wiring harness as required. B. If the wiring harness is okay, continue to step 5. 5. Check for an open circuit. A. Check on the connector SOL−133 between: SOL−135 pin 1 wire (CL) and MOD−64 pin 27 wire (CL) SOL−135 pin 2 wire (CB) and MOD−64 pin 57 wire (CB) if an open circuit is indicated, repair or replace the harness as required. B. If the wiring harness is okay and the error is repeated, download the latest software release, if the error occurs again then remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−6, MOD−64 and SOL−135 sect. 55, chap. 8, fig. 30, fig. 183, fig. 261), (Components, diagram 1÷4. sect. 55, chap. 6, page 327), (Diagram 1, sect. 55, chap. 6, page 329).
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6031 − VOLTAGE FROM THE FRONT SHAFT SPEED SENSOR (VAA) TOO LOW. Control module: Four−wheel drive control unit NOTE: Automatic four−wheel drive is disabled. Possible fault modes: 1. Sensor faulty 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the front shaft speed sensor connector SEN−128, the main connector C−6 and the connector of the control unit MOD−64. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check the sensor supply. A. Disconnect the connector of the sensor SEN−128, turn the ignition switch ON. Measure the voltage between: SEN−128 pin 1 wire (C) and ground if the indicated voltage is not approximately 12 V, repair or replace the harness as required. B. If the supply is okay, continue to step 3. 3. Check for a short to ground. A. Disconnect the connector of the control unit MOD−64. Measure between: MOD−64 pin 22 wire (V) and ground if a short to ground is indicated, repair or replace the wiring harness as required. B. If the wiring harness is okay and the error is repeated, replace the sensor. If the error is repeated, download the latest software release, if this is not enough then remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−6, MOD−64 and SEN−128 sect. 55, chap. 8, fig. 30, fig. 183 and fig. 254), (Components, diagram 1÷4. sect. 55, chap. 6, page 327), (Diagram 1, sect. 55, chap. 6, page 329).
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6032 − VOLTAGE FROM THE FRONT SHAFT SPEED SENSOR (VAA) TOO HIGH. Control module: Four−wheel drive control unit NOTE: Automatic four−wheel drive is disabled. Possible fault modes: 1. Sensor faulty 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the front shaft speed sensor connector SEN−128, the main connector C−6 and the connector of the control unit MOD−64. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check for a short circuit to positive. A. Disconnect the control unit connector MOD−64 and that of the front shaft speed SEN−128. Turn the ignition key ON and check between: MOD−64 pin 22 wire (V) and ground if a short to a positive voltage is indicated, repair or replace the wiring harness as required. B. If the wiring harness is okay, continue to step 3. 3. Check for an open circuit. A. Measure the continuity between the connectors: MOD−64 pin 22 wire (V) and SEN−128 pin 2 wire (V) MOD−64 pin 1 wire (B) and SEN−128 pin 3 wire (B) if an open circuit is indicated, repair or replace the harness as required. B. If the wiring harness is okay and the error is repeated, replace the sensor. If the error is repeated, download the latest software release, if this is not enough then remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−6, MOD−64 and SEN−128 sect. 55, chap. 8, fig. 30, fig. 183 and fig. 254), (Components, diagram 1÷4. sect. 55, chap. 6, page 327), (Diagram 1, sect. 55, chap. 6, page 329).
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6033 − VOLTAGE FROM THE REAR SHAFT SPEED SENSOR (VAP) TOO LOW. Control module: Four−wheel drive control unit NOTE: Automatic four−wheel drive is disabled. Possible fault modes: 1. Sensor faulty 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the rear shaft speed sensor connector SEN−127, the main connector C−6 and the connector of the control unit MOD−64. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check the sensor supply. A. Disconnect the connector of the sensor SEN−127, turn the ignition switch ON. Measure the voltage between: SEN−127 pin 1 wire (C) and ground if the indicated voltage is not approximately 12 V, repair or replace the harness as required. B. If the supply is okay, continue to step 3. 3. Check for a short to ground. A. Disconnect the connector of the control unit MOD−64. Measure between: MOD−64 pin 30 wire (VN) and ground if a short to ground is indicated, repair or replace the wiring harness as required. B. If the wiring harness is okay and the error is repeated, replace the sensor. If the error is repeated, download the latest software release, if this is not enough then remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−6, MOD−64 and SEN−127 sect. 55, chap. 8, fig. 30, fig. 183 and fig. 253), (Components, diagram 1÷4. sect. 55, chap. 6, page 327), (Diagram 1, sect. 55, chap. 6, page 329).
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6034 − VOLTAGE FROM THE REAR SHAFT SPEED SENSOR (VAP) TOO HIGH. Control module: Four−wheel drive control unit NOTE: Automatic four−wheel drive is disabled. Possible fault modes: 1. Sensor faulty 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the rear shaft speed sensor connector SEN−127, the main connector C−6 and the connector of the control unit MOD−64. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check for a short circuit to positive. A. Disconnect the control unit connector MOD−64 and that of the rear shaft speed SEN−127. Turn the ignition key ON and check between: MOD−64 pin 30 wire (VN) and ground if a short to a positive voltage is indicated, repair or replace the wiring harness as required. B. If the wiring harness is okay, continue to step 3. 3. Check for an open circuit. A. Measure the continuity between the connectors: MOD−64 pin 30 wire (VN) and SEN−127 pin 2 wire (VN) MOD−64 pin 1 wire (B) and SEN−127 pin 3 wire (B) if an open circuit is indicated, repair or replace the harness as required. B. If the wiring harness is okay and the error is repeated, replace the sensor. If the error is repeated, download the latest software release, if this is not enough then remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−6, MOD−64 and SEN−127 sect. 55, chap. 8, fig. 30, fig. 183 and fig. 253), (Components, diagram 1÷4. sect. 55, chap. 6, page 327), (Diagram 1, sect. 55, chap. 6, page 329).
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6035 − FREQUENCY FROM THE FRONT SHAFT SPEED SENSOR (VAA) TOO HIGH. Control module: Four−wheel drive control unit NOTE: Automatic four−wheel drive is disabled. Possible fault modes: 1. Sensor faulty 2. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the codes that appear with this. A. Do the tests related to the other codes. B. If after repairing the other codes it appears again, continue to step 2. 2. Replacing sensor SEN−128. A. Replace the sensor. B. If, after replacing the sensor, the error is repeated, download the latest software release, if this is not enough then remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors SEN−128 sect. 55, chap. 8, fig. 254), (Components, diagram 1÷4. sect. 55, chap. 6, page 327), (Diagram 1, sect. 55, chap. 6, page 329).
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6036 − FREQUENCY FROM THE REAR SHAFT SPEED SENSOR (VAP) TOO HIGH. Control module: Four−wheel drive control unit NOTE: Automatic four−wheel drive is disabled. Possible fault modes: 1. Sensor faulty 2. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the codes that appear with this. A. Do the tests related to the other codes. B. If after repairing the other codes it appears again, continue to step 2. 2. Replacing sensor SEN−127. A. Replace the sensor. B. If, after replacing the sensor, the error is repeated, download the latest software release, if this is not enough then remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors SEN−127 sect. 55, chap. 8, fig. 253), (Components, diagram 1÷4. sect. 55, chap. 6, page 327), (Diagram 1, sect. 55, chap. 6, page 329).
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6037 − INCONSISTENT SENSORS (VAA) AND (VAP). Control module: Four−wheel drive control unit NOTE: Automatic four−wheel drive is disabled. Possible fault modes: 1. Sensor faulty 2. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the codes that appear with this. A. Do the tests related to the other codes. B. If after repairing the other codes it appears again, continue to step 2. 2. Check the advances and the transmission ratio fitted on the axle. A. After checking the transmission ratio fitted on the axle, check the advance is correct either by changing the tyre or by inflating it correctly. B. If the transmission ratio is okay and the advance has been repaired and the error is repeated, continue to step 3. 3. Replacing the sensors SEN−127 and SEN−128. A. Replacing the sensors starting from the one on the front shaft SEN−128, to then move on to the one on the rear shaft SEN−127. B. If, after replacing the sensors, the error is repeated, download the latest software release, if this is not enough then remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors SEN−127 and SEN−128 sect. 55, chap. 8, fig. 253 and fig. 254), (Components, diagram 1÷4. sect. 55, chap. 6, page 327), (Diagram 1, sect. 55, chap. 6, page 329).
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6038 − VOLTAGE FROM TILT SENSOR TOO LOW. Control module: Four−wheel drive control unit NOTE: The control unit ignores the indications of the tilt sensor and follows the logic of the four−wheel drive engagement on the flat surface. Possible fault modes: 1. Sensor faulty 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the tilt sensor in H9. A. Enter the HH diagnostics program, select program H9 of the control unit SC, at the channel ch11, with the tractor on level ground the display will show a number equal to approximately 150÷300, if this does not happen, continue to phase 2. B. If the values displayed are okay, while in H9, with the lever in neutral, wiggle the harness, the tilt sensor connector SEN−33 and the connector of the control unit MOD−64 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the tilt sensor connector SEN−33 and the connector of the control unit MOD−64. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the sensor supply. A. Disconnect the connector of the sensor SEN−33, turn the ignition switch ON. Measure the voltage between: SEN−33 pin 1 wire (C) and ground if the indicated voltage is not approximately 12 V, repair or replace the harness as required. B. If the supply is okay, continue to step 4. 4. Check for a short to ground. A. Disconnect the connector of the control unit MOD−64. Measure between: MOD−64 pin 25 wire (GV) and ground if a short to ground is indicated, repair or replace the wiring harness as required. B. If the wiring harness is okay, continue to step 5. 5. Check for an open circuit. A. Measure the continuity between the connectors: MOD−64 pin 25 wire (GV) and SEN−33 pin 2 wire (GV) MOD−64 pin 1 wire (B) and SEN−33 pin 3 wire (B) if an open circuit is indicated, repair or replace the harness as required. B. If the wiring harness is okay and the error is repeated, replace the sensor. If the error is repeated, download the latest software release, if this is not enough then remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors SEN−33 and MOD−64 sect. 55, chap. 8, fig. 127 and fig. 183), (Components, diagram 1÷4. sect. 55, chap. 6, page 327), (Diagram 1, sect. 55, chap. 6, page 329).
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6039 − VOLTAGE FROM TILT SENSOR TOO HIGH. Control module: Four−wheel drive control unit NOTE: The control unit ignores the indications of the tilt sensor and follows the logic of the four−wheel drive engagement on the flat surface. Possible fault modes: 1. Sensor faulty 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the tilt sensor in H9. A. Enter the HH diagnostics program, select program H9 of the control unit SC, at the channel ch11, with the tractor on level ground the display will show a number equal to approximately 150÷300, if this does not happen, continue to phase 2. B. If the values displayed are okay, while in H9, with the lever in neutral, wiggle the harness, the tilt sensor connector SEN−33 and the connector of the control unit MOD−64 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the tilt sensor connector SEN−33 and the connector of the control unit MOD−64. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check for a short circuit to positive. A. Disconnect the control unit connector MOD−64 and that of the tilt sensor SEN−33. Turn the ignition key ON and check between: MOD−64 pin 25 wire (GV) and ground if a short to a positive voltage is indicated, repair or replace the wiring harness as required. B. If the wiring harness is okay and the error is repeated, replace the sensor. If the error is repeated, download the latest software release, if this is not enough then remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors SEN−33 and MOD−64 sect. 55, chap. 8, fig. 127 and fig. 183), (Components, diagram 1÷4. sect. 55, chap. 6, page 327), (Diagram 1, sect. 55, chap. 6, page 329).
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6041 − VOLTAGE FROM STEERING ANGLE SENSOR TOO HIGH. Control module: Four−wheel drive control unit NOTE: The control unit ignores the indications of the steering sensor. Possible fault modes: 1. Sensor faulty 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the steering angle sensor in H9. A. Enter the HH diagnostics program, select program H9 of the control unit SC, at the channel ch21, with the engine running and steering the display will show a number of approximately 400÷600 with steering < 45° and with steering > 45° there will be a number equal to approximately 150÷300, if this does not happen, continue to phase 2. B. If the values displayed are okay, while in H9, with the lever in neutral, wiggle the harness, the steering switch connector SEN−126, the main cable connector C−6, and the connector of the control unit MOD−64 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the steering switch connector SEN−126, the main cable connector C−6, and the connectors of the control unit MOD−64. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the steering switch SEN−126. A. Disconnect connector SEN−126. Measure the resistance between: SEN−126 pin 1 and pin 2. With steering > 45° (button pressed), it should indicate 0.560 kΩ. With steering < 45° (button released), it should indicate 2.76 kΩ. If the resistances indicated are not okay, remove and replace the range switch. B. If the range position switch is okay, continue to step 4. 4. Check for a short circuit to positive. A. Disconnect the control unit connector MOD−64 and that of the steering sensor SEN−126. Turn the ignition key ON and check between: MOD−64 pin 9 wire (SB) and ground if a short to a positive voltage is indicated, repair or replace the wiring harness as required. B. If the wiring harness is okay and the error is repeated, replace the sensor. If the error is repeated, download the latest software release, if this is not enough then remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−6, MOD−64 and SEN−126 sect. 55, chap. 8, fig. 30, fig. 183 and fig. 252), (Components, diagram 1÷4. sect. 55, chap. 6, page 327), (Diagram 1, sect. 55, chap. 6, page 329).
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6042 − VOLTAGE FROM STEERING ANGLE SENSOR TOO LOW. Control module: Four−wheel drive control unit NOTE: The control unit ignores the indications of the steering sensor. Possible fault modes: 1. Sensor faulty 2. Wiring fault 3. ECU fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the steering angle sensor in H9. A. Enter the HH diagnostics program, select program H9 of the control unit SC/SD, at the channel Ch21, with the engine running and steering the display will show a number of approximately 900 with steering < 45° and with steering > 45° there will be a number of approximately 10, if this does not happen continue to step 2. B. If the values displayed are okay, while in H9, with the lever in neutral, wiggle the harness, the steering switch connector SEN−126, the main cable connector C−6, and the connector of the control unit MOD−64 to check for an intermittent circuit. In this case the display may change. Repair or replace as necessary. 2. Check the steering switch connector SEN−126, the main cable connector C−6, and the connectors of the control unit MOD−64. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the sensor supply. A. Disconnect the connector of the sensor SEN−126, turn the ignition switch ON. Measure the voltage between: SEN−126 pin 1 wire (C) and ground if the indicated voltage is not approximately 12 V, repair or replace the harness as required. B. If the supply is okay, continue to step 4. 4. Check for a short to ground. A. Disconnect the connector of the control unit MOD−64. Measure between: MOD−64 pin 9 wire (SB) and ground if a short to ground is indicated, repair or replace the wiring harness as required. B. If the wiring harness is okay, continue to step 5. 5. Check for an open circuit. A. Measure the continuity between the connectors: MOD−64 pin 9 wire (SB) and SEN−126 pin 2 wire (SB) if an open circuit is indicated, repair or replace the harness as required. B. If the wiring harness is okay and the error is repeated, replace the sensor. If the error is repeated, download the latest software release, if this is not enough then remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−6, MOD−64 and SEN−126 sect. 55, chap. 8, fig. 30, fig. 183 and fig. 252), (Components, diagram 1÷4. sect. 55, chap. 6, page 327), (Diagram 1, sect. 55, chap. 6, page 329).
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FRONT PTO CODES 8007 − SHORT CIRCUIT TO +12 V ON ELECTROMAGNETIC CLUTCH 4WD ECU NOTE: The ECU disables the front PTO Possible fault modes: 1. Faulty electromagnet. 2. Faulty wiring. 3. Faulty ECU. Remedies: NOTE: Once the cause of the fault code has been removed, clear the fault code and test the system for normal operation. 1. Check the PTO engagement electromagnetic clutch SEN−208, the intermediate connector C−13 and the connector of the ECU MOD−204. A. Make sure the connectors are connected, not damaged, the pins are in the correct position and that the coupling is tight. Repair or replace as required. B. If the connectors are okay, continue to the next step. 2. Check for a short circuit to positive. A. Disconnect the connector of the electromagnetic clutch SEN−208 and of the ECU MOD−204. Turn the ignition key ON and measure between: SEN−208 pin 4 wire (AN) and ground if a short circuit to positive is found, repair or replace the wiring harness as required. B. If the wiring harness is okay and the error persists, replace the electromagnetic clutch. If the error is repeated, download the latest software release; if this is not enough, remove and replace the ECU. For the connectors, components and wiring diagrams affected, see (Connectors C−13, MOD−204 and SEN−208, sect. 55, chapt. 8, fig. 59, fig. 331 and fig. 334), (Components, diagram 23÷28, sect. 55, chapt. 6, page 383), (Diagram 28, sect. 55, chapt. 6, page 393).
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8008 − SHORT CIRCUIT TO GROUND OR OPEN CIRCUIT ON ELECTROMAGNETIC CLUTCH. 4WD ECU NOTE: The ECU disables the front PTO Possible fault modes: 1. Faulty electromagnet. 2. Faulty wiring. 3. Faulty ECU. Remedies: NOTE: Once the cause of the fault code has been removed, clear the fault code and test the system for normal operation. 1. Check the PTO engagement electromagnetic clutch SEN−208, the intermediate connector C−13 and the connector of the ECU MOD−204. A. Make sure the connectors are connected, not damaged, the pins are in the correct position and that the coupling is tight. Repair or replace as required. B. If the connectors are okay, continue to the next step. 2. Check for a short circuit to ground. A. Disconnect the connectors of ECU MOD−204 and of the electromagnetic clutch SEN−208. Measure between: SEN−204 pin 4 wire (AN) and ground SEN−204 pin 3 wire (A) and ground if a short circuit to ground is detected, repair or replace the wiring harness as required. B. If the wiring harness is okay, continue to the next step. 3. Check for an open circuit. A. Measure the continuity between the connectors: MOD−204 pin 7 wire (AN) and SEN−208 pin 4 wire (AN) MOD−204 pin 2 wire (A) and SEN−208 pin 3 wire (A) if an open circuit is detected, repair or replace the harness as required. B. If the wiring harness is okay and the error persists, replace the electromagnetic clutch. If the error is repeated, download the latest software release; if this is not enough, remove and replace the ECU. For the connectors, components and wiring diagrams affected, see (Connectors C−13, MOD−204 and SEN−208, sect. 55, chapt. 8, fig. 59, fig. 331 and fig. 334), (Components, diagram 23÷28, sect. 55, chapt. 6, page 383), (Diagram 28, sect. 55, chapt. 6, page 393).
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8017 − SHORT CIRCUIT BETWEEN TERMINALS OF ELECTROMAGNETIC CLUTCH SLIP DETECTOR.
4WD ECU NOTE: The ECU disables the front PTO Possible fault modes: 1. Faulty electromagnetic clutch slipping detector. 2. Faulty wiring. 3. Faulty ECU. Remedies: NOTE: Once the cause of the fault code has been removed, clear the fault code and test the system for normal operation. 1. Check the PTO engagement electromagnetic clutch assembly SEN−208, the intermediate connector C−13 and the connector of the ECU MOD−204. A. Make sure the connectors are connected, not damaged, the pins are in the correct position and that the coupling is tight. Repair or replace as required. B. If the connectors are okay, continue to the next step. 2. Check for a short circuit between terminals. A. Disconnect the connector of the electromagnetic clutch SEN−208 and of the ECU MOD−204. Turn the ignition key ON and measure between: SEN−208 pin 1 wire (VB) and SEN−208 pin 2 wire (BR) if a short circuit is detected, repair or replace the harness as required. B. If the wiring harness is okay and the error persists, replace the electromagnetic clutch. If the error is repeated, download the latest software release; if this is not enough, remove and replace the ECU. For the connectors, components and wiring diagrams affected, see (Connectors C−13, MOD−204 and SEN−208, sect. 55, chapt. 8, fig. 59, fig. 331 and fig. 334), (Components, diagram 23÷28, sect. 55, chapt. 6, page 383), (Diagram 28, sect. 55, chapt. 6, page 393).
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8032 − SHORT CIRCUIT TO +12 V OR OPEN CIRCUIT ON ELECTROMAGNETIC CLUTCH SLIP DETECTOR. 4WD ECU NOTE: The ECU disables the front PTO Possible fault modes: 1. Faulty electromagnetic clutch slipping detector. 2. Faulty wiring. 3. Faulty ECU. Remedies: NOTE: Once the cause of the fault code has been removed, clear the fault code and test the system for normal operation. 1. Check the PTO engagement electromagnetic clutch assembly SEN−208, the intermediate connector C−13 and the connector of the ECU MOD−204. A. Make sure the connectors are connected, not damaged, the pins are in the correct position and that the coupling is tight. Repair or replace as required. B. If the connectors are okay, continue to the next step. 2. Check for a short circuit to positive. A. Disconnect the electromagnetic clutch connector SEN−208 and the connector of the ECU MOD−204. Turn the ignition key ON and measure between: SEN−208 pin 2, wire (BR) and ground. if a short circuit to positive is detected, repair or replace the harness as required. B. If the connectors are okay, continue to the next step. 3. Check for an open circuit. A. Measure the continuity between: SEN−208 pin 2, wire (BR) and MOD−204 pin 19, wire (BR) SEN−208 pin 1, wire (VB) and MOD−204 pin 26, wire (VB) if an open circuit is detected, repair or replace the harness as required. B. If the wiring harness is okay and the error persists, replace the electromagnetic clutch. If the error is repeated, download the latest software release; if this is not enough, remove and replace the ECU. For the connectors, components and wiring diagrams affected, see (Connectors C−13, MOD−204 and SEN−208, sect. 55, chapt. 8, fig. 59, fig. 331 and fig. 334), (Components, diagram 23÷28, sect. 55, chapt. 6, page 383), (Diagram 28, sect. 55, chapt. 6, page 393).
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8033 − OPEN CIRCUIT ON FRONT PTO NC SWITCH. 4WD ECU NOTE: The ECU disables the front PTO Possible fault modes: 1. Switch faulty. 2. Faulty wiring. 3. Faulty ECU. Remedies: NOTE: Once the cause of the fault code has been removed, clear the fault code and test the system for normal operation. 1. Check the 4WD switch in H5. A. Enter the HH menu, select H5 of the ECU SD. Engage the front PTO and then stop it. Automatically, the display shows d140 then d141 respectively; if this does not happen, continue to the next step. B. If the displayed values are okay, while still in H5, wiggle the harness, the front 4WD switch connector SW−12 and the connector of the ECU MOD−204 to check for an intermittent circuit. In this case the display may change. Repair or replace as required. 2. Check the operation of the front PTO engagement switch. A. Disconnect the connector of the push button SW−12. With the push button in rest position (released PTO) there is continuity between: SW−12 pin 1 and pin 3 with engaged PTO there is continuity between: SW−12 pin 1 and pin 2 if the switch does not comply with the specifications, replace the switch. B. If the switch is okay, continue to the next step. 3. Search for an open circuit on the harness. A. Disconnect the connector of the push button MOD−204. Measure the continuity between: SW−12 pin 1, wire (MV) and MOD−204 pin 8, wire (MV) SW−12 pin 3, wire (R) and MOD−204 pin 17, wire (R) if an open circuit is detected, repair or replace the harness as required. B. If the wiring harness is okay and the error persists, download the latest software release; if the error occurs again, remove and replace the ECU. For the connectors, components and wiring diagrams affected, see (Connectors SW−12, C−13 and MOD−204, sect. 55, chapt. 8, fig. 57, fig. 59, fig. 331), (Components, diagram 23÷28, sect. 55, chapt. 6, page 383), (Diagram 28, sect. 55, chapt. 6, page 393).
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8037− SHORT CIRCUIT TO FRONT PTO NO SWITCH. 4WD ECU NOTE: The ECU disables the front PTO Possible fault modes: 1. Switch faulty. 2. Faulty wiring. 3. Faulty ECU. Remedies: NOTE: Once the cause of the fault code has been removed, clear the fault code and test the system for normal operation. 1. Check the 4WD switch in H5. A. Enter the HH menu, select H5 of the ECU SD. Engage the front PTO and then stop it. Automatically, the display shows d140 then d141 respectively; if this does not happen, continue to the next step. B. If the displayed values are okay, while still in H5, wiggle the harness, the front 4WD switch connector SW−12 and the connector of the ECU MOD−204 to check for an intermittent circuit. In this case the display may change. Repair or replace as required. 2. Check the operation of the front PTO engagement switch. A. Disconnect the connector of the push button SW−12. With the push button in rest position (released PTO) there is continuity between: SW−12 pin 1 and pin 3 with engaged PTO there is continuity between: SW−12 pin 1 and pin 2 if the switch does not comply with the specifications, replace the switch. B. If the switch is okay, continue to the next step. 3. Search for a short circuit on the wiring harness. A. Disconnect the connector of the push button MOD−204. Measure the continuity between: SW−12 pin 1, wire (MV) and MOD−204 pin 8, wire (MV) SW−12 pin 2, wire (HV) and MOD−204 pin 16, wire (HV) if a short circuit is detected, repair or replace the harness as required. B. If the wiring harness is okay and the error persists, download the latest software release; if the error occurs again, remove and replace the ECU. For the connectors, components and wiring diagrams affected, see (Connectors SW−12, C−13 and MOD−204, sect. 55, chapt. 8, fig. 57, fig. 59, fig. 331), (Components, diagram 23÷28, sect. 55, chapt. 6, page 383), (Diagram 28, sect. 55, chapt. 6, page 393).
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FRONT ELECTRONIC LIFT ERROR CODES 9001 − OPEN CIRCUIT IN THE FRONT LIFT LINK POSITION POTENTIOMETER. Control module: Four Wheel Drive ECU NOTE: The ECU disables the front lift; the next time the starting switch key is placed in ON, a potentiometer calibration is required. Possible fault modes: 1. Faulty potentiometer. 2. Faulty wiring harness. 3. Faulty ECU. Remedies: NOTE: Once the cause of the error code has been removed, clear the error code and test the system for normal operation. 1. Check the potentiometer in H9. A. Enter the HH menu, select H9 of the SD ECU, then select channel 28. The display shows a digit ≤ 30 to get this code. If the displayed value ranges from 30 to 900, go to the next step. B. If the displayed values are regular, always in H9 twist the harness, the link lift potentiometer connector SEN−101, the intermediate connector C−13 and the ECU connector MOD−204 to detect an intermittent circuit. The displaying could change depending on the conditions. Repair or replace as necessary. 2. Check the potentiometer SEN−101. A. Disconnect the potentiometer and measure between: SEN−101 pin 1 and pin 3 if the resistance is not approximately 4000 Ω ± 20% replace the potentiometer. B. If the potentiometer is ok, go to the next step. 3. Check for an open circuit. A. Disconnect the ECU connector MOD−204. Measure the continuity between: MOD−204 pin 26, cable (VB) and SEN−101 pin 1, cable (VB) MOD−204 pin 24, cable (V) and SEN−101 pin 2, cable (V) MOD−204 pin 1, cable (AB) and SEN−101 pin 3, cable (AB) if an open circuit is found, repair or replace the harness as required. B. If the harness is ok and the error persists, download the latest software version. If this is not sufficient, remove and replace the ECU. For the concerned connectors, components and wiring diagrams, see (connectors C−13, SEN−101 and MOD−204, sect. 55, chapt. 8, fig. 58, fig. 221, fig. 331), (Components, wiring diagram 23÷28, sect. 55, chapt. 6, page 383), (Wiring diagram 28, sect. 55, chapt. 6, page 393).
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9002 − SHORT CIRCUIT TO POSITIVE IN THE FRONT LIFT LINK POSITION POTENTIOMETER. Control module: Four Wheel Drive ECU NOTE: The ECU disables the front lift; the next time the starting switch key is placed in ON, a potentiometer calibration is required. Possible fault modes: 1. Faulty potentiometer. 2. Faulty wiring harness. 3. Faulty ECU. Remedies: NOTE: Once the cause of the error code has been removed, clear the error code and test the system for normal operation. 1. Check the potentiometer in H9. A. Enter the HH menu, select H9 of the SD ECU, then select channel 28. The display shows a digit ≥ 900 to get this code. If the displayed value ranges from 30 to 900, go to the next step. B. If the displayed values are regular, always in H9 twist the harness, the link lift potentiometer connector SEN−101, the intermediate connector C−13 and the ECU connector MOD−204 to detect an intermittent circuit. The displaying could change depending on the conditions. Repair or replace as necessary. 2. Check the potentiometer SEN−101. A. Disconnect the potentiometer and measure between: SEN−101 pin 1 and pin 3 if the resistance is not approximately 4000 Ω ± 20% replace the potentiometer. B. If the potentiometer is ok, go to the next step. 3. Check for a short circuit to positive (+5 V or 12 V). A. Disconnect the ECU connector MOD−204. Place the starting switch key in ON and measure between: MOD−204 pin 24, cable (V) and the ground if a short circuit to +5 V or +12 V is detected, repair or replace the harness as required. B. If the harness is ok and the error persists, download the latest software version. If this is not sufficient, remove and replace the ECU. For the concerned connectors, components and wiring diagrams, see (connectors C−13, SEN−101 and MOD−204, sect. 55, chapt. 8, fig. 58, fig. 221, fig. 331), (Components, wiring diagram 23÷28, sect. 55, chapt. 6, page 383), (Wiring diagram 28, sect. 55, chapt. 6, page 393).
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9011 − OPEN CIRCUIT IN THE FRONT LIFT UPPER LIMIT POTENTIOMETER. Control module: Four Wheel Drive ECU NOTE: The ECU disables the front lift, it can be used only with external push buttons. Possible fault modes: 1. Faulty potentiometer. 2. Faulty wiring harness. 3. Faulty ECU. Remedies: NOTE: Once the cause of the error code has been removed, clear the error code and test the system for normal operation. 1. Check the upper limit potentiometer in H9. A. Enter the HH menu, select H9 of the SD ECU, then select channel 35. The display shows a digit ≤ 30 to get this code. If the displayed value is approximately 30÷900, rotating the potentiometer fully clockwise then counterclockwise, go to the next step. B. If the displayed values are regular, always in H9 twist the harness, the upper limit and working depth potentiometer connector SEN−102 and the ECU connector MOD−204 to detect an intermittent circuit. The displaying could change depending on the conditions. Repair or replace as necessary. 2. Check the upper limit potentiometer in SEN−102. A. Disconnect the potentiometer and measure between: SEN−102 pin 3, cable (AR) and pin 1, cable (AB) SEN−102 pin 3, cable (AR) and pin 2, cable (VB) if the resistance is not approximately 185÷600 Ω rotating the potentiometer from fully clockwise to fully counterclockwise, replace the potentiometer. B. If the potentiometer is ok, go to the next step. 3. Check for an open circuit. A. Disconnect the ECU connector MOD−204. Measure the continuity between: MOD−204 pin 21, cable (AR) and SEN−102 pin 3, cable (AR) MOD−204 pin 26, cable (VB) and SEN−102 pin 2, cable (VB) MOD−204 pin 1, cable (AB) and SEN−102 pin 1, cable (AB) if an open circuit is found, repair or replace the harness as required. B. If there are no open circuits, go to the next step. 4. Check for a short circuit to ground. Measure between: MOD−204 pin 21, cable (AR) and the ground if there is continuity, repair or replace the harness as required. B. If the harness is ok and the error persists, download the latest software version. If this is not sufficient, remove and replace the ECU. For the concerned connectors, components and wiring diagrams, see (connectors SEN−102 and MOD−204, sect. 55, chapt. 8, fig. 222, fig. 331), (components, diagram 23÷28, sect. 55, chapt. 6, page 383), (wiring diagram 28, sect. 55, chapt. 6, page 393).
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9012 − SHORT CIRCUIT TO POSITIVE IN THE FRONT LIFT UPPER LIMIT POTENTIOMETER. Control module: Four Wheel Drive ECU NOTE: The ECU disables the front lift, it can be used only with external push buttons. Possible fault modes: 1. Faulty potentiometer. 2. Faulty wiring harness. 3. Faulty ECU. Remedies: NOTE: Once the cause of the error code has been removed, clear the error code and test the system for normal operation. 1. Check the upper limit potentiometer in H9. A. Enter the HH menu, select H9 of the SD ECU, then select channel 35. The display shows a digit ≥ 900 to get this code. If the displayed value ranges approximately from 30 to 900, rotating the potentiometer fully clockwise then counterclockwise, go to the next step. B. If the displayed values are regular, always in H9 twist the harness, the upper limit and working depth potentiometer connector SEN−102 and the ECU connector MOD−204 to detect an intermittent circuit. The displaying could change depending on the conditions. Repair or replace as necessary. 2. Check the upper limit potentiometer in SEN−102. A. Disconnect the potentiometer and measure between: SEN−102 pin 3, cable (AR) and pin 1, cable (AB) SEN−102 pin 3, cable (AR) and pin 2, cable (VB) if the resistance is not approximately 185÷600 Ω rotating the potentiometer from fully clockwise to fully counterclockwise, replace the potentiometer. B. If the potentiometer is ok, go to the next step. 3. Check for a short circuit to positive (+5 V or 12 V). A. Disconnect the ECU connector MOD−204. Place the starting switch key in ON and measure between: MOD−204 pin 21, cable (AR) and the ground if a short circuit to +5 V or +12 V is detected, repair or replace the harness as required. B. If the harness is ok and the error persists, download the latest software version. If this is not sufficient, remove and replace the ECU. For the concerned connectors, components and wiring diagrams, see (connectors SEN−102 and MOD−204, sect. 55, chapt. 8, fig. 222, fig. 331), (components, diagram 23÷28, sect. 55, chapt. 6, page 383), (wiring diagram 28, sect. 55, chapt. 6, page 393).
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9013 − OPEN CIRCUIT IN THE FRONT LIFT WORKING DEPTH POTENTIOMETER. Control module: Four Wheel Drive ECU NOTE: The ECU disables the front lift, it can be used only with external push buttons. Possible fault modes: 1. Faulty potentiometer. 2. Faulty wiring harness. 3. Faulty ECU. Remedies: NOTE: Once the cause of the error code has been removed, clear the error code and test the system for normal operation. 1. Check the working depth potentiometer in H9. A. Enter the HH menu, select H9 of the SD ECU, then select channel 27. The display shows a digit ≤ 30 to get this code. If the displayed value ranges approximately from 30 to 900, rotating the potentiometer fully clockwise then counterclockwise, go to the next step. B. If the displayed values are regular, always in H9 twist the harness, the upper limit and working depth potentiometer connector SEN−102 and the ECU connector MOD−204 to detect an intermittent circuit. The displaying could change depending on the conditions. Repair or replace as necessary. 2. Check the working depth potentiometer in SEN−102. A. Disconnect the potentiometer and measure between: SEN−102 pin 4, cable (AG) and pin 1, cable (AB) SEN−102 pin 4, cable (AG) and pin 2, cable (VB) if the resistance is not approximately 185÷600 Ω rotating the potentiometer from fully clockwise to fully counterclockwise, replace the potentiometer. B. If the potentiometer is ok, go to the next step. 3. Check for an open circuit. A. Disconnect the ECU connector MOD−204. Measure the continuity between: MOD−204 pin 3, cable (AG) and SEN−102 pin 4, cable (AG) MOD−204 pin 26, cable (VB) and SEN−102 pin 2, cable (VB) MOD−204 pin 1, cable (AB) and SEN−102 pin 1, cable (AB) if an open circuit is found, repair or replace the harness as required. B. If there are no open circuits, go to the next step. 4. Check for a short circuit to ground. Measure between: MOD−204 pin 3, cable (AG) and the ground if there is continuity, repair or replace the harness as required. B. If the harness is ok and the error persists, download the latest software version. If this is not sufficient, remove and replace the ECU. For the concerned connectors, components and wiring diagrams, see (connectors SEN−102 and MOD−204, sect. 55, chapt. 8, fig. 222, fig. 331), (components, diagram 23÷28, sect. 55, chapt. 6, page 383), (wiring diagram 28, sect. 55, chapt. 6, page 393).
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9014 − SHORT CIRCUIT TO POSITIVE IN THE FRONT LIFT WORKING DEPTH POTENTIOMETER. Control module: Four Wheel Drive ECU NOTE: The ECU disables the front lift, it can be used only with external push buttons. Possible fault modes: 1. Faulty potentiometer. 2. Faulty wiring harness. 3. Faulty ECU. Remedies: NOTE: Once the cause of the error code has been removed, clear the error code and test the system for normal operation. 1. Check the working depth potentiometer in H9. A. Enter the HH menu, select H9 of the SD ECU, then select channel 27. The display shows a digit ≥ 900 to get this code. If the displayed value ranges approximately from 30 to 900, rotating the potentiometer fully clockwise then counterclockwise, go to the next step. B. If the displayed values are regular, always in H9 twist the harness, the upper limit and working depth potentiometer connector SEN−102 and the ECU connector MOD−204 to detect an intermittent circuit. The displaying could change depending on the conditions. Repair or replace as necessary. 2. Check the working depth potentiometer in SEN−102. A. Disconnect the potentiometer and measure between: SEN−102 pin 4, cable (AG) and pin 1, cable (AB) SEN−102 pin 4, cable (AG) and pin 2, cable (VB) if the resistance is not approximately 185÷600 Ω rotating the potentiometer from fully clockwise to fully counterclockwise, replace the potentiometer. B. If the potentiometer is ok, go to the next step. 3. Check for a short circuit to positive (+5 V or 12 V). A. Disconnect the ECU connector MOD−204. Place the starting switch key in ON and measure between: MOD−204 pin 3, cable (AG) and the ground if a short circuit to +5 V or +12 V is detected, repair or replace the harness as required. B. If the harness is ok and the error persists, download the latest software version. If this is not sufficient, remove and replace the ECU. For the concerned connectors, components and wiring diagrams, see (connectors SEN−102 and MOD−204, sect. 55, chapt. 8, fig. 222, fig. 331), (components, diagram 23÷28, sect. 55, chapt. 6, page 383), (wiring diagram 28, sect. 55, chapt. 6, page 393).
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9019 − ENGINE RPM TOO LOW FOR CALIBRATION. Control module: Four Wheel Drive ECU NOTE: The ECU prevents the calibration. Possible fault modes: 1. Hand throttle wrong setting. 2. Faulty ECU. Remedies: NOTE: Once the cause of the error code has been removed, clear the error code and test the system for normal operation. 1. Run the engine at about 1200÷1300 rpm. NOTE: for the HH menu description, refer to section 55, chapter 10.
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9024 − LIFT CALIBRATION. Control module: Four Wheel Drive ECU NOTE: The ECU starts the lift link potentiometer calibration; the solenoid valves can be controlled only by the external push buttons. Possible fault modes: 1. Replacement of the potentiometer, open circuit on potentiometer. 2. Faulty ECU. Remedies: NOTE: Once the cause of the error code has been removed, clear the error code and test the system for normal operation. 1. When the cluster displays this failure code, calibrate the potentiometer according to the instructions below. A. Place one weight on the lift links (the weight value is negligible, it should at least correspond to the link weight, as it is used only to lower the links without any stop due to the jamming of cylinders in pistons or to a too high oil density). B. Start the engine and run it at least at 1200÷1300 rpm. The instrument panel display shows the code 9024. C. Place the upper limit potentiometer (next to the upper left part of the instrument panel, the uppermost one) to its max. height (rotate it fully counterclockwise). D. The amber warning light of disabled front lift (on the lower right part of the instrument panel) switches on. E. Press the lifting/lowering switch (three position switch, on the right of the instrument panel, the uppermost of the three available one − it has two rocker positions, pressing to the right and releasing it the links lift, pressing to the left and releasing it the links lower, while the central position is stable) for lowering, then release it to start calibration. F. Grasp the lift links rotating the working depth potentiometer (next to the upper left part of the instrument panel, the lowermost one), until the disabled lift warning light switches off and one of the links starts moving. G. Place the working depth potentiometer to the minimum depth (links completely lifted) (rotate the potentiometer fully clockwise). All lift links reach the upper mechanical lifting limit (note that the relief valve starts operating). Wait until the disabled lift warning light switches on, confirming that the ECU read the upper value of the link height potentiometer. H. Place the working depth potentiometer to the maximum depth (links completely lowered) (rotate the potentiometer fully counterclockwise). All lift links reach the lower position (during their travel, the warning light switches off). Wait until the lift warning light switches on, confirming that the ECU read the lower value of the link height potentiometer. I. Switch the machine off, so that the ECU can store both values − the link fully lifted and fully lowered values − the code 9024 is not stored anymore.
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9041 − UPPER LIMIT POTENTIOMETER NOT SET CORRECTLY FOR THE CALIBRATION PROCEDURE. Control module: Four Wheel Drive ECU NOTE: The ECU prevents the calibration. Possible fault modes: 1. Upper limit potentiometer wrong setting. 2. Faulty ECU. Remedies: NOTE: Once the cause of the error code has been removed, clear the error code and test the system for normal operation. 1. Remove all height stops, rotating the potentiometer fully clockwise. NOTE: for the HH menu description, refer to section 55, chapter 10.
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9063 − OPEN CIRCUIT IN THE LOWERING SOLENOID VALVE. Control module: Four Wheel Drive ECU NOTE: The ECU disables the front lift. Possible fault modes: 1. Faulty solenoid valve. 2. Faulty wiring harness. 3. Faulty ECU. Remedies: NOTE: Once the cause of the error code has been removed, clear the error code and test the system for normal operation. 1. Check the front lift lowering solenoid valve SOL−100, the intermediate connector C−13 and the ECU connector MOD−204. A. Make sure all connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are ok, go to the next step. 2. Check the front lift lowering solenoid valve SOL−100. A. Disconnect the solenoid valve and measure between: SOL−100 pin 1 and pin 2 if the resistance is not about 6.50 Ω replace the solenoid valve. B. If the solenoid valve is ok, go to the next step. 3. Check for an open circuit. A. Disconnect the ECU connector MOD−204. Measure the continuity between: MOD−204 pin 8, cable (MV) and SOL−100 pin 1, cable (MV) MOD−204 pin 4, cable (BN) and SOL−100 pin 2, cable (BN) if an open circuit is found, repair or replace the harness as required. B. If there are no open circuits, go to the next step. 4. Check for a short circuit to ground. Measure between: MOD−204 pin 4, cable (BN) and the ground if there is continuity, repair or replace the harness as required. B. If the harness is ok and the error persists, download the latest software version. If this is not sufficient, remove and replace the ECU. For the concerned connectors, components and wiring diagrams, see (connectors C−13, SOL−100 and MOD−204, sect. 55, chap. 8, fig. 58, fig. 220, fig. 331), (components, wiring diagram 23÷28, sect. 55, chapt. 6, page 383), (Wiring diagram 28, sect. 55, chapt. 6, page 393).
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9064 − OPEN CIRCUIT IN THE LIFTING SOLENOID VALVE. Control module: Four Wheel Drive ECU NOTE: The ECU disables the front lift. Possible fault modes: 1. Faulty solenoid valve. 2. Faulty wiring harness. 3. Faulty ECU. Remedies: NOTE: Once the cause of the error code has been removed, clear the error code and test the system for normal operation. 1. Check the front lift lifting solenoid valve SOL−99, the intermediate connector C−13 and the ECU connector MOD−204. A. Make sure all connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are ok, go to the next step. 2. Check the front lift lifting solenoid valve SOL−99. A. Disconnect the solenoid valve and measure between: SOL−99 pin 1 and pin 2 if the resistance is not about 6.50 Ω replace the solenoid valve. B. If the solenoid valve is ok, go to the next step. 3. Check for an open circuit. A. Disconnect the ECU connector MOD−204. Measure the continuity between: MOD−204 pin 8, cable (MV) and SOL−99 pin 2, cable (MV) MOD−204 pin 5, cable (ZN) and SOL−99 pin 1, cable (ZN) if an open circuit is found, repair or replace the harness as required. B. If there are no open circuits, go to the next step. 4. Check for a short circuit to ground. Measure between: MOD−204 pin 5, cable (ZN) and the ground if there is continuity, repair or replace the harness as required. B. If the harness is ok and the error persists, download the latest software version. If this is not sufficient, remove and replace the ECU. For the concerned connectors, components and wiring diagrams, see (connectors C−13, SOL−99 and MOD−204, sect. 55, chap. 8, fig. 58, fig. 219, fig. 331), (components, wiring diagram 23÷28, sect. 55, chapt. 6, page 383), (Wiring diagram 28, sect. 55, chapt. 6, page 393).
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9065 − SHORT CIRCUIT TO POSITIVE IN THE LOWERING SOLENOID VALVE. Control module: Four Wheel Drive ECU NOTE: The ECU disables the front lift. Possible fault modes: 1. Faulty solenoid valve. 2. Faulty wiring harness. 3. Faulty ECU. Remedies: NOTE: Once the cause of the error code has been removed, clear the error code and test the system for normal operation. 1. Check the front lift lowering solenoid valve SOL−100, the intermediate connector C−13 and the ECU connector MOD−204. A. Make sure all connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are ok, go to the next step. 2. Check the front lift lowering solenoid valve SOL−100. A. Disconnect the solenoid valve and measure between: SOL−100 pin 1 and pin 2 if the resistance is not about 6.50 Ω replace the solenoid valve. B. If the solenoid valve is ok, go to the next step. 3. Check for a short circuit. A. Disconnect the ECU connector MOD−204. Place the starting switch key in ON, measure the continuity between: MOD−204 pin 8, cable (MV) and the ground MOD−204 pin 4, cable (BN) and the ground if a short circuit to positive is found, repair or replace the harness as required. B. If the harness is ok and the error persists, download the latest software version. If this is not sufficient, remove and replace the ECU. For the concerned connectors, components and wiring diagrams, see (connectors C−13, SOL−100 and MOD−204, sect. 55, chap. 8, fig. 58, fig. 220, fig. 331), (components, wiring diagram 23÷28, sect. 55, chapt. 6, page 383), (Wiring diagram 28, sect. 55, chapt. 6, page 393).
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9066 − SHORT CIRCUIT TO POSITIVE IN THE LIFTING SOLENOID VALVE. Control module: Four Wheel Drive ECU NOTE: The ECU disables the front lift. Possible fault modes: 1. Faulty solenoid valve. 2. Faulty wiring harness. 3. Faulty ECU. Remedies: NOTE: Once the cause of the error code has been removed, clear the error code and test the system for normal operation. 1. Check the front lift lifting solenoid valve SOL−99, the intermediate connector C−13 and the ECU connector MOD−204. A. Make sure all connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are ok, go to the next step. 2. Check the front lift lifting solenoid valve SOL−99. A. Disconnect the solenoid valve and measure between: SOL−99 pin 1 and pin 2 if the resistance is not about 6.50 Ω replace the solenoid valve. B. If the solenoid valve is ok, go to the next step. 3. Check for a short circuit. A. Disconnect the ECU connector MOD−204. Place the starting switch key in ON, measure the continuity between: MOD−204 pin 8, cable (MV) and the ground MOD−204 pin 5, cable (ZN) and the ground if a short circuit to positive is found, repair or replace the harness as required. B. If the harness is ok and the error persists, download the latest software version. If this is not sufficient, remove and replace the ECU. For the concerned connectors, components and wiring diagrams, see (connectors C−13, SOL−99 and MOD−204, sect. 55, chap. 8, fig. 58, fig. 219, fig. 331), (components, wiring diagram 23÷28, sect. 55, chapt. 6, page 383), (Wiring diagram 28, sect. 55, chapt. 6, page 393).
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13011 − SA (EDC CONTROL UNIT) +12VF TOO HIGH. Control module: Rear electronic lift control unit. NOTE: Fault that the control unit highlights after a few seconds of supply with a voltage above 18 V, lift disabled. Possible fault modes: 1. Alternator faulty 2. Batteries of +12 V connected in series Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check both the alternator and the connection of the batteries.
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13012 − SB (POWER SHUTTLE CONTROL UNIT) +12VF TOO HIGH. Control module: Power Shuttle control unit NOTE: Fault that the control unit highlights after a few seconds of supply with a voltage above 18 V, tractor disabled. Possible fault modes: 1. Alternator faulty 2. Batteries of +12 V connected in series Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check both the alternator and the connection of the batteries.
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13013 − SC/SD (CONTROL UNIT OF FOUR−WHEEL DRIVE, LIFT AND FRONT POWER TAKE−OFF)+12VF TOO HIGH. Control module: Power Shuttle control unit NOTE: Fault that the control unit highlights after a few seconds of supply with a voltage above 18 V, services disabled. Possible fault modes: 1. Alternator faulty 2. Batteries of +12 V connected in series Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check both the alternator and the connection of the batteries.
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13021 − SA (EDC CONTROL UNIT) +12VF TOO LOW. Control module: Rear electronic lift control unit. NOTE: Fault that the control unit highlights after a few seconds of supply with a voltage below 9 V, lift disabled. Possible fault modes: 1. Alternator faulty 2. Dead batteries 3. Wiring fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the supply of the control unit in H9. A. Enter the HH menu, select H9. Select the channel ch7. The display will show a value from 700 to a maximum of 900, if the value displayed remains very low continue to phase 2. B. If the display shows a correct value, while still in H9, wiggle the harness and the connector of the control unit MOD−27 and the fuse holder connector MOD−25−A to check for an intermittent circuit. The display will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check the connector of the control unit MOD−27 and the connectors behind the fuse box MOD−25−A pin 17A. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check for a short to ground. A. Disconnect the connector of the control unit MOD−27 and pin 17A of the connector MOD−25−A. Check between the connector: MOD−27 between pin 3, wire (MV) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors MOD−25−A and MOD−27 sect. 55, chap. 8, fig. 95, figs. 117), (Components, diagram 5÷8. sect. 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339).
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13022 − SB (POWER SHUTTLE CONTROL UNIT) +12VF TOO LOW. Control module: Power Shuttle control unit NOTE: Fault that the control unit highlights after a few seconds of supply with a voltage below 9 V, tractor disabled. Possible fault modes: 1. Alternator faulty 2. Dead batteries 3. Wiring fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the supply of the control unit in H9. A. Enter the HH menu, select H9. Select the channel ch7. The display will show a value from 600 to a maximum of 800, if the value displayed remains very low continue to phase 2. B. If the display shows a correct value, while still in H9, wiggle the harness and the connector of the control unit MOD−150 and the main connector C−21 to check for an intermittent circuit. The display will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check the connector of the control unit MOD−150, the main connector C−21 and the connectors behind the fuse box MOD−25−A pin 14. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check for a short to ground. A. Disconnect the connector of the control unit MOD−150 and pin 14 of the connector MOD−25−A. Check between the connector: MOD−150 between pin 3, wire (MN) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−21, MOD−25−A and MOD−150 sect. 55, chap. 8, fig. 81, fig. 95, figs. 280−281), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 24−26, sect. 55, chap. 6, pages 385−389).
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13023 − SC/SD (CONTROL UNIT OF FOUR−WHEEL DRIVE, LIFT AND FRONT POWER TAKE−OFF)+12VF TOO LOW. Control module: Four−wheel drive control unit NOTE: Fault that the control unit highlights after a few seconds of supply with a voltage above 9 V, services disabled. Possible fault modes: 1. Alternator faulty 2. Dead batteries 3. Wiring fault Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the supply of the control unit in H9. A. Enter the HH menu, select H9. Select the channel ch7. The display will show a value from 700 to a maximum of 900, if the value displayed remains very low continue to phase 2. B. If the display shows a correct value, while still in H9, wiggle the harness and the connector of the control unit MOD−64 to check for an intermittent circuit. The display will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check the connector of the control unit MOD−64 and the connectors behind the fuse box MOD−25−A. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check for a short to ground. A. Disconnect the connector of the control unit MOD−64 and pin 18A of the connector MOD−25−A. Check between the connector: MOD−64 between pin 3, wire (MN) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors MOD−25−A and MOD−64 sect. 55, chap. 8, fig. 95, fig. 183), (Components, diagram 1÷4. sect. 55, chap. 6, page 327), (Diagram 1, sect. 55, chap. 6, page 329).
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13031 − SA (EDC CONTROL UNIT) ERROR ON +8V REFERENCE VOLTAGE. Control module: Power Shuttle control unit NOTE: Critical fault, it appears accompanied by the critical alarm with lift disabled. Possible fault modes: 1. ECU fault 2. Wiring fault 3. Faulty connectors Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the supply of the control unit to the sensors and switches in H9. A. Enter the HH menu, select H9. Select the channel ch6. The display will show a value from 700 to a maximum of 900, if the value displayed exceeds this range continue to phase 2. B. If the display shows a correct value, while still in H9, wiggle the harness and the connectors of the control unit MOD−27, of the lift control panel MOD−43, of the working depth control panel MOD−40, of the arms position sensor SEN−132, of the main connector C−18 and of the draft sensor SEN−131 to check for an intermittent circuit. The display will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check for a short to ground. A. Disconnect the connector of the control unit MOD−27. Check between the connector: MOD−27 pin 11, wire (AB) and ground If a short a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, continue to step 3. 3. Check for a short to + 12 V. A. Turn the ignition key ON. Measure the voltage between the connector: MOD−27 pin 11, wire (AB) and ground If a voltage is indicated, repair or replace the harness as required. B. If no voltage is indicated, download the correct level of software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−18, MOD−27, MOD−40, MOD−43, SEN−131 and SEN−132 sect. 55, chap. 8, fig. 72, fig. 117, fig. 150, fig. 155, fig. 257, fig. 258), (Components, diagram 5÷8. sect. 55, chap. 6, page 337), (Diagram 5, sect. 55, chap. 6, page 339).
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13032 − SB (POWER SHUTTLE CONTROL UNIT) ERROR ON +5V REFERENCE VOLTAGE. Control module: Power Shuttle control unit NOTE: Critical fault, it appears accompanied by the critical alarm with transmission disabled. Possible fault modes: 1. ECU fault 2. Wiring fault 3. Faulty connectors Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the supply of the control unit to the sensors and switches in H9. A. Enter the HH menu, select H9. Select the channel ch5. The display will show a value from 400 to a maximum of 600, if the value displayed exceeds this range continue to phase 2. B. If the display shows a correct value, while still in H9, wiggle the harness and the connectors of the control unit MOD−150, of the clutch pedal potentiometer SEN−153, of the shuttle lever SW−152, of the range, gear and creeper switches SW−141, SW−142 and SW−143, of the pressure switch SEN−182, the synchro potentiometer SEN−203, and the transmission temperature sensor SEN−148 to check for an intermittent circuit. The display will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check for a short to ground. A. Disconnect the connector of the control unit MOD−150. Check between the connector: MOD−150 pin 11, wire (AB) and ground If a short a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, continue to step 3. 3. Check for a short to + 12 V. A. Turn the ignition key ON. Measure the voltage between the connector: MOD−150 pin 11, wire (AB) and ground If a voltage is indicated, repair or replace the harness as required. B. If no voltage is indicated, download the correct level of software. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors SW−141, SW−142, SW−143, SEN−148, MOD−150, SW−152, SEN−153 and SEN−203 sect. 55, chap. 8, fig. 270, fig. 271, fig. 272, fig. 279, fig. 280−281, fig. 283, fig. 284, fig. 330), (Components, diagram 24÷28. sect. 55, chap. 6, page 383), (Diagram 24−26, sect. 55, chap. 6, pages 385−389).
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13033 − SC/SD (ECU FOR 4WD, FRONT PTO AND LIFT) ERROR ON +5 V REFERENCE VOLTAGE. Control module: Four Wheel Drive ECU NOTE: Critical failure, it occurs with the critical alarm with disabled services. Possible fault modes: 1. Faulty ECU 2. Faulty wiring harness 3. Faulty connectors Remedies: NOTE: Once the cause of the error code has been removed, clear the error code and test the system for normal operation. 1. Check the ECU supply to sensors and switches in H9. A. Enter the HH menu and select H9. Select the channel ch5. The display shows a value ranging from 400 to max. 600. If the displayed value exceeds this range, go to step 2. B. If the display shows a correct value, in H9 twist the wiring harness and the connectors of the ECU MOD−64, of the link position potentiometer SEN−101 and the front electronic lift control panel MOD−102 to check for an intermittent circuit. The displaying changes if intermittent circuits are found; repair or replace as required. 2. Check the presence of a short−circuit to ground. A. Disconnect the connector of the ECU MOD−64. Make a check between the connector: MOD−64 pin 1, cable (AB) and the ground If a short−circuit to ground is detected, repair or replace the wiring harness as required. B. If the wiring harness is okay, go to step 3. 3. Check the presence of a short−circuit to +12 V. A. Place the keystart switch on ON. Measure the voltage between the connector: MOD−64 pin 1, cable (AB) and the ground If a voltage is detected, repair or replace the wiring harness as required. B. If no voltage is found, download the correct level of software. If the error persists, remove and replace the ECU. For the concerned connectors, components and wiring diagrams, see (connectors SEN−101, MOD−102 and MOD−204 sect. 55, chap. 8, fig. 221, fig. 222, fig. 331), (Components, wiring diagram 24÷28, sect. 55, chap. 6, page 383), (Wiring diagram 28, sect. 55, chap. 6, page 393).
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13102 − SB (POWER SHUTTLE CONTROL UNIT) DATA NOT RECORDED CORRECTLY WHEN SWITCHING OFF. Control module: Power Shuttle control unit NOTE: When switching off the machine, the control unit records the data to a number of memories; when switching on the next time, these data are compared and if there are any discrepancies the control unit will give this code. Possible fault modes: 1. No supply at the moment of switching off 2. Internal control unit error Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Once the code appears, make sure the machine has a stable supply. A. Turn the ignition switch OFF, after a few seconds turn it back ON. The code should not appear again if it is only a matter of supply. B. If the error is repeated, remove and replace the control unit.
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14001 − REAR PTO SENSOR SHORTED TO + 12 V. Control module: Control panel control unit (ADIC)
Possible fault modes: 1. 2. 3. 4.
Faulty connector PTO speed sensor faulty Wiring fault Faulty analog−digital instrument cluster (ADIC)
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the PTO speed sensor connector SEN−130, the connector of the control panel (ADIC) MOD−11−A and MOD−11−B and the main connector C−6. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check the PTO speed sensor. A. Disconnect connector SEN−130. Measure the resistance in the connector: SEN−130 between pins 1 and 2 If the resistance indicated is not approximately 680 Ω at 20 degrees centigrade, remove and replace the PTO speed sensor. B. If the speed sensor is okay, continue to step 3. 3. Check for short to a positive voltage. A. Disconnect connector MOD−11−A and MOD−11−B. Turn the ignition key ON. Measure the voltage between the connector: SEN−130 pin 2, wire (BG) and ground If a short to a positive voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the fault occurs again, remove and replace the control panel (ADIC). For the connectors, components and wiring diagrams affected, see (Connectors C−6, MOD−11−A, MOD−11−B and SEN−130 sect. 55, chap. 8, fig. 30, fig. 52, fig. 54 and fig. 256), (Components, diagram 5÷8 sect. 55, chap. 6, page 337), (Diagram 7, sect. 55, chap. 6, page 343).
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14002 − REAR PTO SENSOR SHORTED TO GROUND. Control module: Control panel control unit (ADIC)
Possible fault modes: 1. 2. 3. 4.
Faulty connector PTO speed sensor faulty Wiring fault Faulty analog−digital instrument cluster (ADIC)
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the PTO speed sensor connector SEN−130, the connector of the control panel (ADIC) MOD−11−A and MOD−11−B and the main connector C−6. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check the PTO speed sensor. A. Disconnect connector SEN−130. Measure the resistance in the connector: SEN−130 between pins 1 and 2 If the resistance indicated is not approximately 680 Ω at 20° C, remove and replace the PTO speed sensor. B. If the speed sensor is okay, continue to step 3. 3. Check for a short to ground. A. Disconnect connector MOD−11−B. Check for a short to ground between connector: SEN−130 pin 2, wire (BG) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the fault occurs again, remove and replace the control panel (ADIC). For the connectors, components and wiring diagrams affected, see (Connectors C−6, MOD−11−A, MOD−11−B and SEN−130 sect. 55, chap. 8, fig. 30, fig. 52, fig. 54 and fig. 256), (Components, diagram 5÷8 sect. 55, chap. 6, page 337), (Diagram 7, sect. 55, chap. 6, page 343).
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14011 − ENGINE SPEED SENSOR SHORTED TO POSITIVE OR CIRCUIT OPEN. Control module: Control panel control unit (ADIC)
Possible fault modes: 1. 2. 3. 4.
Faulty connector Faulty engine speed sensor Wiring fault Faulty analog−digital instrument cluster (ADIC)
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the engine speed sensor connector SEN−176, the control panel connector (ADIC) MOD−11−A and the main connector C−1. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check the engine speed sensor. A. Check the connector: SEN−176 between pins 1 and 2. If the resistance indicated is not between 850 and 950 Ω at 20° C, remove and replace the sensor B. If the resistance indicated is okay, continue to step 3. 3. Check for an open circuit. A. Disconnect the connectors SEN−176 and MOD−11−A. Check between: SEN−176 pin 1, wire (ZB) and MOD−11−A pin 5, wire (ZB) SEN−176 pin 2, wire (HV) and MOD−11−A pin 7, wire (HV) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicate, continue to step 4. 4. Check for short to a positive voltage. A. Turn the key start ON. Measure the voltage between the connector: SEN−176 pin 2, wire (HV) and ground If a short to a positive voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the fault occurs again, remove and replace the control panel (ADIC). For the connectors, components and wiring diagrams affected, see (Connectors C−1, MOD−11−A and SEN−176 sect. 55, chap. 8, fig. 1, fig. 52, fig. 371), (Components, diagram 14÷17 sect. 55, chap. 6, page 359), (Diagram 17, sect. 55, chap. 6, page 367).
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14012 − ENGINE SPEED SENSOR SHORTED TO GROUND. Control module: Control panel control unit (ADIC)
Possible fault modes: 1. 2. 3. 4.
Faulty connector Faulty engine speed sensor Wiring fault Faulty analog−digital instrument cluster (ADIC)
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the engine speed sensor connector SEN−176, the control panel connector (ADIC) MOD−11−A and the main connector C−1. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check the engine speed sensor for a short to ground. A. Disconnect connector SEN−176. Check between: SEN−176 pin 1, and ground SEN−176 pin 2, and ground If a short to ground is indicated, remove and replace the engine speed sensor. B. If a short to ground is not indicated, continue to step 3. 3. Check for a short to ground. A. Disconnect connector MOD−11−A. Check between the connector SEN−176 pin 2, wire (HV) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control panel (ADIC). For the connectors, components and wiring diagrams affected, see (Connectors C−1, MOD−11−A and SEN−176 sect. 55, chap. 8, fig. 1, fig. 52, fig. 317), (Components, diagram 14÷17 sect. 55, chap. 6, page 359), (Diagram 17, sect. 55, chap. 6, page 367).
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14021 − CRANKING LINE SENSING SHORTED TO + 12 V. Control module: Control panel control unit (ADIC)
Possible fault modes: 1. Faulty connector 2. Wiring fault 3. Faulty analog−digital instrument cluster (ADIC) Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the relay connector RLY−13, the control panel connector (ADIC) MOD−11−A and the shuttle lever connector SW−152. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check the shuttle lever. A. Disconnect the shuttle lever connector SW−152 with the lever in the neutral position, check that: SW−152 pin 7 and pin 6 there is continuity and circuit open, with the lever in the forward or reverse position. If this occurs, the lever is okay, otherwise replace the lever. B. If the lever is okay, continue to step 3. 3. Check for short to a positive voltage. Disconnect connector MOD−11−A, the wire (Z) of pin 86 of the cranking relay RLY−13. A. Turn the key start ON. Measure the voltage between the connector: MOD−11−A pin 8, wire (Z) and ground If a short to a positive voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the fault occurs again, remove and replace the control panel (ADIC). For the connectors, components and wiring diagrams affected, see (Connectors MOD−11−A and SW−152 sect. 55, chap. 8, fig. 52, fig. 283), (Components, diagram 24÷28 sect. 55, chap. 6, page 383), (Diagram 24−26, sect. 55, chap. 6, pages 385−389).
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14022 − CRANKING LINE SENSING SHORTED TO GROUND. Control module: Control panel control unit (ADIC)
Possible fault modes: 1. Faulty connector 2. Wiring fault 3. Faulty analog−digital instrument cluster (ADIC) Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the relay connector RLY−13, the control panel connector (ADIC) MOD−11−A and the shuttle lever connector SW−152. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check for a short to ground. A. Disconnect connector MOD−11−A, the wire (Z) of pin 86 of the cranking relay RLY−13 and the shuttle lever connector SW−152. Measure between connector: MOD−11−A pin 8, wire (Z) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the fault occurs again, remove and replace the control panel (ADIC). For the connectors, components and wiring diagrams affected, see (Connectors MOD−11−A and SW−152 sect. 55, chap. 8, fig. 52, fig. 283), (Components, diagram 24÷28 sect. 55, chap. 6, page 383), (Diagram 24−26, sect. 55, chap. 6, pages 385−389).
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14041 − ENGINE COOLANT TEMPERATURE SENSOR SHORTED TO POSITIVE OR CIRCUIT OPEN. Control module: Control panel control unit (ADIC)
Possible fault modes: 1. 2. 3. 4.
Faulty connector Engine coolant temperature sensor faulty Wiring fault Faulty analog−digital instrument cluster (ADIC)
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the engine coolant temperature sensor connector SEN−93, the control panel connector (ADIC) MOD−11−A, grid heater connector C−16, grid heater control unit connector MOD−156 and the main connector C−1. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check the temperature sensor. A. Disconnect connector SEN−93. Measure the resistance in the connector: SEN−93 between pin A and C If the resistance indicated is not approximately 2.5 kΩ at 20° C, remove and replace the temperature sensor. B. If the temperature sensor is okay, continue to step 3. 3. Check for an open circuit. A. Disconnect the connectors MOD−11−A. Check between: SEN−93 pin A, wire (VN) and MOD−11−A pin 3, wire (VN) SEN−93 pin C, wire (ZB) and MOD−11−A pin 5, wire (ZB) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicate, continue to step 4. 4. Check for short to a positive voltage. A. Turn the ignition key ON. Measure the voltage between connector: SEN−93 pin C, wire (ZB) and ground SEN−93 pin B, wire (HR) and ground SEN−93 pin A, wire (VN) and ground If a short to a positive voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the fault occurs again, remove and replace the control panel (ADIC). For the connectors, components and wiring diagrams affected, see (Connectors C−1, MOD−11−A, C−16, SEN−93 and MOD−156 sect. 55, chap. 8, fig. 1, fig. 52, fig. 69, fig. 213, fig. 287), (Components, diagram 14÷17 sect. 55, chap. 6, page 359), (Diagram 17, sect. 55, chap. 6, page 367).
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14042 − ENGINE COOLANT TEMPERATURE SENSOR SHORTED TO GROUND. Control module: Control panel control unit (ADIC)
Possible fault modes: 1. 2. 3. 4.
Faulty connector Engine coolant temperature sensor faulty Wiring fault Faulty analog−digital instrument cluster (ADIC)
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the engine coolant temperature sensor connector SEN−93, the control panel connector (ADIC) MOD−11−A, grid heater connector C−16, grid heater control unit connector MOD−156 and the main connector C−1. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check the temperature sensor. A. Disconnect connector SEN−93. Measure the resistance in the connector: SEN−93 between pin A and C If the resistance indicated is not approximately 2.5 kΩ at 20° C, remove and replace the temperature sensor. B. If the temperature sensor is okay, continue to step 3. 3. Check for a short to ground on the sensor. A. Measure the voltage between connector: SEN−93 pin C, and ground SEN−93 pin B, and ground SEN−93 pin A, and ground If a short to ground is indicated, remove and replace the sensor. B. If the sensor is okay, continue to step 4. 4. Check for a short to ground on the wiring harness. A. Disconnect connector MOD−11−A. Check between: SEN−93 pin B, wire (HR) and ground SEN−93 pin A, wire (VN) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the fault occurs again, remove and replace the control panel (ADIC). For the connectors, components and wiring diagrams affected, see (Connectors C−1, MOD−11−A, C−16, SEN−93 and MOD−156 sect. 55, chap. 8, fig. 1, fig. 52, fig. 69, fig. 213, fig. 287), (Components, diagram 14÷17 sect. 55, chap. 6, page 359), (Diagram 17, sect. 55, chap. 6, page 367).
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14051 − FUEL LEVEL SENSOR SHORTED TO POSITIVE OR CIRCUIT OPEN. Control module: Control panel control unit (ADIC)
Possible fault modes: 1. 2. 3. 4.
Faulty connector Fuel tank level sender faulty Wiring fault Faulty analog−digital instrument cluster (ADIC)
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the fuel tank level sender potentiometer in H9, channel ch25. A. Remove the fuel level sender. With the connector still connected move sender from the maximum to minimum position. If the values displayed do not change continuously between 20 and 580, continue to step 2. B. If the values displayed are okay, while still in H9 channel 25, wiggle the harness and connectors SEN−123, MOD−11−A and C−6 to check for an intermittent circuit. Channel 25 values will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check the fuel level sender connector SEN−123, control panel connectors MOD−11−A the main connector C−6. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the fuel level sender operation. A. Disconnect connector SEN−123. Check the connector: SEN−123 between pins 1 and 2 If the resistances indicated are not between approximately 20 Ω when the tank is full and 276 Ω when the tanks is empty, remove and replace the transmitter. B. If the resistances indicated are okay, continue to step 4. 4. Check for an open circuit. A. Disconnect the connectors of the control panel MOD−11−A. Check between: SEN−123 pin 1, wire (S) and MOD−11−A pin 2 wire (S). SEN−123 pin 2, wire (ZB) and MOD−11−A pin 5, wire (ZB) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue with step 5. 5. Check for short to a positive voltage. A. Turn the key start ON. Check between the connector: SEN−123 pin 1, wire (S) and ground If a short to a positive voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control panel (ADIC). For the connectors, components and wiring diagrams affected, see (Connectors C−6, MOD−11−A, and SEN−123 sect. 55, chap. 8, fig. 30, fig. 52, fig. 249), (Components, diagram 5÷8 sect. 55, chap. 6, page 337), (Diagram 7, sect. 55, chap. 6, page 343).
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14052 − FUEL LEVEL SENSOR SHORTED TO GROUND. Control module: Control panel control unit (ADIC)
Possible fault modes: 1. 2. 3. 4.
Faulty connector Fuel tank level sender faulty Wiring fault Faulty analog−digital instrument cluster (ADIC)
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the fuel tank level sender potentiometer in H9, channel ch25. A. Remove the fuel level sender. With the connector still connected move sender from the maximum to minimum position. If the values displayed do not change continuously between 20 and 580, continue to step 2. B. If the values displayed are okay, while still in H9 channel 25, wiggle the harness and connectors SEN−123, MOD−11−A and C−6 to check for an intermittent circuit. Channel 25 values will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check the fuel level sender connector SEN−123, control panel connectors MOD−11−A the main connector C−6. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the fuel level sender operation. A. Disconnect connector SEN−123. Check the connector: SEN−123 between pins 1 and 2 If the resistances indicated are not between approximately 20 Ω when the tank is full and 276 Ω when the tanks is empty, remove and replace the transmitter. B. If the resistances indicated are okay, continue to step 4. 4. Check for a short to ground. A. Disconnect the connector MOD−11−A. Check between the connector: SEN−123 pin 2, wire (S) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the fault occurs again, remove and replace the control panel (ADIC). For the connectors, components and wiring diagrams affected, see (Connectors C−6, MOD−11−A, and SEN−123 sect. 55, chap. 8, fig. 30, fig. 52, fig. 249), (Components, diagram 5÷8 sect. 55, chap. 6, page 337), (Diagram 7, sect. 55, chap. 6, page 343).
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14058 − SEAT SWITCH ON FOR LONGER THAN 25 HOURS. Control module: Control panel control unit (ADIC) NOTE: The control unit sees no change on the operator present switch in the last 25 hours of continuous work, switch jammed on or shorted to ground. Possible fault modes: 1. 2. 3. 4.
Faulty connector Operator present switch faulty Wiring fault Faulty analog−digital instrument cluster (ADIC)
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the operator present switch in H5 of the control unit (ADIC). A. Get up and then sit down again. The display will show ch10 every time the switch changes status. If the display shows ch10 in H5, wiggle the harness and the connectors MOD−11−A, MOD−11−B and SW−32 to check for an intermittent circuit. The values displayed will change if an intermittent circuit is detected; Repair or replace as necessary. B. If on channel H5 the display is okay, continue to phase 2. 2. Check connectors SW−32 of the operator present switch, control unit MOD−11−A and MOD−11−B. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the operator present switch. A. Disconnect the operator present connector SW−32. Check the resistance between: SW−32 pin 1 and pin 2 the resistance values must be, with the operator seated (≅ 500 Ω), with the operator standing (≅ 2000 Ω), otherwise replace the switch B. If the operator present switch is okay, continue to step 4. 4. Check for a short to ground. A. Disconnect the connectors MOD−11−A and MOD−11−B of the control unit (ADIC). Check for a short circuit on the connector. SW−32 pin 1, wire (RF) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the system is okay, download the correct software release. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors MOD−11−A, MOD−11−B and SW−32 sect. 55, chap. 8, fig. 52, fig. 54, fig. 126), (Components, diagram 5÷8 sect. 55, chap. 6, page 337), (Diagram 7, sect. 55, chap. 6, page 343).
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14091 − TRANSMISSION OUTPUT SPEED SHORTED TO + 12 V. Control module: Control panel control unit (ADIC)
Possible fault modes: 1. 2. 3. 4.
Faulty connector Faulty transmission speed sensor Wiring fault Faulty analog−digital instrument cluster (ADIC)
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the transmission speed sensor connector SEN−129, the connector of the control panel (ADIC) MOD−11−A and MOD−11−B, the main connector C−6. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check the PTO speed sensor. A. Disconnect connector SEN−129. Measure the resistance in the connector: SEN−129 between pins 1 and 2 If the resistance indicated is not approximately 680 Ω at 20° C, remove and replace the transmission speed sensor. B. If the speed sensor is okay, continue to step 3. 3. Check for short to a positive voltage. A. Disconnect connector MOD−11−A and MOD−11−B. Turn the ignition key ON. Measure the voltage between the connector: SEN−129 pin 2, wire (HB) and ground If a short to a positive voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the fault occurs again, remove and replace the control panel (ADIC). For the connectors, components and wiring diagrams affected, see (Connectors C−6, MOD−11−A, MOD−11−B and SEN−129 sect. 55, chap. 8, fig. 27, fig. 51, fig. 53, fig. 255), (Components, diagram 5÷7 sect. 55, chap. 6, page 189), (Diagram 5, sect. 55, chap. 6, page 195*). * see version 3 “Electrohydraulic 4WD, electrohydraulic differential locking, rear electronic lift”
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14092 − TRANSMISSION OUTPUT SPEED SHORTED TO GROUND. Control module: Control panel control unit (ADIC)
Possible fault modes: 1. 2. 3. 4.
Faulty connector Faulty transmission speed sensor Wiring fault Faulty analog−digital instrument cluster (ADIC)
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the transmission speed sensor connector SEN−129, the connector of the control panel (ADIC) MOD−11−A and MOD−11−B, the main connector C−6. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check the PTO speed sensor. A. Disconnect connector SEN−129. Measure the resistance in the connector: SEN−129 between pins 1 and 2 If the resistance indicated is not approximately 680 Ω at 20° C, remove and replace the PTO speed sensor. B. If the speed sensor is okay, continue to step 3. 3. Check for a short to ground. A. Disconnect connector MOD−11−B. Check for a short to ground between connector: SEN−129 pin 2, wire (HB) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the fault occurs again, remove and replace the control panel (ADIC). For the connectors, components and wiring diagrams affected, see (Connectors C−6, MOD−11−A, MOD−11−B and SEN−129 sect. 55, chap. 8, fig. 27, fig. 51, fig. 53, fig. 255), (Components, diagram 5÷7 sect. 55, chap. 6, page 189), (Diagram 5, sect. 55, chap. 6, page 195*). * see version 3 “Electrohydraulic 4WD, electrohydraulic differential locking, rear electronic lift”
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14093 − SEAT SWITCH SHORTED TO POSITIVE OR CIRCUIT OPEN. Control module: Control panel control unit (ADIC)
Possible fault modes: 1. 2. 3. 4.
Faulty connector Operator present switch faulty Wiring fault Faulty analog−digital instrument cluster (ADIC)
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the operator present switch in H5 of the control unit (ADIC). A. Get up and then sit down again. The display will show ch10 every time the switch changes status. If the display shows ch10 in H5, wiggle the harness and the connectors MOD−11−A, MOD−11−B and SW−32 to check for an intermittent circuit. The values displayed will change if an intermittent circuit is detected; Repair or replace as necessary. B. If on channel H5 the display is okay, continue to phase 2. 2. Check connectors SW−32 of the operator present switch, control unit MOD−11−A and MOD−11−B. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the operator present switch. A. Disconnect the operator present connector SW−32. Check the resistance between: SW−32 pin 1 and pin 2 the resistance values must be, with the operator seated (≅ 500 Ω), with the operator standing (≅ 2000 Ω), otherwise replace the switch B. If the operator present switch is okay, continue to step 4. 4. Check for open circuit. A. Disconnect the connectors MOD−11−A and MOD−11−B of the control unit (ADIC). Check for an open circuit on the connector: SW−32 pin 2, wire (RV) and MOD−11−B pin 11 wire (RV) SW−32 pin 1, wire (ZB) and MOD−11−A pin 5 wire (ZB) If an open circuit is indicated, repair or replace the harness as required. B. If the switch has no open circuit, continue to step 5. 5. Check for short to positive. A. Turn the ignition switch ON. Check for a short on the connector. SW−32 pin 2, wire (RV) and ground If a short to a positive voltage is indicated, repair or replace the harness as required. B. If the system is okay, download the correct software release. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors MOD−11−A, MOD−11−B and SW−32 sect. 55, chap. 8, fig. 52, fig. 54, fig. 126), (Components, diagram 5÷8 sect. 55, chap. 6, page 337), (Diagram 7, sect. 55, chap. 6, page 343).
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14094 − SEAT SWITCH SHORTED TO GROUND. Control module: Control panel control unit (ADIC)
Possible fault modes: 1. 2. 3. 4.
Faulty connector Operator present switch faulty Wiring fault Faulty analog−digital instrument cluster (ADIC)
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the operator present switch in H5 of the control unit (ADIC). A. Get up and then sit down again. The display will show ch10 every time the switch changes status. If the display shows ch10 in H5, wiggle the harness and the connectors MOD−11−A, MOD−11−B and SW−32 to check for an intermittent circuit. The values displayed will change if an intermittent circuit is detected; Repair or replace as necessary. B. If on channel H5 the display is okay, continue to phase 2. 2. Check connectors SW−32 of the operator present switch, control unit MOD−11−A and MOD−11−B. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the operator present switch. A. Disconnect the operator present connector SW−32. Check the resistance between: SW−32 pin 1 and pin 2 the resistance values must be, with the operator seated (≅ 500 Ω), with the operator standing (≅ 2000 Ω), otherwise replace the switch B. If the operator present switch is okay, continue to step 4. 4. Check for a short to ground. A. Disconnect the connector of the control unit MOD−11−A and MOD−11−B. Check for a short on the connector. SW−32 pin 2, wire (RV) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the system is okay, download the correct software release. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors MOD−11−A, MOD−11−B and SW−32 sect. 55, chap. 8, fig. 52, fig. 54, fig. 126), (Components, diagram 5÷8 sect. 55, chap. 6, page 337), (Diagram 7, sect. 55, chap. 6, page 343).
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14101 − SEDIMENT UNIT FILTER SENSOR NOT CONNECTED. Control module: Control panel control unit (ADIC) NOTE: The control unit sees no change on the filter in a certain length of time after the supply, open circuit or short to ground. Possible fault modes: 1. 2. 3. 4.
Faulty connector Sediment filter sensor faulty Wiring fault Faulty analog−digital instrument cluster (ADIC)
Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the connector SEN−89 sediment unit filter, control unit MOD−11−A main connector C−1. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check the sediment filter supply. A. Disconnect the sediment filter connector SEN−89. Test on the connector between. SEN−89 pin 3 wire (LR) and ground Check there is a voltage of 12 V, otherwise replace the wiring harness or repair it as required. B. If the sensor supply is okay, continue to step 3. 3. Check for an open circuit. A. Disconnect the control unit connectors MOD−11−A. Test on the connectors between. SEN−89 pin 1 wire (MN) and MOD−11−A pin 37 wire (MN) If an open circuit is indicated, repair or replace the harness as required. B. If the switch has no open circuit, continue to step 4. 4. Check for a short to ground. A. Test on the connector between: SEN−89 pin 1 wire (MN) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the system is okay, replace the sediment filter sensor. If the error is repeated, download the correct software release. If the error is repeated, remove and replace the control unit. For the connectors, components and wiring diagrams affected, see (Connectors C−1, MOD−11−A and SEN−89 sect. 55, chap. 8, fig. 1, fig. 52, fig. 208), (Components, diagram 14÷17 sect. 55, chap. 6, page 359), (Diagram 17, sect. 55, chap. 6, page 367).
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14106 − FRONT PTO FITTED BUT NOT CONFIGURED. Control module: Control panel control unit (ADIC) NOTE: The control unit receives the signal from the front PTO but it has not been configured in H3. Possible fault modes: 1. Configuration error 2. Faulty analog−digital instrument cluster (ADIC) Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the machine configuration. A. Using tool 380000843 enter the HH menu select on control unit ZA menu H3 at option “Front PTO” select the option MECH, in the case of the PTO with servoassisted engagement or ELEC in the case of the PTO managed by the control unit of the automatic four−wheel drive. NOTE: for a description of the HH menus, refer to section 55 chapter 10.
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14107 − FRONT LIFT FITTED BUT NOT CONFIGURED. Control module: Control panel control unit (ADIC) NOTE: The control unit receives the signal from the front lift but it has not been configured in H3. Possible fault modes: 1. Configuration error 2. Faulty analog−digital instrument cluster (ADIC) Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the machine configuration. A. Using tool 380000843 enter the HH menu select on control unit ZA menu H3 at option “Front Hitch” select the option YES. NOTE: for a description of the HH menus, refer to section 55 chapter 10.
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
14108 − REAR PTO RPM SENSOR PRESENT YET NOT CONFIGURED. Control module: Control board ECU (ADIC) NOTE: The ECU receives a signal from the front lift, but it has not been configured in H3. Possible fault modes: 1. Configuration error. 2. Faulty analog−digital control board (ADIC) Remedies: NOTE: Once the cause of the error code has been removed, clear the error code and test the system for normal operation. 1. Check the machine configuration. A. With the tool 380000843, enter the HH menu, select on the ECU ZA the menu H3; at the option “PTO sensor” select YES. NOTE: for the HH menu description, refer to section 55, chapter 10.
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
149
14201 − STEERING SENSOR SHORTED TO POSITIVE OR CIRCUIT OPEN. Control module: Control panel control unit (ADIC) NOTE: The control unit does not see the steering sensor. Possible fault modes: 1. Incorrect configuration (on machines there is no steering sensor*) 2. Faulty analog−digital instrument cluster (ADIC) Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check the machine configuration. A. Using tool 380000843 enter the HH menu select on control unit ZA menu H3 at option “HSD 4DT” select the option NO. * The option of electrohydraulic four−wheel drive disengagement according to steering angle is not yet available. NOTE: for a description of the HH menus, refer to section 55 chapter 10.
87666787A2 − 06 − 2009
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
14900 − NO SB. Control module: Control panel control unit (ADIC) NOTE: The control unit does not see the Power Shuttle control unit. Possible fault modes: 1. Error on the CAN BUS line. 2. Faulty analog−digital instrument cluster (ADIC) Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check connectors MOD−11−B of the ADIC control unit ZA, MOD−150 of the power shuttle control unit SB, MOD−64 of the four−wheel drive control unit SC, MOD−27 of the EDC control unit SA and C−28 of the diagnosis pin. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check for open circuit on the CAN line. Disconnect the connectors MOD−11−A, MOD−11−B, MOD−64, MOD−150 and MOD−27 of the control units. Test on the connectors between the pins: C−28 pin C wire (G−CAN H) and MOD−11−B pin 12 wire (G−CAN H) C−28 pin D wire (V−CAN L) and MOD−11−B pin 13 wire (V−CAN L) C−28 pin C wire (G−CAN H) and MOD−64 pin 12 wire (G−CAN H) C−28 pin D wire (V−CAN L) and MOD−64 pin 13 wire (V−CAN L) C−28 pin C wire (G−CAN H) and MOD−27 pin 12 wire (G−CAN H) C−28 pin D wire (V−CAN L) and MOD−27 pin 13 wire (V−CAN L) C−28 pin C wire (G−CAN H) and MOD−150 pin 12 wire (G−CAN H) C−28 pin D wire (V−CAN L) and MOD−150 pin 13 wire (V−CAN L) If an open circuit is indicated, repair or replace the wiring harness as required. B. If the wiring harness is okay, continue with step 3. 3. Check ADIC control unit terminator. Re−connect connector MOD−11−B to the control unit. Test the resistance between pins: C−28 pin C wire (G−CAN H) and C−28 pin D wire (V−CAN L) If the resistance indicated is not approximately 120 Ω replace the ADIC control unit, the terminator is faulty. B. If the terminator is okay, continue with step 4. 4. Check the power shuttle control unit terminator. Re−connect connector MOD−150 to the control unit. Test the resistance between pins: C−28 pin C wire (G−CAN H) and C−28 pin D wire (V−CAN L) if the resistance indicated is not approximately 60 Ω, replace the power shuttle control unit the terminator is faulty. B. If the terminator is okay. If the error is repeated, download the correct software release. If the error is repeated, remove and replace the control unit. NOTE: This fault code may be due to having replaced the original dashboard with one recovered from a machine with this control unit; this keeps the presence of the control unit in memory and it expects to find it on the machine where it is to be fitted too. To delete the presence of this code, taking care there is not the above−mentioned control unit (perhaps the problem is of another nature, CAN line open circuit), it is possible to do H8 at option “NETWORK CONFIGURATION” to delete the memory and force reconfiguration at the next control unit “key on”. Caution, carrying out the operation described above with the above−mentioned control unit, the next re−configuration will ignore the control unit and this will not transmit/receive the messages from the others. For the connectors, components and wiring diagrams affected, see (Connectors MOD−11−A, MOD−11−B, MOD−27, C−28, MOD−64 and MOD−150 sect. 55, chap. 8, fig. 52, fig. 54, fig. 117, fig. 118, fig. 183 fig. 280−281). 87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
151
14901 − SA MISSING. Control module: Control panel control unit (ADIC) NOTE: The control unit does not see the EDC control unit. Possible fault modes: 1. Error on the CAN BUS line 2. Faulty analog−digital instrument cluster (ADIC) Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check connectors MOD−11−B of the ADIC control unit ZA, MOD−150 of the power shuttle control unit SB, MOD−64 of the four−wheel drive control unit SB/SC, MOD−27 of the EDC control unit SA and C−28 of the diagnosis pin. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check for open circuit on the CAN line. Disconnect the connectors MOD−11−A, MOD−11−B, MOD−64, MOD−150 and MOD−27 of the control units. Test on the connectors between the pins: C−28 pin C wire (G−CAN H) and MOD−11−B pin 12 wire (G−CAN H) C−28 pin D wire (V−CAN L) and MOD−11−B pin 13 wire (V−CAN L) C−28 pin C wire (G−CAN H) and MOD−64 pin 12 wire (G−CAN H) C−28 pin D wire (V−CAN L) and MOD−64 pin 13 wire (V−CAN L) C−28 pin C wire (G−CAN H) and MOD−27 pin 12 wire (G−CAN H) C−28 pin D wire (V−CAN L) and MOD−27 pin 13 wire (V−CAN L) C−28 pin C wire (G−CAN H) and MOD−150 pin 12 wire (G−CAN H) C−28 pin D wire (V−CAN L) and MOD−150 pin 13 wire (V−CAN L) If an open circuit is indicated, repair or replace the wiring harness as required. B. If the wiring harness is okay, continue with step 3. 3. Check ADIC control unit terminator. Re−connect connector MOD−11−B to the control unit. Test the resistance between pins: C−28 pin C wire (G−CAN H) and C−28 pin D wire (V−CAN L) If the resistance indicated is not approximately 120 Ω replace the ADIC control unit, the terminator is faulty. B. If the terminator is okay, continue with step 4. 4. Check SB control unit terminator. Re−connect connector MOD−150 to the control unit. Test the resistance between pins: C−28 pin C wire (G−CAN H) and C−28 pin D wire (V−CAN L) if the resistance indicated is not approximately 60 Ω, replace the SA control unit the terminator is faulty. B. If the terminator is okay. If the error is repeated, download the correct software release. If the error is repeated, remove and replace the control unit. NOTE: This fault code may be due to having replaced the original dashboard with one recovered from a machine with this control unit; this keeps the presence of the control unit in memory and it expects to find it on the machine where it is to be fitted too. To delete the presence of this code, taking care there is not the above−mentioned control unit (perhaps the problem is of another nature, CAN line open circuit), it is possible to do H8 at option “NETWORK CONFIGURATION” to delete the memory and force reconfiguration at the next control unit “key on”. Caution, carrying out the operation described above with the above−mentioned control unit, the next re−configuration will ignore the control unit and this will not transmit/receive the messages from the others. For the connectors, components and wiring diagrams affected, see (Connectors MOD−11−A, MOD−11−B, MOD−27, C−28, MOD−64 and MOD−150 sect. 55, chap. 8, fig. 52, fig. 54, fig. 117, fig. 118, fig. 183 fig. 280−281). 87666787A2 − 06 − 2009
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 9
14913 − SC/SD MISSING. Control module: Control panel control unit (ADIC) NOTE: The control unit does not see the four−wheel drive control unit, front power take−off and front lift. Possible fault modes: 1. Error on the CAN BUS line. 2. Faulty analog−digital instrument cluster (ADIC) Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Check connectors MOD−11−B of the ADIC control unit ZA, MOD−150 of the power shuttle control unit SB, MOD−64 of the four−wheel drive control unit SB/SC, MOD−27 of the EDC control unit SA and C−28 of the diagnosis pin. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2. 2. Check for open circuit on the CAN line. Disconnect the connectors MOD−11−A, MOD−11−B, MOD−64, MOD−150 and MOD−27 of the control units. Test on the connectors between the pins: C−28 pin C wire (G−CAN H) and MOD−11−B pin 12 wire (G−CAN H) C−28 pin D wire (V−CAN L) and MOD−11−B pin 13 wire (V−CAN L) C−28 pin C wire (G−CAN H) and MOD−64 pin 12 wire (G−CAN H) C−28 pin D wire (V−CAN L) and MOD−64 pin 13 wire (V−CAN L) C−28 pin C wire (G−CAN H) and MOD−27 pin 12 wire (G−CAN H) C−28 pin D wire (V−CAN L) and MOD−27 pin 13 wire (V−CAN L) C−28 pin C wire (G−CAN H) and MOD−150 pin 12 wire (G−CAN H) C−28 pin D wire (V−CAN L) and MOD−150 pin 13 wire (V−CAN L) If an open circuit is indicated, repair or replace the wiring harness as required. B. If the wiring harness is okay, continue with step 3. 3. Check ADIC control unit terminator. Re−connect connector MOD−11−B to the control unit. Test the resistance between pins: C−28 pin C wire (G−CAN H) and C−28 pin D wire (V−CAN L) If the resistance indicated is not approximately 120 Ω replace the ADIC control unit, the terminator is faulty. B. If the terminator is okay, continue with step 4. 4. Check SB control unit terminator. Re−connect connector MOD−150 to the control unit. Test the resistance between pins: C−28 pin C wire (G−CAN H) and C−28 pin D wire (V−CAN L) if the resistance indicated is not approximately 60 Ω, replace the SA control unit the terminator is faulty. B. If the terminator is okay. If the error is repeated, download the correct software release. If the error is repeated, remove and replace the control unit. NOTE: This fault code may be due to having replaced the original dashboard with one recovered from a machine with this control unit; this keeps the presence of the control unit in memory and it expects to find it on the machine where it is to be fitted too. To delete the presence of this code, taking care there is not the above−mentioned control unit (perhaps the problem is of another nature, CAN line open circuit), it is possible to do H8 at option “NETWORK CONFIGURATION” to delete the memory and force reconfiguration at the next control unit “key on”. Caution, carrying out the operation described above with the above−mentioned control unit, the next re−configuration will ignore the control unit and this will not transmit/receive the messages from the others. For the connectors, components and wiring diagrams affected, see (Connectors MOD−11−A, MOD−11−B, MOD−27, C−28, MOD−64 and MOD−150 sect. 55, chap. 8, fig. 52, fig. 54, fig. 117, fig. 118, fig. 183 fig. 280−281).
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
1
SECTION 55 − ELECTRICAL SYSTEM Chapter 10 − HH MENU AND CALIBRATIONS INDEX Section
Description
Page
HH MENU access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 H1 − Calibrations (SB − SA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 H2 − View All calibration values (SB − SD − SA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 H3 − Options (SB − ZA − SD − SC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 H4 − Software revision level (ZA − SD − SC − SB − SA) . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 H5 − Control switches diagnosis (ZA − SD − SC − SB − SA) . . . . . . . . . . . . . . . . . . . . . . . 17 H7 − Service Procedures (SB − SA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 H8 − Deletion of the stored data (ZA − SD − SC − SB − SA) . . . . . . . . . . . . . . . . . . . . . . . 23 H9 − Voltmeter (ZA − SD − SC − SB − SA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 HB − Displays stored error codes (ZA − SD − SC − SB − SA) . . . . . . . . . . . . . . . . . . . . . . 31 HC − Deletes all the stored error codes (ZA − SD − SC − SB − SA) . . . . . . . . . . . . . . . . . 33 HE − Frequency (ZA − SD − SC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 HF − Displays the hardware information (ZA − SD − SC − SB − SA) . . . . . . . . . . . . . . . . . 37
87666787A2 − 06 − 2009
2
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
HH MENU ACCESS −
Connect the tool 380000843 (1) to the diagnosis connection (2).
1 −
Turn the ignition switch (1) onto position (B) (control panel powered).
26083
2 −
The information display will show HH MENU.
HH MENU
3 −
Now, using the switch (2), it is possible to select the module to examine. The modules are: ZA = Control panel. SA = Electronically controlled rear lift. SB = Power Shuttle. SC = Automatic four−wheel drive. SD = Automatic four−wheel drive and front power take−off.
4 87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10 −
−
−
Now it is possible to select the desired HH MENU by pressing the switch (2) into positions (C) to go forward or (D) to go back and lastly by pressing the switch (1) into position (B) to access it. The HH MENU that will be displayed are: H1 Displays all the calibration procedures. H2 Displays all the calibration values. H3 Options. H4 Displays the software revision level. H5 Switch operation test. H7 Service procedures. H8 Deletes all the stored data. H9 Voltmeter. HB Displays the stored error codes. HC Deletes all the stored error codes. HE Displays all the speed inputs. HF Displays the hardware information. At the end of the MENU it is possible to go back to the HH MENU by pressing the switch (1, fig. 4) into position (B).
HH MENU
3
HH
ZA
ZA
−−−− 5
ATTENTION Park the tractor on level ground in an unobstructed area (in case of sudden movement). Engage the handbrake, switch off all electrical switches and the air conditioning system, if on. Set the Shuttle control lever in neutral, the hydraulic lift lower arms down, the remote control valve levers in neutral and switch off the engine. Put safety wedges under the front and rear wheels. Check that the transmission oil temperature is between 20 to 50 °C. Unless otherwise specified, the levers: − Shuttle control; − gear control; − range gear control; − creeper lever; are in the NEUTRAL position.
87666787A2 − 06 − 2009
4
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
H1 − CALIBRATIONS (SB − SA) CALIBRATION OF THE CLUTCHES AND SYNCHRONIZER (SB) NOTE: If the information display shows an error code, it is necessary to remove the cause before being able to make the calibrations. −
Turn the ignition switch (1) onto position (C) (engine starting). 26083
6 − − − − − − −
Select the module (SB) and access the H1 MENU proceeding as described on page 2. The display will show “CAL” and the oil temperature “20C”. Select the fast range and engage 1st gear. Bring the engine revs to 1200 to 1300 rpm. Ensure that the parking brake is engaged. Release the clutch pedal. Place the shuttle lever in forward.
NOTE: Pressing the switch (2) into position (C) will calibrate the clutches and the synchronizer automatically, at the end of which the display will show “End”. Manual calibration − The synchronizer is calibrated automatically. − Press and release the switch (2, fig. 7) in position (D), on the information display, aligned on the left, the letter will be shown corresponding to the clutch (A) that is being calibrated (on Dual Command (2−Speed Power Shift) versions it is possible to obtain the same result by pressing the HI button). − Press and hold down the switch (2) in position (D), the display will show the letter corresponding to the clutch that is being calibrated followed by a dash (on Dual Command (2−Speed Power Shift) versions it is possible to obtain the same result by pressing the HI button). − When the calibration process starts, the letter will be followed by the current in mA that will increase. − When the calibration current is reached the display will show the calibration current flashing.
87666787A2 − 06 − 2009
7
Incorrect
b 262
20C
Sc − −
A 266
End 8
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10 −
− −
Release the switch (2, fig. 7) (or the HI button), press the switch (2) in position (C) (on Dual Command (2−Speed Power Shift) versions it is possible to obtain the same result by pressing the HI button) to display the next clutch (B) to calibrate. Repeat the steps carried out for the clutch (B). Switch off the engine by turning switch (1) to A (OFF), hold in this position for at least 5 seconds to save the calibration values.
NOTE: The rear transmission revs (wheels), the clutch pedal position, the Shuttle lever position, the gear shift and Range levers are constantly checked. Calibration cannot proceed if: the tractor is moving, the Shuttle lever is not engaged, the clutch pedal is not released (raised) and the range and gear levers are not engaged. If an anomalous condition is detected during calibration, the display will show the relative fault code with the flashing alarm lamps, if there is an anomaly in calibration, a U−type fault code will be displayed. Refer to the following list for U−type faults. −
5
26083
9
It is possible to calibrate the clutches without the aid of the tool 380000843 but keeping the switch (1, fig. 7) pressed in position (A) or simultaneously holding down the Dual Command (2−Speed Power Shift) buttons, lastly start the engine by turning the ignition switch (1, fig. 9) onto position (C) (engine starting), in this way clutch calibration is accessed. Select the clutch to calibrate by pressing the switch (2, fig. 7) in position (C) or pressing the “HI” button, to calibrate press the switch (2, fig. 7) in position (D) or press the “LO” button.
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
6
UXX FAULT CODES FAULT CODE
DESCRIPTION
U17
Seat switch not activated.
U18
Correct start−up procedure was not used.
U19
Transmission oil temperature below 10 °C (*).
U20
Parking brake is not applied.
U21
Engine speed below 1150 rpm, increase the speed.
U22
Engine speed above 1350 rpm, lower the speed.
U23
Reverser control lever in neutral, position it on forward gear.
U26
Clutch pedal not fully raised, release it.
U31
Wheel speed detected: the tractor is moving, check the parking brake and calibrate again.
U32
Clutch A calibration value too low, the speed has dropped too quickly, the clutch pressure is not governed correctly or other factors have caused the speed to drop.
U33
Clutch A calibration value too high, the speed has not dropped, there is no pressure in the clutch or there is a mechanical fault with the transmission.
U34
Clutch B calibration value too low, the speed has dropped too quickly, the clutch pressure is not governed correctly or other factors have caused the speed to drop.
U35
Clutch A calibration value too high, the speed has not dropped, there is no pressure in the clutch or there is a mechanical fault with the transmission.
U49
No movement of the synchronizer sensed.
U51
Engine speed error.
U60
Range gear lever in neutral.
U61
Gearbox (gear) lever in neutral.
U64
Solenoid valve connections of the reverse gear synchronizer and fast forward gear reversed.
U91
Synchronizer potentiometer signal is not within allowable limits for HILO position; potentiometer signal incorrect or synchronizer jammed.
U92
Synchronizer potentiometer signal is not within allowable limits for shuttle position; potentiometer signal incorrect or synchronizer jammed.
U111
Impossible to calibrate the transmission.
(*) − For temperatures between 10 to 20 °C or above 100 °C calibration is permissible even if the display shows “CL” or “CH” (on pressing switch 2 in position C the warning disappears). For temperatures below 10 °C it is not possible to calibrate the clutches.
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
7
LIFT CALIBRATIONS (SA) Lifting and lowering control solenoid valve calibrations This procedure is necessary when there is one (or all) of the following conditions: − replacing the control valve (solenoid valves); − replacing the control unit (EDC); − deleting the data contained in the memory via the H8 MENU. Proceed as follows. − Disconnect all implements from the rear PTO. − Apply a weight of 100 to 200 kg to the lift arms. − Turn the ignition switch (1) onto position (C) (engine starting), take the engine speed to 1200 to 1300 rpm. −
Select the module (SA) and access the H1 MENU proceeding as described on page 2.
−
Move potentiometers (1, 2, 3 and 4) to the following positions: Potentiometer (1) to the max. raise position (turn clockwise); Potentiometer (2) to the arms descent speed max. position (turn clockwise); Potentiometer (3) to the max. lowered position (turn clockwise); Potentiometer (4) to the controlled operation position (turn anticlockwise); Put the switch (2, fig. 15) into the middle position (work).
26083
10
11
− − − − −
12
87666787A2 − 06 − 2009
8 −
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10 Using the knob (1), capture the lift by making a full clockwise rotation, turn this knob anticlockwise as far as the stop and turn it again clockwise to the height of number 2.
4
13 − −
The display will show “CAL”, then: 0 − 1 − 2 − End. Switch off the engine by turning the switch (1, fig. 10) onto position (A).
SA H1
0 1 2
CAL
3
End 14
NOTE: It is possible to access lift solenoid valve calibration also by holding down the switch (2) in the rapid ground entry position, start the engine then release the switch, putting it into the work position.
15
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
9
UXX FAULT CODES FAULT CODE
DESCRIPTION
U12
Procedure for calibrating ACP interrupted/vehicle in motion.
U21
Engine speed below 1150 rpm, increase the engine speed.
U22
Engine speed above 1350 rpm, decrease the engine speed.
U130
Implement connector too low.
U131
Implement connector too high.
U132
Knob of the dial moved by the operator.
U133
Rocker arms shaft not calibrated correctly.
U134
Calibration current not within prescribed values.
U135
Height Limit Potentiometer not at maximum.
U136
Height Limit Potentiometer not at minimum.
U137
Lower limit not at maximum.
U138
Lower limit not at minimum.
U139
Lowering speed not at maximum.
U140
Lowering speed not at minimum.
U141
Combined position/draft control potentiometer not on “pure draft”.
U142
Combined position/draft control potentiometer not on “pure position”.
U143
Rocker arms shaft not calibrated.
U144
Control unit (EDC) disabled.
U145
Position error too high.
U146
Impossible to calibrate the control unit (EDC).
87666787A2 − 06 − 2009
10
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
Lift arms calibrations. This procedure is necessary when there is one (or all) of the following conditions: − when error code 1024 appears; − deleting the data contained in the memory via the H8 MENU; − replacement of the working depth control knob (1, fig. 13); − replacement of the lift arms position sensor.
4
Proceed as follows. − Disconnect all implements from the rear PTO. − Apply a weight of 100 to 200 kg to the lift arms. − Position the control panel potentiometers as described for fig. 12. − put the switch (2, fig. 15) into the middle position (work). − Turn the ignition switch (1) onto position (C) (engine starting), take the engine speed to 1200 to 1300 rpm. − Make sure the lift arms can make their full travel. − Using the knob (1), capture the lift by making a full clockwise rotation, turn this knob clockwise, the arms will reach their lift limit stop (warning light to the left of the knob will come on). Turn the knob (1) fully anticlockwise, the arms will reach their bottom limit stop wait for the warning light to come on. − Switch off the engine by turning the switch (1) onto position (A).
16
26083
17
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
11
H2 − DISPLAYS ALL THE CALIBRATION VALUES (SB − SD − SA) CLUTCH CALIBRATION VALUES (SB) − − − −
Select the module (SB) and access the H2 MENU proceeding as described on page 2. Using the switch (2) select the channel number. The calibration values in milliAmperes are shown on the display. The prescribed calibration values are stated in the table below. 18
CHANNEL
ELEMENT
RANGE OF VALUES
Ch. 1
Clutch A
210 to 480
Ch. 2
Clutch B
210 to 480
Ch. 3
Dual Command (2 Speed Power Shift) synchronizer position
75 to 345
Ch. 4
Reverser synchronizer position
730 to 880
Ch. 5
Clutch pedal released
2126 to 2967
Ch. 6
Clutch pedal depressed
165 to 1005
CLUTCH CALIBRATION VALUES (SD) − − − −
Select the module (SD) and access the H2 MENU proceeding as described on page 2. Using the switch (2) select the channel number. The calibration values in milliAmperes are shown on the display. The prescribed calibration values are stated in the table below.
19
CHANNEL
ELEMENT
RANGE OF VALUES
Ch. 1
Front lift arms position sensor (TOP)
32000 to 40000
Ch. 2
Front lift arms position sensor (BOTTOM)
3000 to 12000
Ch. 3
Working depth control (clockwise direction)
28000 to 40000
Ch. 4
Working depth control (anticlockwise direction)
Ch. 5
Height limit control knob (TOP)
Ch. 6
Height limit control knob (BOTTOM)
400 to 8000 18000 to 35000 400 to 8000
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
12
LIFT CALIBRATION VALUES (SA) − −
Select the module (SA) and access the H2 MENU proceeding as described on page 2. Using the switch (2) select the channel number. RANGE OF VALUES
ELEMENT
CHANNEL Ch. 1
Lifting valve.
1000 to 4000
Ch. 2
Lowering valve.
1000 to 4000
Ch. 3
Lift arms position sensor. (TOP)
32000 to 40000
Ch. 4
Lift arms position sensor. (BOTTOM)
4000 to 12000
Ch. 5
Working depth control. (TOP)
28000 to 40000
Ch. 6
Working depth control. (BOTTOM)
Ch. 7
Height limit control knob. (TOP)
Ch. 8
Height limit control knob. (BOTTOM)
Ch. 9
Lowering limit control knob. (TOP)
Ch. 10
Lowering limit control knob. (BOTTOM)
Ch. 11
Drop rate control knob. (TOP)
Ch. 12
Drop rate control knob. (BOTTOM)
Ch. 13
Combined draft/position control knob. (TOP)
Ch. 14
Combined draft/position control knob. (BOTTOM)
400 to 8000 28000 to 40000 400 to 8000 28000 to 40000 400 to 8000 28000 to 40000 400 to 8000 28000 to 40000 400 to 8000
H3 − OPTIONS (SB − ZA − SD − SC) GEARBOX OPTIONS (SB) −
Select the module (SB) and access the H3 MENU proceeding as described on page 2.
−
The display will show “ch_ _”, using the switch (2) select the desired channel. After a countdown, the “standard” or “hilo” options or specific numbers will be displayed, select the desired option with the switch (2) and save it with the switch (1) in position (B), saving will be confirmed by an audible warning. Using the switch (1, fig. 20) in position (A), exit the gearbox option and go back to the previous point.
20
−
−
SB H3
standard
hilo ch 1 21
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
CHANNEL
RANGE OF VALUES Standard HI LO OFF ON 30 to 150 30 to 150 NEF F5C
PARAMETER
Ch. 1
Setup.
Ch. 2
Creeper unit.
Ch. 3 Ch. 4
Clutch A quick fill. Clutch B quick fill.
Ch. 5
Type of engine.
13
UNIT − − − − ms ms − −
OPTIONS FOR CONTROL PANEL (ZA) − − − −
− − −
−
Select the module (ZA) and access the H3 MENU proceeding as described on page 2. Press the switch (1, fig. 20) into position (B) and the various options will be displayed. Select the desired option with the switch (2, fig. 20). The first option “!” is the diagnosis mode: the display will show: LIVE − FACTORY − ECR, (if Error Code Reduction “ECR” mode is entered some warnings will not be displayed on the control panel). Confirm the desired mode by pressing the switch (1) into position (B). Select the cab option with the switch (1) in position (B). The display will show “CAB” and, pressing the switch (1) into position (B), it will then show: YES − NO. By pressing the switch (2) it is possible to select “YES” or “NO” to decrease or increase the volume of the cab audible warning and press the switch (1) into position (B) to confirm the selection and pass on to another option.
ZA
H3
ZA
H3
22
CAB
CAB YES NO
23 − −
Select the battery cut−out option with the switch (1) in position (B). By pressing the switch (2) it is possible to select “YES” or “NO” and with the switch (1) in position (B) confirm the selection and pass on to another option.
YES NO
24 87666787A2 − 06 − 2009
14 − −
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10 Select the operator present switch option with the switch (1) in position (B). By pressing the switch (2) it is possible to select “YES” or “NO” and with the switch (1) in position (B) confirm the selection and pass on to another option.
operator SW
operator
YES NO
SW
25 − −
Select the rear PTO sensor option with the switch (1) in position (B). By pressing the switch (2) it is possible to select “YES” or “NO” and with the switch (1) in position (B) confirm the selection and pass on to another option.
NOTE: YES, sensor present, the speed of the PTO is detected by the sensor. NO, sensor not present, the PTO speed is calculated according to the engagement data and the speed of engine rotation.
−
−
− −
select the mechanical four−wheel drive cut−out option according to the steering angle with the switch (1) in position (B). By pressing the switch (2) it is possible to select “YES” or “NO” and with the switch (1) in position (B) confirm the selection and pass on to another option.
Select the front PTO sensor option with the switch (1) in position (B). By pressing the switch (2) it is possible to select “OFF” or “MECH” or “ELEC” and with the switch (1) in position (B) confirm the selection and pass on to another option.
NOTE: OFF, front PTO not present. MECH, front PTO with hydraulic control. ELEC, front PTO with electromagnetic control.
PTO SENSOR
PTO SENSOR YES NO
26
HSD − 4WD HSD − 4WD
YES NO
27
F
F OFF MECH ELEC
28 87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10 − −
−
Select the front electronically controlled lift option with the switch (1) in position (B). By pressing the switch (2) it is possible to select “YES” or “NO” and with the switch (1) in position (B) confirm the selection and pass on to another option. Using the switch (1, fig. 20) exit the gearbox option and go back to the previous point.
15
YES NO
29
AUTOMATIC FOUR−WHEEL DRIVE AND FRONT POWER TAKE−OFF OPTIONS (SD) − − −
Select the module (SD) and access the H3 MENU proceeding as described on page 2. Select the four−wheel drive mode by pressing the switch (1, fig. 20) into position (B). By pressing the switch (2) it is possible to select “OFF” or “Auto” and with the switch (1) in position (B) confirm the selection. OFF: on starting, four−wheel drive is off. Auto: on starting, four−wheel drive is engaged in automatic mode.
SD
H3
OFF Auto 30
AUTOMATIC FOUR−WHEEL DRIVE AND FRONT POWER TAKE−OFF OPTIONS (SD) − −
−
SD
H3
Select the module (SD) and access the H3 MENU proceeding as described on page 2. Select the front lift mode with switch (1, fig. 20) in position (B) the display will show “UP L” or “FHPL”, select the latter with switch (1, fig. 20). By pressing the switch (2) it is possible to select “OFF” or “ON” and with the switch (1) in position (B) confirm the selection. OFF = front lift not present. ON = front lift present.
UP L FHPL ON OFF 31
− −
−
−
Select “UP L” with the switch (1, fig. 20). The display will show a value (percentage of the total travel) of the lifting limit with adjustment knobs (11 and 12, sect. 35 Chap. 6, page 11). turned anticlockwise and operating the front lift with the switch (3, sect. 35 Chap. 6, page 11) By pressing the switch (2, fig. 20) it is possible to vary the value of the lifting limit between 10% to 90%. By using knobs (11 and 12, sect. 35 Chap. 6, page 11) it is possible to have the front lift arms make their full travel.
SD
H3
UP L 50 32 87666787A2 − 06 − 2009
16
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
AUTOMATIC FOUR−WHEEL DRIVE AND FRONT POWER TAKE−OFF OPTIONS (SD) − − −
SD
H3
Select the module (SD) and access the H3 MENU proceeding as described on page 2. Select the PTO mode with switch (1, fig. 20) in position (B) the display will show ”PrE5”. By pressing the switch (2) it is possible to select ”no” or ”yes” and press the switch (1) into position (B) to confirm the selection. no: PTO with immediate engagement. yes: PTO with modulated engagement.
PrE5 SOFT no yes 33
AUTOMATIC FOUR−WHEEL DRIVE OPTIONS (SC) − − −
Select the module (SC) and access the H3 MENU proceeding as described on page 2. Select the four−wheel drive mode by pressing the switch (1, fig. 20) into position (B). By pressing the switch (2) it is possible to select “OFF” or “Auto” and with the switch (1) in position (B) confirm the selection. OFF: on starting, four−wheel drive is off. Auto: on starting, four−wheel drive is engaged in automatic mode.
SC
H3
OFF Auto 34
H4 − SOFTWARE REVISION LEVEL (ZA − SD − SC − SB − SA) SOFTWARE REVISION LEVEL OF THE CONTROL PANEL (ZA) − −
−
1104 ZA
H4
0200
Select the module (ZA) and access the H4 MENU proceeding as described on page 2. Pressing the switch (1, fig. 20) into position (B) access the menu, the display will show the software revision levels. Using the switch (1, fig. 20) in position (A), exit and go back to the previous point.
0000 35
SOFTWARE REVISION LEVEL OF THE AUTOMATIC FOUR−WHEEL DRIVE AND FRONT POWER TAKE−OFF CONTROL UNIT (SD) − −
−
Select the module (SD) and access the H4 MENU proceeding as described on page 2. Pressing the switch (1, fig. 20) into position (B) access the menu, the display will show the software revision levels. Using the switch (1, fig. 20) in position (A), exit and go back to the previous point.
1103 SD
H4
0101 2001 36
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10 SOFTWARE REVISION LEVEL OF THE AUTOMATIC FOUR−WHEEL DRIVE CONTROL UNIT (SC) − −
−
Select the module (SC) and access the H4 MENU proceeding as described on page 2. Pressing the switch (1, fig. 20) into position (B) access the menu, the display will show the software revision levels. Using the switch (1, fig. 20) in position (A), exit and go back to the previous point.
17
1102 SC
H4
0101 2001 37
SOFTWARE REVISION LEVEL OF THE POWER SHUTTLE CONTROL UNIT (SB) − −
−
Select the module (SB) and access the H4 MENU proceeding as described on page 2. Pressing the switch (1, fig. 20) into position (B) access the menu, the display will show the software revision levels. Using the switch (1, fig. 20) in position (A), exit and go back to the previous point.
1099 SB
H4
0102 0103 38
SOFTWARE REVISION LEVEL OF THE REAR LIFT CONTROL UNIT (SA) − −
−
Select the module (SA) and access the H4 MENU proceeding as described on page 2. Pressing the switch (1, fig. 20) into position (B) access the menu, the display will show the software revision levels. Using the switch (1, fig. 20) in position (A), exit and go back to the previous point.
H5 − CONTROL SWITCH DIAGNOSTICS (ZA − SD − SC − SB − SA)
1101 SA
H4
0000 9137 39
This module is requested by the Diagnostics Menu to check for any control module switch and analog input circuit status changes on the control unit. A status change, for the analog inputs, means that a fixed threshold has been exceeded. The display (2) shows a “d” and a number each time a status change occurs.
40 87666787A2 − 06 − 2009
18
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
If the same circuit has two consecutive status changes, the message on the display (2) changes to “d0” when the second change occurs. This menu also checks compatibility problems on the Forward, Neutral and Reverse push−buttons. The neutral pushbutton cannot be checked separately with the number d, as the operator cannot cause a status change on the neutral switch without simultaneously changing the Forward or Reverse switches. If the Shuttle lever is moved with the clutch raised, the neutral switch will also create a status change on the 12VD line used to control the clutch pedal.
As a result of the interaction between these push− buttons, consider the following: − The Forward and Reverse push−buttons must be checked with the clutch pedal lowered. − The clutch pedal push−button must be checked with the Shuttle lever engaged. − If the starter key (1) is turned to position C to start the engine, with the Shuttle lever in the neutral position and the clutch pedal lowered (normal starting procedure), a fault on the pushbuttons may occur (only in the diagnostics mode). When there is a status change on the clutch pedal push−button (the pedal is released), the clutch pedal potentiometer calibration values are checked, together with push−button adjustment. To check efficiently, proceed as follows: − Select the H5 menu, as described on page 2 and with the clutch pedal fully raised. − Fully press down the clutch pedal and hold down for at least 1 second. − Release the clutch pedal slowly (taking at least 2 seconds to move from the pedal pressed to the pedal released position.
87666787A2 − 06 − 2009
41
ZA H5
d__
42
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
19
CONTROL SWITCHES DIAGNOSTICS OF THE CONTROL PANEL (ZA) − − −
−
Select the module (ZA) and access the H5 MENU proceeding as described on page 2. Turn the ignition switch (1, fig. 40) onto position (C) (engine starting). Pressing the switch (1, fig. 41) into position (B) access the menu, the display will show “d” followed by the number of the switch. Switch off the engine by turning the switch (1, fig. 40) into position (A).
Control panel switches diagnostics (ZA). Number
Meaning
0
No switch or two switches activated at the same time.
10
Seat switch.
11
Parking brake switch.
42
Automatic four−wheel drive on/off switch (when present).
66
Main beam.
67
Sidelights.
68
Uncoupled brakes (only for Japanese variant).
70
Left−hand turn indicator.
71
Right−hand turn indicator.
72
Implement switch in operating status.
110
Enter key switch.
131
Home key switch.
132
Up key switch.
133
Down key switch.
135
Work lights.
AUTOMATIC FOUR−WHEEL DRIVE AND FRONT POWER TAKE−OFF SWITCHES DIAGNOSTICS (SD) − − −
−
Select the module (SD) and access the H5 MENU proceeding as described on page 2. Turn the ignition switch (1, fig. 40) onto position (C) (engine starting). Pressing the switch (1, fig. 41) into position (B) access the menu, the display will show “d” followed by the number of the switch. Switch off the engine by turning the switch (1, fig. 40) into position (A).
SD H5
d__
43
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
20
Automatic four−wheel drive switches diagnostics (SD). Number
Meaning
0
No switch or two switches activated at the same time.
9
Fuse 12 sensor.
12
Right hand brake pedal switch.
13
Left hand brake pedal switch.
16
Reverse gear switch (mechanical transmission only).
40
Four−wheel drive pressure switch.
41
Four−wheel drive switch with manual engagement.
42
Four−wheel drive switch with automatic engagement.
140
Front power take−off control switch pressed.
141
Front power take−off control switch pulled.
142
Lowering control switch.
143
Lifting control switch.
144
Switch not present.
145
Lowering control external switch.
146
Lifting control external switch.
154
Slope switch.
AUTOMATIC FOUR−WHEEL DRIVE SWITCHES DIAGNOSTICS (SC) − − −
−
Select the module (SC) and access the H5 MENU proceeding as described on page 2. Turn the ignition switch (1, fig. 40) onto position (C) (engine starting). Pressing the switch (1, fig. 41) into position (B) access the menu, the display will show “d” followed by the number of the switch. Switch off the engine by turning the switch (1, fig. 40) into position (A).
SC H5
d__
44
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
21
Automatic four−wheel drive switches diagnostics (SC). Number
Meaning
0
No switch or two switches activated at the same time.
9
Fuse 12 sensor.
12
Right hand brake pedal switch.
13
Left hand brake pedal switch.
16
Reverse gear switch (mechanical transmission only).
40
Four−wheel drive pressure switch.
41
Four−wheel drive switch with manual engagement.
42
Four−wheel drive switch with automatic engagement.
154
Slope switch.
POWER SHUTTLE SWITCHES DIAGNOSTICS (SB) − − −
−
Select the module (SB) and access the H5 MENU proceeding as described on page 2. Turn the ignition switch (1, fig. 40) onto position (C) (engine starting). Pressing the switch (1, fig. 41) into position (B) access the menu, the display will show “d” followed by the number of the switch. Switch off the engine by turning the switch (1, fig. 40) into position (A).
SB H5
d__
45 Power Shuttle transmission switches diagnostics (SB). Number
Meaning
0
No switch or two switches activated at the same time.
14
Clutch pedal switch (12V VD) (reverser lever on).
15
Reverser lever switch in forward position.
16
Reverser lever switch in reverse drive position.
17
Slow speed button (LO).
18
Fast speed button (HI).
19
Range switch in neutral.
22
Dump clutch switch.
25
Gear switch engaged (on return in neutral).
156
Gears in neutral sensor switch.
158
Creeper switch.
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
22
ELECTRONICALLY CONTROLLED REAR LIFT SWITCHES DIAGNOSTICS (SA) − − −
−
Select the module (SA) and access the H5 MENU proceeding as described on page 2. Turn the ignition switch (1, fig. 40) onto position (C) (engine starting). Pressing the switch (1, fig. 41) into position (B) access the menu, the display will show “d” followed by the number of the switch. Switch off the engine by turning the switch (1, fig. 40) into position (A).
SA H5
d__
46 Electronically controlled rear lift switches diagnostics (SA). Number
Meaning
0
No switch or two switches activated at the same time.
1
Lift control external switch (EDC) on fender − lowering.
2
Lift control external switch (EDC) on fender − lifting.
3
Lifting work switch (EDC).
6
Lift float switch (EDC).
H7 − SERVICE PROCEDURES (SB − SA) SERVICE PROCEDURES FOR TRANSMISSION (SB) −
Select the module (SB) and access the H7 MENU proceeding as described on page 2.
−
Pressing the switch (1, fig. 47) into position (B) access the menu, the display will show “ch _ _”. Select the desired channel using the switch (2, fig. 47).
47
−
SB H7
ch _
48
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10 Channel 1 − Clutch pedal switch test. − The display will show: ch 1 − 0 − 100 where: 0 = % of travel of the clutch pedal pressed. 100 = % of travel of the clutch pedal released. the percentage of travel of the pedal must be between 0 and 100. − Press the switch (1) to go back to the conditions of the previous point.
23
ch 1 SB H7
0 100 49
Channel 2 − Synchronizer movement test. − Position the reverser control lever on neutral. − Turn the ignition switch (1, fig. 40) onto position (C) (engine starting). − Press the HI or LO button, the display will show: ch 2 − ∼200 − ∼800 where: ∼200 = value of synchronizer position on “HI”. ∼800 = value of synchronizer position on “LO”. − Switch off the engine by turning the switch (1, fig. 40) onto position (A). − Press the switch (1) to go back to the conditions of the previous point.
ch 2 SB H7
220 785 50
Channel 3 − Power Shuttle clutches test. − Move the reverser control lever onto the forward drive position, the display will show: A270. − Move the reverser control lever onto the reverse drive position, the display will show: B265. where: A270 = calibration value of clutch “A”. B265 = calibration value of clutch “B”. − By pressing the switch (2, fig. 47) it is possible to change the measured values.
ch 3 SB H7
A270 B265 51
H8 − DELETION OF STORED DATA (ZA − SD − SC − SB − SA) DELETION OF STORED DATA IN THE CONTROL PANEL (ZA) − −
Select the module (ZA) and access the H8 MENU proceeding as described on page 2. Pressing the switch (2, fig. 47) access the H8 MENU CLEAR NETWORK CONFIG, the display will show “EECL”:
ZA H8 NETWORK CONFIG
ZA H8 CLEAR NETWORK CONFIG
EECL 52 87666787A2 − 06 − 2009
24 − − −
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10 Press and hold down the switch (2, fig. 47), the display will show: 5 − 4 − 3 − 2 − 1 − EE. When “EE” appears deletion is over. Switch off the engine by turning the switch (1, fig. 40) onto position (A). To be done when replacing the control panel (ZA), it deletes all the control units configured on it and proceed to configure the control units that the panel detects to be on the tractor.
5
2
4
1
3
EE 53
− −
Select the module (ZA) and access the H8 MENU proceeding as described on page 2. Pressing the switch (2, fig. 47) access the H8 MENU CLEAR SETTING, the display will show “EECL”:
ZA H8 ZA H8 CLEAR SETTING
CLEAR SETTING
EECL 54 − − −
Press and hold down the switch (2, fig. 47), the display will show: 5 − 4 − 3 − 2 − 1 − EE. When “EE” appears deletion is over. Switch off the engine by turning the switch (1, fig. 40) onto position (A). To be done when desired: − delete the error codes, − go back to FACTORY mode; − restore backlighting to 50%, − restore the switch audible warning.
5
2
4
1
3
EE 55
DELETION OF STORED DATA FOR AUTOMATIC FOUR−WHEEL DRIVE AND FRONT POWER TAKE−OFF (SD) − −
Select the module (SD) and access the H8 MENU proceeding as described on page 2. Pressing the switch (2, fig. 47) access the H8 MENU, the display will show “EECL”:
SD H8
EECL
56 87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10 − −
Press and hold down the switch (2, fig. 47), the display will show: 5 − 4 − 3 − 2 − 1 − EE. When “EE” appears deletion is over. Switch off the engine by turning the switch (1, fig. 40) onto position (A).
25
5
2
4
1
3
EE 57
DELETION OF STORED DATA FOR AUTOMATIC FOUR−WHEEL DRIVE (SC) − −
Select the module (SC) and access the H8 MENU proceeding as described on page 2. Pressing the switch (2, fig. 47) access the H8 MENU, the display will show “EECL”:
SC H8
EECL
58 − −
Press and hold down the switch (2, fig. 47), the display will show: 5 − 4 − 3 − 2 − 1 − EE. When “EE” appears deletion is over. Switch off the engine by turning the switch (1, fig. 40) onto position (A).
5
2
4
1
3
EE 59
DELETION OF STORED DATA FOR POWER SHUTTLE (SB) − −
Select the module (SB) and access the H8 MENU proceeding as described on page 2. Pressing the switch (2, fig. 47) access the H8 MENU, the display will show “EECL”:
SB H8
EECL
60 87666787A2 − 06 − 2009
26 − −
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10 Press and hold down the switch (2, fig. 47), the display will show: 5 − 4 − 3 − 2 − 1 − EE. When “EE” appears deletion is over. Switch off the engine by turning the switch (1, fig. 40) onto position (A).
5
2
4
1
3
EE 61
DELETION OF STORED DATA FOR ELECTRONICALLY CONTROLLED REAR LIFT (SA) − −
Select the module (SA) and access the H8 MENU proceeding as described on page 2. Pressing the switch (2, fig. 47) access the H8 MENU, the display will show “EECL”:
SA H8
EECL
62 − −
Press and hold down the switch (2, fig. 47), the display will show: 5 − 4 − 3 − 2 − 1 − EE. When “EE” appears deletion is over. Switch off the engine by turning the switch (1, fig. 40) onto position (A).
5
2
4
1
3
EE 63
H9 − VOLTMETER ( ZA − SD − SC − SB − SA) This menu checks the power supply voltage status, the frequency and the solenoid valve circuits.
CONTROL PANEL VOLTMETER (ZA) − −
Select the module (ZA) and access the H9 MENU proceeding as described on page 2. It is possible to scroll through the channels by using the switch (2, fig. 47), the display will show the channel number and the related value.
ZA H9
ch 04 510 64
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
27
Voltmeter − Control panel (ZA) Channel Number
Meaning
Measured value
4
Programming Voltage Vpp.
400 to 600
7
Source volts + 12 VF.
340 to 670
23
engine coolant temperature.
4 to 680
25
Fuel level.
20 to 580
AUTOMATIC FOUR−WHEEL DRIVE AND FRONT POWER TAKE−OFF VOLTMETER (SD) − −
Select the module (SD) and access the H9 MENU proceeding as described on page 2. It is possible to scroll through the channels by using the switch (2, fig. 47), the display will show the channel number and the related value.
SD H9
ch 05 0 65
Voltmeter − Automatic four−wheel drive (SD) Channel Number
Meaning
Measured value
5
5 V sensor supply.
800 to 950
7
Source volts + 12 VF.
500 to 900
11
Angle sensor (with tractor on level ground).
10 to 900
14
Front power take−off clutch current (with engine running).
650 to 850
Steering angle sensor (wheels straight).
10 to 900
Steering angle sensor (wheels fully turned).
10 to 900
27
Working depth potentiometer.
50 to 850
28
Front lift arms position potentiometer.
50 to 850
35
Front lifting arms lift limit potentiometer.
50 to 850
130
Four−wheel drive solenoid valve.
0 to 700
21
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
28
AUTOMATIC FOUR−WHEEL DRIVE VOLTMETER (SC) − −
Select the module (SC) and access the H9 MENU proceeding as described on page 2. It is possible to scroll through the channels by using the switch (2, fig. 47), the display will show the channel number and the related value.
SC H9
ch 05 0 66
Automatic four−wheel drive voltmeter (sc) Channel Number
Meaning
Measured value
5
5 V sensor supply.
800 to 950
7
Source volts + 12 VF.
500 to 900
11
Angle sensor (with tractor on level ground).
10 to 900
Steering angle sensor (wheels straight).
10 to 900
Steering angle sensor (wheels fully turned).
10 to 900
Four−wheel drive solenoid valve.
0 to 700
21 130
POWER SHUTTLE VOLTMETER (SB) − −
Select the module (SB) and access the H9 MENU proceeding as described on page 2. It is possible to scroll through the channels by using the switch (2, fig. 47), the display will show the channel number and the related value.
SB H9
ch 01 880 67
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
29
Power Shuttle voltmeter (SB) Channel Number 1
Meaning
Measured value
Clutch pedal tension (pedal released).
50 to 950
Clutch pedal tension (pedal pressed).
50 to 950
2
Transmission oil temperature (*).
80 to 920
5
5 V sensor supply.
450 to 500
7
Source volts + 12 VF.
500 to 900
8
Source volts + 12 VD (with reverser lever on).
500 to 900
18
Engine rpm.
800 to 2600
43
Clutch A/1 current filtered.
0 to 500
44
Clutch B/2 current filtered.
0 to 500
53
Clutch A/1 current fast.
0 to 500
54
Clutch B/2 current fast.
0 to 500
58
Filtered HI LO solenoid valve.
0 to 700
59
Filtered reverser solenoid valve.
0 to 700
Reverser − Dual Command (2 Speed Power Shift) potentiometer (in reverse drive).
75 to 880
Reverser − Dual Command (2 Speed Power Shift) potentiometer (in forward drive).
75 to 880
72 86
Transmission oil temperature sensor.
(−40°) to (+120°)
(*) = A/D count and 20° temperature.
ELECTRONICALLY CONTROLLED REAR LIFT VOLTMETER (SA) − −
Select the module (SA) and access the H9 MENU proceeding as described on page 2. It is possible to scroll through the channels by using the switch (2, fig. 47), the display will show the channel number and the related value.
SA H9
ch 06 810 68
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
30
Electronically controlled rear lift voltmeter (sa) Channel Number
Meaning
Measured value
6
8 V sensor supply.
740 to 830
7
Source volts + 12 VF.
500 to 900
30
Current of the rear lift up solenoid valve (EDC).
10 to 800
31
Current of the rear lift down solenoid valve (EDC).
10 to 800
32
33 34 35 36 38 40
87666787A2 − 06 − 2009
Potentiometer of the rear lift arms shaft (EDC) (shafts fully raised).
100 to 1000
Potentiometer of the rear lift arms shaft (EDC) (shafts fully lowered).
100 to 1000
Lift control potentiometer (anticlockwise).
130 to 900
Lift control potentiometer (clockwise).
130 to 900
Arms drop rate potentiometer (control panel) (anticlockwise).
130 to 900
Arms drop rate potentiometer (control panel) (clockwise).
130 to 900
Height limit potentiometer (control panel) (anticlockwise).
130 to 900
Height limit potentiometer (control panel) (clockwise).
130 to 900
Lowering limit potentiometer (anticlockwise).
130 to 900
Lowering limit potentiometer (clockwise).
130 to 900
LVDT (with no load).
130 to 750
Combined control potentiometer (anticlockwise).
130 to 900
Combined control potentiometer (clockwise).
130 to 900
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
31
HB − DISPLAYS STORED ERROR CODES (ZA − SD − SC − SB − SA) Up to 10 error codes for each module can be stored.
DISPLAYS THE ERROR CODES STORED IN THE CONTROL PANEL (ZA) −
Select the module (ZA) and access the HB MENU proceeding as described on page 2.
69 −
−
−
The display will show the first error code (14913) followed by the time of the first occurrence (125), the time of the last occurrence (130) and the number of times the error occurred (11). If, on the contrary, the module contains no errors, the display will show the letter “F” followed by the number “0”. By pressing the switch (2, fig. 69) it is possible to pass on to the next codes.
14913 ZA HB
125 130 11 70
DISPLAYS THE ERROR CODES STORED IN THE FOUR−WHEEL DRIVE AND FRONT POWER TAKE−OFF CONTROL UNIT (SD) −
Select the module (SD) and access the HB MENU proceeding as described on page 2.
−
The display will show the first error code (6014) followed by the time of the first occurrence (125), the time of the last occurrence (130) and the number of times the error occurred (11). If, on the contrary, the module contains no errors, the display will show the letter “F” followed by the number “0”. By pressing the switch (2, fig. 73) it is possible to pass on to the next codes.
71
−
−
6014 SD HB
125 130 11 72 87666787A2 − 06 − 2009
32
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
DISPLAYS THE ERROR CODES STORED IN THE FOUR−WHEEL DRIVE CONTROL UNIT (SC) −
Select the module (SC) and access the HB MENU proceeding as described on page 2.
73 −
−
−
The display will show the first error code (6014) followed by the time of the first occurrence (125), the time of the last occurrence (130) and the number of times the error occurred (11). If, on the contrary, the module contains no errors, the display will show the letter “F” followed by the number “0”. By pressing the switch (2, fig. 73) it is possible to pass on to the next codes.
6014 SC HB
125 130 11 74
DISPLAYS THE ERROR CODES STORED IN THE POWER SHUTTLE CONTROL UNIT (SB) −
Select the module (SB) and access the HB MENU proceeding as described on page 2.
−
The display will show the first error code (2051) followed by the time of the first occurrence (125), the time of the last occurrence (130) and the number of times the error occurred (11). If, on the contrary, the module contains no errors, the display will show the letter “F” followed by the number “0”. By pressing the switch (2, fig. 75) it is possible to pass on to the next codes.
75
−
−
2051 SB HB
125 130 11 76
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
33
DISPLAYS THE ERROR CODES STORED IN THE ELECTRONICALLY CONTROLLED REAR LIFT CONTROL UNIT (SA) −
Select the module (SA) and access the HB MENU proceeding as described on page 2.
−
The display will show the first error code (1021) followed by the time of the first occurrence (125), the time of the last occurrence (130) and the number of times the error occurred (11). If, on the contrary, the module contains no errors, the display will show the letter “F” followed by the number “0”. By pressing the switch (2, fig. 75) it is possible to pass on to the next codes.
77
−
−
1021 SA HB
125 130 11 78
HC − DELETES ALL THE STORED ERROR CODES (ZA − SD − SC − SB − SA) DELETES ALL THE STORED ERROR CODES (ZA) − − −
ZA HC
F CL
Select the module (ZA) and access the HC MENU proceeding as described on page 2. Pressing the switch (1, fig. 77) access the HC MENU, the display will show “F CL”. Press and hold down the push−button (2, fig. 77) in position (B), the display will show: 5 − 4 − 3 − 2 − 1 − EE.
79
−
Where: The numbers indicate the countdown and “EE” means that deletion has been performed correctly. Turn the key onto position (A, fig. 40) “OFF” to exit or to access another MENU.
5
2
4
1
3
EE 80 87666787A2 − 06 − 2009
34
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
DELETES ALL THE STORED ERROR CODES (SD) − − −
Select the module (SC) and access the HC MENU proceeding as described on page 2. Pressing the switch (1, fig. 77) access the HC MENU, the display will show “F CL”. Press and hold down the push−button (2, fig. 77) in position (B), the display will show: 5 − 4 − 3 − 2 − 1 − EE.
SD HC
F CL
81
−
Where: The numbers indicate the countdown and “EE” means that deletion has been performed correctly. Turn the key onto position (A, fig. 40) “OFF” to exit or to access another MENU.
5
2
4
1
3
EE 82
DELETES ALL THE STORED ERROR CODES (SC) − − −
Select the module (SC) and access the HC MENU proceeding as described on page 2. Pressing the switch (1, fig. 77) access the HC MENU, the display will show “F CL”. Press and hold down the push−button (2, fig. 77) in position (B), the display will show: 5 − 4 − 3 − 2 − 1 − EE.
SC HC
F CL
83
−
Where: the numbers indicate the countdown and “EE” means that deletion has been performed correctly. Turn the key onto position (A, fig. 40) “OFF” to exit or to access another MENU.
5
2
4
1
3
EE 84
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
35
DELETES ALL THE STORED ERROR CODES (SB) − − −
Select the module (SB) and access the HC MENU proceeding as described on page 2. Pressing the switch (1, fig. 77) access the HC MENU, the display will show “F CL”. Press and hold down the push−button (2, fig. 77) in position (B), the display will show: 5 − 4 − 3 − 2 − 1 − EE.
SB HC
F CL
85
−
Where: the numbers indicate the countdown and “EE” means that deletion has been performed correctly. Turn the key onto position (A, fig. 40) “OFF” to exit or to access another MENU.
5
2
4
1
3
EE 86
DELETES ALL THE STORED ERROR CODES (SA) − − −
Select the module (SA) and access the HC MENU proceeding as described on page 2. Pressing the switch (1, fig. 77) access the HC MENU, the display will show “F CL”. Press and hold down the push−button (2, fig. 77) in position (B), the display will show: 5 − 4 − 3 − 2 − 1 − EE.
SA HC
F CL
87
−
Where: the numbers indicate the countdown and “EE” means that deletion has been performed correctly. Turn the key onto position (A, fig. 40) “OFF” to exit or to access another MENU.
5
2
4
1
3
EE 88 87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
36
HE − FREQUENCY (ZA − SD − SC) FREQUENCY (ZA) − − −
− −
Turn the ignition switch (1, fig. 40) onto position (C) (engine starting). Select the module (ZA) and access the HE MENU proceeding as described on page 2. Pressing the switch (1, fig. 77) access the menu, the display will show the channel number followed by the corresponding voltage. By pressing the switch (2, fig. 77) it is possible to scroll through the channels. Switch off the engine by turning the switch (1, fig. 40) onto position (A).
ZA HE
CH 18 850 89
Frequency − Control panel (ZA) Channel Number
Meaning
Measured value
18
Engine speed (rpm).
0 to 2600
19
Tractor speed (km/h).
0 to 55
96
Rear PTO speed (rpm).
0 to 1200
FREQUENCY (SD) − − −
− −
Turn the ignition switch (1, fig. 40) onto position (C) (engine starting). Select the module (SD) and access the HE MENU proceeding as described on page 2. Pressing the switch (1, fig. 77) access the menu, the display will show the channel number followed by the corresponding voltage. By pressing the switch (2, fig. 77) it is possible to scroll through the channels. Switch off the engine by turning the switch (1, fig. 40) onto position (A).
SD HE
CH 10 850 90
Frequency − Automatic four−wheel drive (SD) Channel Number
Meaning
Measured value
7
Front power take−off sensor.
0 to 200
10
Rear axle speed (for four−wheel drive) (according to speed).
0 to 200
11
Front axle speed (for four−wheel drive) (according to speed).
0 to 200
87666787A2 − 06 − 2009
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
37
FREQUENCY (SC) − − −
− −
Turn the ignition switch (1, fig. 40) onto position (C) (engine starting). Select the module (SC) and access the HE MENU proceeding as described on page 2. Pressing the switch (1, fig. 77) access the menu, the display will show the channel number followed by the corresponding voltage. By pressing the switch (2, fig. 77) it is possible to scroll through the channels. Switch off the engine by turning the switch (1, fig. 40) onto position (A).
SC HE
CH 10 850 91
Frequency − Automatic four−wheel drive (SC) Channel Number
Meaning
Measured value
10
Rear axle speed (for four−wheel drive) (according to speed).
0 to 200
11
Front axle speed (for four−wheel drive) (according to speed).
0 to 200
HF − DISPLAYS THE HARDWARE INFORMATION (ZA − SD − SC − SB − SA)
ZA HE
DISPLAYS THE HARDWARE INFORMATION (ZA) − −
−
Select the module (ZA) and access the HF MENU proceeding as described on page 2. Pressing the switch (1, fig. 77) access the menu, the display will show: hardware identification: 0581; hardware version 1: 0000; hardware version 2: 0003; serial number 1: 6110; next serial number: 0008. On ending the sequence it is possible to select the other modules with the switch (1, fig. 77).
DISPLAYS THE HARDWARE INFORMATION (SD) − −
−
Select the module (SD) and access the HF MENU proceeding as described on page 2. Pressing the switch (1, fig. 77) access the menu, the display will show: hardware identification: 0579; hardware version 1: 0256; hardware version 2: 0000; serial number 1: 0081; next serial number: 10262. On ending the sequence it is possible to select the other modules with the switch (1, fig. 77).
0000 0003
0581
6110 0008 92
SD HE
0256 0000
0579
0081 10262 93
87666787A2 − 06 − 2009
38
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 10
DISPLAYS THE HARDWARE INFORMATION (SC) − −
−
Select the module (SC) and access the HF MENU proceeding as described on page 2. Pressing the switch (1, fig. 77) access the menu, the display will show: hardware identification: 0579; hardware version 1: 0256; hardware version 2: 0000; serial number 1: 0081; next serial number: 10262. On ending the sequence it is possible to select the other modules with the switch (1, fig. 77).
SC HE
0000 0579
−
−
Select the module (SB) and access the HF MENU proceeding as described on page 2. Pressing the switch (1, fig. 77) access the menu, the display will show: hardware identification: 0576; hardware version 1: 0006; hardware version 2: 0000; serial number 1: 6062; next serial number: 16737. On ending the sequence it is possible to select the other modules with the switch (1, fig. 77).
SB HE
−
−
Select the module (SA) and access the HF MENU proceeding as described on page 2. Pressing the switch (1, fig. 77) access the menu, the display will show: hardware identification: 0578; hardware version 1: 0006; hardware version 2: 0000; serial number 1: 2684; next serial number: 61824. On ending the sequence it is possible to select the other modules with the switch (1, fig. 77).
87666787A2 − 06 − 2009
10262 0006 0000
0576
6062 16737 95
DISPLAYS THE HARDWARE INFORMATION (SA) −
0081 94
DISPLAYS THE HARDWARE INFORMATION (SB) −
0256
SA HE
0006 0000
0578
2684 61824 96
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11
1
SECTION 55 - ELECTRICAL SYSTEM Chapter 11 - ELECTRONIC FRONT LIFT
CONTENT
Description
Page
Electrical circuit components (numerical order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Wiring diagram components (functional order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Wiring diagrams 1-2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Diagram 1 - Front lift circuit (transmission side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Diagram 2 - Front lift circuit (front side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Diagram 1 - Front lift circuit (cab side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 List of connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
87666787A1 - 03 - 2008
2
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11 ELECTRICAL CIRCUIT COMPONENTS (NUMERICAL order)
C-26 C-27 C-34 MOD-601 SW-602 SW-603 SW-604 GND-605 SEN-606 SW-607 SW-608 SOL-609 SOL-610 SOL-611 SW-612 SEN-613 MOD-614 SOL-615
Front lift circuit supply connection (8 PIN) Front lift circuit cab controls connection (13 PIN) Front lift circuit front connection (6 PIN) Front electronic lift control unit Front lift up/down control switch (on instrument panel) Front lift up/down control switch (on cab mudguard) Front lift operating mode selection switch Front lift circuit ground Front lift arms position sensor Front lift “up” external control button Front lift “down” external control button 40 bar pressure solenoid valve for front lift Front lift arms down solenoid valve 14 bar pressure solenoid valve for front lift Multicontroller lever (Dual Command (2 Speed Power Shift / front lift) Pressure sensor for front lift Front lift control panel Front lift arms up solenoid valve
87666787A1 - 03 - 2008
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11
3
ELECTRICAL CIRCUIT COMPONENTS (functional order)
COMPONENT
DESCRIPTION
CONNECTIONS C-26
Front lift circuit supply connection (8 PIN)
C-27
Front lift circuit cab controls connection (14 PIN)
C-34
Front lift circuit front connection (6 PIN)
GROUND GND-605
Front lift circuit ground
ELECTRONIC MODULES - CONTROL UNITS MOD-601
Front electronic lift control unit
MOD-614
Front lift control panel
SENSORS SEN-606
Front lift arms position sensor
SEN-613
Pressure sensor for front lift
SOLENOID VALVES SOL-609
40 bar pressure solenoid valve for front lift
SOL-610
Front lift arms down solenoid valve
SOL-611
14 bar pressure solenoid valve for front lift
SOL-615
Front lift arms up solenoid valve
CONTROL SWITCHES SW-602
Front lift up/down control switch (on instrument panel)
SW-603
Front lift up/down control switch (on right-hand mudguard)
SW-604
Front lift operating mode selection switch
SW-607
Front lift “up” external control button
SW-608
Front lift “down” external control button
SW-612
Multicontroller lever (Dual Command (2 Speed Power Shift / front lift)
87666787A1 - 03 - 2008
4
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11 WIRING DIAGRAMS 1-2-3
MPM1229
81 87666787A1 - 03 - 2008
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11
5
87666787A1 - 03 - 2008
6
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11 FRONT LIFT CIRCUIT (TRANSMISSION SIDE) (Diagram 1)
C-27
Front lift circuit cab controls connection (13 PIN)
SOL-609
40 bar pressure solenoid valve for front lift
SOL-610
Front lift arms down solenoid valve
SOL-611
14 bar pressure solenoid valve for front lift
SW-612
Multicontroller lever (Dual Command (2 Speed Power Shift / front lift)
SEN-613
Pressure sensor for front lift
MOD-614 Front lift control panel SOL-615
Front lift arms up solenoid valve
87666787A1 - 03 - 2008
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11
7 FRONT LIFT CIRCUIT (TRANSMISSION SIDE) - DIAGRAM 1
MPM1226A
87666787A1 - 03 - 2008
8
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11 FRONT LIFT CIRCUIT (FRONT SIDE) (Diagram 2)
*
C-26
Front lift circuit supply connection (8 PIN)
C-34
Front lift circuit front connection (6 PIN)
SEN-606
Front lift arms position sensor
SW-607
Front lift “up” external control button
SW-608
Front lift “down” external control button
To connection C-170 (see chap. 6 - Diagram 5 - Page 191)
87666787A1 - 03 - 2008
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11
9 FRONT LIFT CIRCUIT (FRONT SIDE) - DIAGRAM 2
MPM1227A
87666787A1 - 03 - 2008
10
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11 FRONT LIFT CIRCUIT (CAB SIDE) (Diagram 3)
MOD-601 Front electronic lift control unit SW-602
Front lift up/down control switch (on instrument panel)
SW-603
Front lift up/down control switch (on right-hand mudguard)
SW-604
Front lift operating mode selection switch
GND-605 Front lift circuit ground
87666787A1 - 03 - 2008
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11
11 FRONT LIFT CIRCUIT (CAB SIDE) - DIAGRAM 3
MPM1228A
87666787A1 - 03 - 2008
12
87666787A1 - 03 - 2008
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11
13
LIST OF CONNECTORS
87666787A1 - 03 - 2008
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11
Col.
Sect.
5
A
1.0
2
G
1.5
6
H
1.5
3
G
1.5
7
-
-
4
-
-
8
-
-
C-26
8
Pin
1.5
3
Sect.
R
6 7
Col.
1
4 5
Pin
1 2
14
82 Sect.
1
M
1.5
8
S
1.0
2
V
1.0
9
S
1.0
3
S
1.0
10
S
1.0
4
S
1.0
11
M
1.5
5
S
1.5
12
C
1.0
6
M
1.5
13
-
-
7
C
1.0
14
-
-
C-27
4
8
12
5
9
13
3
2
10
Col.
11
Pin
1
Sect.
6
Col.
7
Pin
Transmission side connection
Pin
Col.
Sect.
Pin
Col.
Sect.
1
M
1.5
8
S
1.0
2
V
1.0
9
S
1.0
3
S
1.0
10
S
1.0
4
S
1.0
11
M
1.5
5
S
1.5
12
C
1.0
6
M
1.5
13
-
-
2
7
7
C
1.0
-
-
-
1
6
83
9 8
12 13
5
10 11
3
4
C-27
Cab side connection
84 Sect.
Pin
Col.
Sect.
1
M
1.0
4
S
1.0
2
V
1.0
5
S
1.0
3
C
1.0
6
C
1.0
Front side connection
C-34
1 2 3 4 5 6
Col.
1 2 3 4 5 6
Pin
85 87666787A1 - 03 - 2008
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11
Sect.
Pin
Col.
Sect.
M
1.0
4
S
1.0
2
V
1.0
5
S
1.0
3
C
1.0
6
C
1.0
Cab side connection
C-34
6 5 4 3 2 1
Col.
1
6 5 4 3 2 1
Pin
15
86 Pin
Col.
Sect.
Pin
Col.
Sect.
1
-
-
29
R
1.5
2
C
1.0
30
-
-
3
V
1.0
31
S
1.0
4
V
1.0
32
-
-
5
-
-
33
-
-
6
-
-
34
-
-
7
-
-
35
M
1.5
MOD-601
38
20
39
21
40
22 23
4
8
V
1.0
36
S
1.0
42
24
9
C
1.0
37
S
1.0
43
25
44
26
45
27
46
28
47
29
48
30
49
31
50
32
51
33
52
34
53
35
54
36
55
37
-
-
38
M
1.5
11
-
-
39
C
1.0
12
V
1.0
40
-
-
2 3
41
10
1
5 6 7 8 9
13
A
1.0
41
-
-
14
-
-
42
-
-
15
V
1.0
43
-
-
10 11 12 13 14
16
V
1.0
44
-
-
17
V
1.0
45
-
-
18
-
-
46
M
1.5
19
S
1.5
47
R
1.5
20
M
1.0
48
-
-
21
S
1.0
49
-
-
22
V
1.0
50
-
-
23
V
1.0
51
-
-
24
G
1.5
52
-
-
25
V
1.0
53
M
1.5
26
-
-
54
-
-
27
-
-
55
-
-
28
M
1.5
-
-
-
15 16 17 18 19
87
87666787A1 - 03 - 2008
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11
2
C
1.0
6
-
-
3
C
1.0
7
-
-
4
S
1.0
8
-
-
SW-602-A
8
-
7
Sect.
-
6
Col.
5
5
Pin
1.0
4
Sect.
S
3
Col.
1
2
Pin
1
16
88 Pin
Col.
Sect.
Pin
Col.
Sect.
1
H
1.0
2
N
1.0
SW-602-B
1
2
89 1.0
5
-
-
2
C
1.0
6
-
-
3
C
1.0
7
-
-
4
S
1.0
8
-
-
Pin
Col.
Sect.
Pin
Col.
Sect.
1
H
1.0
2
N
1.0
SW-603-A
8
S
7
1
6
Sect.
5
Col.
4
Pin
3
Sect.
2
Col.
1
Pin
90 SW-603-B
1
2
91 87666787A1 - 03 - 2008
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11
Col.
Sect.
3
S
1.0
2
S
1.0
4
-
-
SW-604-A
2
Pin
1.0
4
Sect.
S
1
Col.
1
3
Pin
17
92 Pin
Col.
Sect.
Pin
Col.
Sect.
1
H
1.0
2
N
1.0
SW-604-B
1
2
93 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
2.5
-
-
-
Pin
Col.
Sect.
Pin
Col.
Sect.
1
M
1.0
3
C
1.0
2
V
1.0
-
-
-
GND-605
94
3 2 1
SEN-606
95
87666787A1 - 03 - 2008
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11
Sect.
-
-
2
C
1.0
-
-
-
SW-607
1
Col.
3
2
Pin
1.0
3
Sect.
S
1
Col.
1
2
Pin
3
18
96 1
S
1.0
3
-
-
2
C
1.0
-
-
-
SW-608
1
Sect.
2
Col.
3
Pin
1
Sect.
2
Col.
3
Pin
97 Col.
Sect.
Pin
Col.
Sect.
1
S
1.0
2
M
1.5
Pin
Col.
Sect.
Pin
Col.
Sect.
1
S
1.5
2
M
1.5
SOL-609
1 2
Pin
98
1 2
SOL-610
99 87666787A1 - 03 - 2008
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11
Col.
Sect.
Pin
Col.
Sect.
1
S
1.0
2
M
1.5
SOL-611
1 2
Pin
19
100 Sect.
Pin
Col.
Sect.
1
C
1.0
3
S
1.0
2
S
1.0
-
-
-
SW-612
3
Col.
2
2
1
1
3
Pin
101 Col.
Sect.
Pin
Col.
Sect.
1
M
1.0
3
C
1.0
2
V
1.0
-
-
-
SEN-613
3 2 1
Pin
102
87666787A1 - 03 - 2008
20
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 11
Pin
Col.
Sect.
Pin
Col.
Sect.
1
S
1.0
11
C
1.0
2
N
1.5
12
V
1.0
3
G
1.5
13
S
1.0
4
H
1.0
14
S
1.0
5
V
1.0
15
V
1.0
9
6
V
1.0
16
V
1.0
20 19 18
7
S
1.0
17
V
1.0
8
S
1.0
18
V
1.0
9
M
1.0
19
C
1.0
10
S
1.0
20
S
1.0
MOD-614
9
8
8
7
7
6
5
4
17 16 15 14 13
6
5
4
3
2
1
12 11 10
3
2
1
103 Col.
Sect.
Pin
Col.
Sect.
1
S
1.0
2
M
1.5
SOL-615
1 2
Pin
104
87666787A1 - 03 - 2008
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
1
SECTION 90 -- CAB Chapter 1 -- Cab CONTENT
Operation
Description
Page
90 100 22
Bonnet Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
90 110 14
Instrument panel lower guard R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
90 110 36
Platform assembly R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
90 114 10
Safety frame roof R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
90 150 10
Cab with platform assembly R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
90 156 14 and 90 156 28 Cab windows (Replacing glued cab windows) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 90 160 16
RH or LH upright seals R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
90 160 60
Cab ceiling fitting R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
88 120 10
Sun blind. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
87666787A - 11 - 2007
2
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
OP. 90 100 22 BONNET Removal--Installation
Removal
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows: 1. Disconnect the electrical connections of the front headlamps. 27640
2. Remove the two retaining bolts (2) holding the pivot bracket (1) to the base support. 3. Remove the retaining spring and shock absorber (1) from the upper pivot and remove the hood.
1
Installation Proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 27641
2 4. Position the bonnet on the relative bracket, insert the shock absorber (1,fig. 2) and the retaining clip on the top hinge. 5. Fit the hinging bracket (1,fig. 1) on the base support and lock the two retaining bolts (2). 6. Connect the electrical connections of the front headlamps.
87666787A - 11 - 2007
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
3
OP. 90 110 14 INSTRUMENT PANEL LOWER GUARD R.I. Removal
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 27648
3 Proceed as follows.
1. Remove the three retaining bolts (1) and the instrument panel lower LH side guard (2).
2. Remove the three retaining bolts (2) and the instrument panel lower RH side guard (1). 27649
4
Installation
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
Proceed as follows.
3. Fit the instrument panel lower RH side guard (1, fig. 4) and the three retaining bolts (2).
4. Fit the instrument panel lower LH side guard (2, fig. 3) and the three retaining bolts (1).
87666787A - 11 - 2007
4
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
OP. 90 110 36 PLATFORM ASSEMBLY R.I.
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted.
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
Removal
Proceed as follows.
1. Carry out operation 90 100 22--Bonnet R.I. (Only removal).
2. Carry out operation 90 114 10--Safety frame roof R.I. (Only removal).
3. If the exhaust pipe is horizontally fitted, carry out operation 10 254 44--Exhaust pipe R.I. (Only removal).
4. Carry out operation 21 130 11--Range gear control hand lever R.I. (Only removal).
87666787A - 11 - 2007
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
5
5. Carry out operation 21 130 10--Gear control hand lever R.I. (Only removal). 6. Carry out operation 21 130 52-Creeper/shuttle control hand lever R.I. (Only removal). 7. Remove the clips (1), disconnect the fork control rods (2), remove the two retaining bolts (3). 27811
5 8. Note: if an electronic lift is fitted, disconnect the oil delivery piping (1) on the electronic lift.
27812
6 9. Remove the bracket (1), complete with control rods, from the control valve housing.
27813
7 10. Remove the accelerator control cable (1) from the injection pump.
27660
8 87666787A - 11 - 2007
6
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
11. Remove the four retaining bolts and the hood rear support (1).
27666
9 12. Disconnect the electrical connections (1) connected to the platform, the two electrical connections connected to the brake block pressure switches, the thermostarter connection and the brake fluid tank connection.
13. Carry out operation 90 110 14--Instrument panel lower guard R.I. (Only removal).
27124
10 14. Loosen the nut (1) and remove the PTO clutch control cable (2). Note: For models with mechanical gears, remove the clutch control cable.
27650
11 15. Detach the four hoses (1) on the steering circuit pipes.
27662
12 87666787A - 11 - 2007
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
7
16. Drain off the brake fluid and disconnect the brake control pipes (2) from the block (1).
27125
13 17. Disconnect the brake feed pump pipes (2) from the relative tank (1).
18. Note: if an analogue control panel is fitted, disconnect the rev counter control rod.
27126
14 19. Note: if the differential lock is mechanically operated, disconnect the relative lever on the transmission gearbox.
20. Note: if an electronic lift is fitted, remove the springs (2) and detach the lift control lever rods (1). 27814
15 21. Note: if a mechanical lift is fitted, remove the seal ring and detach the LIFT--O--MATIC control rods (1).
27659
16 87666787A - 11 - 2007
8
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
22. Working from the lower LH side of the transmission gearbox, disconnect the handbrake return rod (2) and the PTO control rod synchronized with the gear (1). Note: the tank is not shown in the photo in order to highlight the two parts in question.
27652
17 23. Position a hydraulic jack (1) under the front part of the fuel tank, remove the retaining bolt (3) and the front clamp (2).
27815
18 24. Lower the hydraulic jack (1) by 7--8 centimeters and unscrew the platform LH front retaining bolts (2) then, from the opposite side, remove the platform RH front retaining bolt.
27816
19 25. Fit the front RH eyebolt (1) to the platform surface.
Carry out the same operation on the LH side.
27817
20 87666787A - 11 - 2007
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
9
26. Fit the lifting bracket (1) on the platform RH rear mudguard support bracket (2).
Carry out the same operation on the LH side.
27818
21 27. Remove the two rods (1) and the LH rear bracket (2) that secures the final drive housing to the platform.
Carry out the same operation on the RH side.
27819
22 28. Connect the hoist (1) and the nylon sling (2) to the two front eyebolts (3). 29. Connect the hoist (1) and the chains (4) to the two rear eyebolts, adjusting the chains so that the platform is raised on the level. Note: Carefully raise the platform, making sure that all interconnecting parts are disconnected, and position the platform on the ground.
27820
23
87666787A - 11 - 2007
10
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1 --
Refit the four hoses to the steering circuit pipes.
--
Refit the PTO clutch control cable and tighten the lock nut.
--
Note: for models with mechanical gears, reconnect the gear clutch control cable.
--
Carry out operation 90 110 14--Instrument panel lower guard R.I. (Only installation).
--
Connect the electrical connections connected to the platform, the two electrical connections connected to the brake block pressure switches, the thermostarter connection and the brake fluid tank connection.
--
Fit the bonnet rear support and the four retaining bolts.
--
Reconnect the accelerator control cable to the injection pump.
--
Fit the bracket, complete with control rods, on the control valve housing.
--
Fit the two bracket retaining bolts and the control rods to the forks, then position the clips.
--
Note: if a mechanical lift is fitted, refit the LIFT--O--MATIC control rods by inserting the seal ring.
Note: if an electronic lift is fitted, reconnect the oil delivery line to the electronic lift control valve.
--
Carry out operation 21 130 52-Creeper/shuttle control hand lever R.I. (Only installation).
--
Note: if a mechanical lift is fitted, refit the lift control lever rods and the securing springs.
--
Carry out operation 21 130 10--Gear control hand lever R.I. (Only installation).
--
Note: if the differential lock is mechanically operated, refit the relative lever on the transmission gearbox.
--
Carry out operation 21 130 11--Range gear control hand lever R.I. (Only installation).
--
Carry out operation 10 254 44--Exhaust pipe R.I. (Only installation).
--
Carry out operation 90 114 10--Safety frame roof R.I. (Only installation).
--
Carry out operation 90 100 22--Bonnet R.I. (Only installation).
Installation (Op. 90 110 36 ) 30. To refit the platform, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Proceed as follows.
--
Using a hoist, nylon sling and chains, position the cab on the tractor, checking that the gear and PTO clutch control rods are correctly inserted in the respective holes on the platform.
--
Fit the two front bolts and the four rear tie--rods that hold the platform in position.
--
Position a hydraulic jack under the front part of the fuel tank, raise the tank and fit the front securing clamps.
--
--
--
--
Working from the lower LH side of the transmission gearbox, connect the handbrake return rod and the PTO control rod synchronized with the gear.
Note: if an analogue control panel is fitted, refit the rev counter control rod. Connect the brake pump feed pipes to the tank, connect the brake control pipes to the relative block, top up the oil level in the tank and proceed with bleeding operations.
87666787A - 11 - 2007
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
11
OP. 90 114 10 SAFETY FRAME ROOF R.I. Removal
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows.
1. Remove the six retaining bolts (1) and the roof (2) from the frame (3).
Installation leave it to dry thoroughly (approximately 15 minutes). 27810
24
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
Proceed as follows.
2. Fit the roof (2) on the frame (3), and tighten the six retaining bolts (1).
87666787A - 11 - 2007
12
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
OP. 90 150 10 CAB WITH PLATFORM ASSEMBLY R.I.
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted.
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Removal
Proceed as follows.
1. Carry out operation 90 100 22--Bonnet R.I. (Only removal).
2. Remove the plug (1) and drain off the engine cooling system refrigerant.
3. Carry out operation 10 254 44--Exhaust pipe R.I. (Only removal).
27644
25
87666787A - 11 - 2007
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
13
4. Loosen the clamp retaining bolts (1) and detach the red and black pipes (2) of the cab heating system.
5. Carry out operation 90 110 14--Instrument panel lower guard R.I. (Only removal).
27647
26 6. Loosen the nut (1) and remove the PTO clutch control cable (2). Note: for models with mechanical gears, remove the clutch control cable.
7. Carry out operation 21 130 52-Creeper/shuttle control hand lever R.I. (Only removal). 27650
27 8. Working from the lower LH side of the transmission gearbox, disconnect the handbrake return rod (2) and the PTO control rod synchronized with the gear (1). Note: the tank is not shown in the photo in order to highlight the two parts in question
9. Carry out operation 21 130 11--Range gear control hand lever R.I. (Only removal). 27652
28 10. Carry out operation 21 130 10--Gear control hand lever R.I. (Only removal).
11. Remove the clips (1), disconnect the fork control rods (2), remove the two retaining bolts (3).
27655
29 87666787A - 11 - 2007
14
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
12. Note: if an electronic lift is fitted, disconnect the oil delivery piping (1) on the electronic lift.
27656
30 13. Remove the bracket (1), complete with control rods, from the control valve housing.
27657
31 14. Note: if an electronic lift is fitted, remove the springs (2) and detach the lift control lever rods (1).
27658
32 15. Note: if a mechanical lift is fitted, remove the seal ring and detach the LIFT--O--MATIC control rods (1).
27659
33 87666787A - 11 - 2007
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
15
16. Note: if the differential lock is mechanically operated, disconnect the relative lever on the transmission gearbox. 17. Remove the accelerator control cable (1) from the injection pump. 18. Note: if an analogue control panel is fitted, disconnect the rev counter control rod
27660
34 19. Detach the four hoses (1) on the steering circuit pipes. 20. Remove the conditioning system pipe retaining clamps.
27662
35 21. Disconnect the electrical connection, remove the retaining bolts, remove the conditioning system compressor (1) without disconnecting the piping, and place in the cab.
27123
36 22. Remove the retaining bolt, remove the filter/dryer (1) without disconnecting the piping, and place in the cab.
27663
37 87666787A - 11 - 2007
16
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
23. Remove the retaining wing nut, extract the conditioning system condenser (1) from the bracket on the engine radiator, without disconnecting the piping.
NOTE: If necessary, also remove the bracket fitted on the radiator. 27664
38 24. Position the condenser (1) on the cab floor, together with the other conditioning system components that were disassembled in operations 23 and 24. Anchor them to the brake pedals so as to prevent damage when lifting to remove the cab.
NOTE: The pipes are not disconnected so as to avoid re--charging the system.
27665
39 25. Drain off the brake fluid and disconnect the brake control pipes (2) from the block (1).
27125
40 26. Disconnect the brake feed pump pipes (2) from the relative tank (1).
27126
41 87666787A - 11 - 2007
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
17
27. Remove the four retaining bolts and the hood rear support (1).
27666
42 28. Disconnect all electrical connections (1) connected to the cab, the two electrical connections connected to the brake block pressure switches and the thermostarter connection.
27124
43 29. Disconnect the electrical connection (1) from the window washer spray tank / multiple connector.
27667
44 30. Position a hydraulic jack (1) under the front part of the fuel tank, remove the retaining bolt (3) and the front clamp (2).
27668
45 87666787A - 11 - 2007
18
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
31. Lower the hydraulic jack (1) by 7--8 centimeters and unscrew the platform LH front retaining bolt (2) then, from the opposite side, remove the cab RH front retaining bolt.
27669
46 32. Remove the cab rear RH retaining bolt (1).
Carry out the same operation on the LH side.
27670
47 33. Remove the spring clip, detach the cab RH door shock absorber (1), so as to leave the door completely open.
Carry out the same operation on the LH side.
27671
48 34. Position tool 380000294 (1) inside the cab -18--20 centimetres from the central upright (cab centre line) and, by means of a hoist and nylon sling (2), lift the cab, making sure there is no sticking and that all parts are disconnected. Check that the doors are locked in the open position, to prevent contact between the windows and the tool 380000294.
35. Position the cab on a suitable support.
27672
49 87666787A - 11 - 2007
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1 Installation (Op. 90 150 10 ) 36. To re--fit the cab, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. ------
---
-----
---
-----
Proceed as follows. Using a hoist, nylon sling and tool 380000294 position the cab on the tractor. Fit the front retaining bolts and the rear RH and LH cab retaining bolts. Fit the shock absorbers on the RH and LH cab doors and insert the relative spring clips. Position a hydraulic jack under the front part of the fuel tank, raise the tank and fit the front securing clamp. Connect the electrical connection of the window washer spray tank / multiple connector. Connect all electrical connections connected to the cab, the two electrical connections connected to the brake block pressure switches and the thermostarter connection. Fit the bonnet rear support and the four retaining bolts. Connect the brake pump feed pipes to the relative tank. Connect the brake control pipes to the block. If previously disassembled, fit the bracket on the engine radiator, then position the condenser, complete with the relative piping, and lock in position with the wing nut. Fit the filter/dryer, complete with the relative piping and tighten the retaining bolt. Fit the conditioning system compressor, complete with the relative piping, fit the retaining bolts and connect the electrical connection. Refit the four hoses to the steering circuit pipes. Fit new retaining clamps on the conditioning system pipes. Reconnect the accelerator control cable to the injection pump. Note: if an analogue control panel is fitted, reconnect the rev counter control rod.
--
--
--------
--
----------
19
Note: if a mechanical lift is fitted, refit the LIFT--O--MATIC control rods by inserting the seal ring. Note: if the differential lock is mechanically operated, reconnect the relative lever on the transmission gearbox. Note: if a mechanical lift is fitted, refit the lift control lever rods and the securing springs. Fit the bracket, complete with control rods, on the control valve housing. Note: if an electronic lift is fitted, reconnect the oil delivery line to the electronic lift control valve. Fit the two bracket retaining bolts and the control rods to the forks, then position the clips. Carry out operation 21 130 10--Gear control hand lever R.I. (Only installation). Carry out operation 21 130 11--Range gear control hand lever R.I. (Only installation). Working from the lower LH side of the transmission gearbox, connect the handbrake return rod and the PTO control rod synchronized with the gear. Carry out operation 21 130 52-Creeper/shuttle control hand lever R.I. (Only installation). Refit the PTO clutch control cable and tighten the lock nut. Note: for models with mechanical gears, reconnect the gear clutch control cable. Carry out operation 90 110 14--Instrument panel lower guard R.I. (Only installation). Refit the cab heating system red and black pipes and tighten the clamp retaining bolts. Carry out operation 10 254 44--Exhaust pipe R.I. (Only installation). Carry out operation 90 100 22--Bonnet R.I. (Only installation). Screw on the plug and fill up the engine cooling system with refrigerant. Fill up the brake fluid tank and reposition the closing plug. Bleed the air from the brake system and carry out the conditioning system functional tests.
87666787A - 11 - 2007
20
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
OP. 90 156 14 -- 90 156 28 CAB WINDOWS Replacement of glued cab windows Removal
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Thread the cutting wire (1, fig. 50) into the tool and lock in position. 2. From inside the cab push the cutting wire (1, fig. 50) through the adhesive (2) between the window and its surround.
27870
50 3. Secure the wire (1, fig. 51) to the handgrip (2).
27871
51
87666787A - 11 - 2007
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
21
4. Lock the tool on the adhesive (see fig. A) and, keeping the wire close to the window, pull on the handgrip (2, fig. 52). 5. Repeat this operation until the window is completely detached. Make long cuts on straight sections and short cuts around corners to prevent the window from breaking. 6. Using suction cups, remove the window and place on a suitable surface to avoid damage. 27872
52 7. Using a spatula, remove all the adhesive (1) from the window surround, taking care to cause no damage. 8. Remove the adhesive from the window as described in the previous operation. NOTE: When replacing a broken window: remove any fragments still attached to the cab and carry out operations no. 1 -- 8. 9. Clean the window surround using a suitable solvent.
27873
53
Re--fitting the window Proceed as follows. 1. Make sure that the contact area between the window and its surround is perfectly clean. 2. Apply the glass activator VP 04604 GURIT ESSEX on the edge of the window (contact area with the adhesive) using the applicator supplied (see fig. 54) and thoroughly dry with a dry cloth. 27874
54
87666787A - 11 - 2007
22
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
3. Apply the glass primer Betaprime 5100 GURIT ESSEX on the edge of the window (contact area with the adhesive) using the applicator supplied and leave to dry thoroughly (> 30 seconds).
60
65
4. Apply the metal plate primer Beta Wipe 5402 GURIT ESSEX on the window surround (contact area with the adhesive) using the applicator supplied and leave to dry thoroughly.
5. Cut the spout on the adhesive dispenser as shown in fig. 55 to obtain a triangular cross--section bead.
6. Apply a bead of polyurethane based Betaseal 7120 GURIT ESSEX on the window (the cross--section of the bead must be triangular, with a base of 10 mm and a height of 12 รท 15 mm).
NOTE: Make sure that there are no areas where adhesive is missing, otherwise water may penetrate.
7. Insert the window support blocks, if present. 8. Using suction cups, position the window and its surround and use clamps to apply uniform pressure, providing a 4 mm thickness of adhesive and to ensure perfect adhesion.
NOTE: Leave the clamps in place for 4 hours until the adhesive has completely polymerized. It takes 48 hours for the adhesive to polymerize definitively. To ensure efficient bonding, do not move the cab or tractor during this period.
87666787A - 11 - 2007
7.0 3.0
27875
55
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
23
OP. 90 160 16 RH OR LH UPRIGHT SEALS R.I.
Removal
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
Proceed as follows. 1. Remove the six retaining plugs (1) and the LH lateral seal (2).
27675
56
2. Remove the six retaining plugs (1) and the RH lateral seal (2), without disconnecting the switch electrical connections.
Installation
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 27676
57
Proceed as follows.
3. Fit the RH lateral seal (2, fig. 57) and the six new retaining plugs (1).
4. Fit the LH lateral seal (2, fig. 56) and the six new retaining plugs (1).
87666787A - 11 - 2007
24
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
OP. 90 160 60 CAB CEILING FITTING R.I. Removal
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Carry out operation 90 160 16--Right or left--hand upright seals R.I. (Only removal). 2. Carry out operation 88 120 10--Sun blind R.I. (Only removal). 3. Remove the three retaining bolts (1) and the outer frame (2) of the cab air conditioning control unit. 4. Carry out operation 55 514 22--Cab lighting support R.I. (Only removal). 27679
58 5. Carry out operation 55 512 34--Loudspeakers R.I. (Only removal).
6. Remove the two fixing screws (1) and the stereo bracket (2).
27684
59
87666787A - 11 - 2007
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
25
7. Carry out operation 50 206 14--Cab air inlet vents R.I. (Only removal).
8. Remove the 19 plastic screws (1) and the two retaining screws (2) that retain the cab ceiling fitting.
27686
60 9. Remove the cab ceiling fitting (1) through the rear window.
Installation (Op. 90 160 60)
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
27687
61
--
Proceed as follows.
--
Carry out operation 55 512 34--Loudspeakers R.I. (Only installation).
--
Fit the cab ceiling fitting, inserting through the rear window.
--
Carry out operation 55 514 22--Cab lighting support R.I. (Only installation).
--
Fit the 19 plastic screws and the two retaining screws of the cab ceiling fitting.
--
Fit the outer frame of the cab air conditioning control unit and the three retaining bolts .
--
Carry out operation 50 206 14--Cab air inlet vents R.I. (Only installation).
--
Carry out operation 88 120 10--Sun blind R.I. (Only installation).
--
Fit the two retaining screws and the bracket on the cab radio.
--
Carry out operation 90 160 16--Right or left--hand upright seals R.I. (Only installation).
87666787A - 11 - 2007
26
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
OP. 88 120 10
SUN BLIND R.I.
Removal
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Take out the two bolts (3) and three plastic plugs (1) securing the sun blind together with the support (2).
27677
62 2. Remove the sun blind and support (1).
Installation
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 27678
Proceed as follows.
3. Fit the sun blind and support (1, fig. 63).
4. Secure the sun blind and support (1, fig. 62) with the three plastic plugs (2) and two bolts (3).
87666787A - 11 - 2007
63