T5030 -- T5040 -- T5050 -- T5060 -- T5070 TRACTORS SERVICE MANUAL SECTIONS GENERAL GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 TRANSMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 DRIVE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 FRONT MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 REAR MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 POWER TAKE- OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 AXLE AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 CAB AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 PLATFORM, CAB, BODYWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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INTRODUCTORY NOTES --
This manual is divided into sections identified by two--figure numbers and each section has independent page numbering.
--
The different sections can easily be found by consulting the table of contents on the following pages.
--
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 87679925A -- 1st update 87679925A1 -- 2nd update 87679925A2 -- 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 87679925B, this indicates that the manual is composed of the standard version 87679925A completed with all the updates: 1st update 87679925A1 -- 2nd update 87679925A2 -- etc.
--
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.
--
Anyone performing the operations described herein without strictly following the instructions is personally responsible for any eventual injury or damage to property.
--
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
 CNH GLOBAL N.V.
Print No. 87679925A2 -- 02 -- 2010
PRINT NO. 87679925A1 15 Service Manual Update mod. T5030, T5040, T5050, T5060 Print No. 87679925A IMPORTANT NOTES These pages replace the corresponding pages in the Manual of mod. T5030, T5040, T5050, T5060 − contents volume 1 pages 3 to 8. − section 10 chap. 1, pages 1 to 6 and 53−54. − section 18, Chapter 1, pages 9−10. − section 25, Chapter 1, pages 7−8, 29−30 and 47−48. − section 33, Chapter 1, pages 3−4. − section 33, Chapter 2, pages 1 to 18. − section 35 Chap. 1, pages 23−24. − section 35 Chap. 4, pages 5 to 10. − contents volume 2 pages 1 to 4.
− section 35 Chap. 7, pages 17−18. − section 41, Chapter 1, pages 7−8. − section 55 Chap. 6, pages 1 to 32, 39−40, 49−50, 57 to 60, 71 to 74, 83 to 86, 93−94, 99 to 02, 113 to 116 and 125 to 128. − contents volume 3 pages 1−2. − section 55 Chap. 7, pages 1P4, 11 to 22, 69−70, 73−74, 79 to 82, 91 to 94 and 111 to 118. − section 55 Chap. 10, pages 7−8 and 27−28.
The following pages are newly issued: − section 33, Chapter 2, pages 19 to 22. − section 35 Chap. 8, pages 1 to 106. − section 55 Chap. 3, pages 1 to 14. − section 55 Chap. 4, pages 1 to 8.
− section 55 Chap. 5, pages 1 to 14. − section 55 Chap. 7, pages 141 to 142. − section 55 Chap. 8, pages 1 to 30. − section 55 Chap. 9, pages 1 to 234.
PRINTED IN FRANCE CNH GLOBAL N.V. Print No. 87679925A1 − 02 − 2008
PRINT NO. 87679925A2 2nd Service Manual Update mod. T5030, T5040, T5050, T5060 Print No. 87679925A IMPORTANT NOTES These pages replace the corresponding pages in the Manual of mod. T5030, T5040, T5050, T5060: --------------
preface pages 1--2 contents volume 1 pages 3 to 8. Sect. 00, Chapter 1, pages 5-- 6. Sect. 10 chap. 1, pages 1 to 6, 53 and 54. Sect. 18, Chapter 1, pages 5-- 6. Sect. 21 Chap. 3, pages 35--36 and 39--40. Sect. 21 Chap. 4, pages 49--50 and 53 to 56. Sect. 27, Chapter 1, pages 3-- 4, 15 to 18 and 49 to 54. Sect. 31, Chapter 2, pages 1 to 4 and 25--26. Sect. 33, Chapter 1, pages 3-- 4. Sect. 35 Chap. 1, pages 3--4 and 49--50. contents volume 2 pages 1 to 4. Sect. 35 Chap. 6, pages 3--4 and 19--20.
-- Sect. 35 Chap. 7, pages 1-- 2 and 15-- 16. -- Sect. 35 Chap. 8, pages 3-- 4. -- Sect. 41, Chapter 1, pages 19--20. -- Sect. 55 Chap. 3, pages 1-- 2. -- Sect. 55 Chap. 5, pages 1-- 2. -- Sect. 55 Chap. 6, pages 1-- 2, 39 to 56, 63 to 68, 77 to 80 85 to 88, 91 to 98, 105 to 110, 119 to 122, 129 to 134, 147 to 150, 161-- 162, 177 to 180, 189-- 190, 205 to 208, 219-- 220, 235 to 238 and 243 to 250. -- contents volume 3 pages 1-- 2. -- Sect. 55 Chap. 7, pages 1 to 8, 11-- 12, 15-- 16, 53 to 62, 77-- 78, 87-- 88, 109 to 112, 125-- 126 and 131-- 132. -- Sect. 55 Chap. 9, pages 23 to 34, 87-- 88, 117-- 118, 133-- 134, 169-- 170, 187-- 188, -- Sect. 55 Chap. 10, pages 1 to 42.
The following pages are newly issued: -- Sect. 21 Chap. 5, pages 1 to 26. -- Sect. 55 Chap. 6, pages 251 to 254 -- Sect. 55 Chap. 7, pages 143 to 150,
-- Sect. 55 Chap. 9, pages 235 to 254, -- Sect. 55 Chap. 10, pages 43--44.
PRINTED IN FRANCE  CNH GLOBAL N.V. Print No. 87679925A2 -- 02 -- 2010
3
CONTENTS
CONTENTS VOLUME 1 Page 00 -- GENERAL GUIDELINES General instructions . . . . . 1--2 Safety regulations . . . . . . . 3--4--5 Tractor refuelling . . . . . . . . 6
11--07 11--07 02--10
10 -- ENGINE Summary . . . . . . . . . . . . . . . General specifications . . . . Fuel system data . . . . . . . . Torque Specifications . . . . Special Tools . . . . . . . . . . . View of 4--cylinder engine Fault diagnosis . . . . . . . . . . Engine removal--installation . . . . . . . . . . . . . . . . . . . . Replacing crankshaft front seal . . . . . . . . . . . . . . . . . . . Replacing crankshaft rear seal . . . . . . . . . . . . . . . . . . . Adjusting tappet, valve and rocker arm clearance . . . . Removal--Installation -- injectors . . . . . . . . . . . . . . . . . Removal -- Installation -Bosch injection pump . . . . Injection pump, renewal and checking timing . . . . . . Bosch injection pump -- air bleeding . . . . . . . . . . . . . . . . Removal--Installation -coolant pump . . . . . . . . . . . Removal--Installation -thermostat valve . . . . . . . . . Removal--Installation -- radiator . . . . . . . . . . . . . . . . . . Coolant pump drive belt adjustment . . . . . . . . . . . . . . . .
1 2÷4 5 6÷8 9 10 11÷14
02--10 02--10 02--10 11--07 11--07 11--07 11--07
15÷32
11--07
33÷35
11--07
36÷38
11--07
39÷41
11--07
42÷44
11--07
45÷49
11--07
50÷54
02--10
54
11--07
55--56
11--07
57--58
11--07
59÷65
11--07
66÷67
11--07
18 -- CLUTCH Summary . . . . . . . . . . . . . . . Main Data . . . . . . . . . . . . . . Torque Specifications . . . . Special Tools . . . . . . . . . . . Sections . . . . . . . . . . . . . . . Fault diagnosis . . . . . . . . . .
1 2 3 3 4--5 6
Page
Date
11--07 11--07 11--07 11--07 02--10 11--07
Date
Checks and measurements -- clutch . . . . . . . . . . 7--8 Adjustments -- clutch pedal 9
11--07 02--08
Removal--Installation -clutch . . . . . . . . . . . . . . . . . . 10÷12 Clutch Overhaul . . . . . . . . . 13÷16
11--07 11--07
Adjustments -- clutch disengagement levers . . . . . . . . 17
11--07
21 -- TRANSMISSIONS CHAPTER 1 -- Reverser Summary . . . . . . . . . . . . . . . 1
11--07
Main Data . . . . . . . . . . . . . . 2
11--07
Transmission diagrams . . . 3
11--07
Torque Specifications . . . . 4
11--07
Special Tools . . . . . . . . . . . 5
11--07
Sections . . . . . . . . . . . . . . . 5--6
11--07
Description and operation . 7
11--07
Fault diagnosis . . . . . . . . . . 7--8
11--07
Disassembly--Assembly -reverser--clutch casing . . . 8÷12 Transmission longitudinal cutaway section view . . . . 13--14
11--07 11--07
CHAPTER 2 -- Reverser and creeper unit Summary . . . . . . . . . . . . . . . 1
11--07
Main Data . . . . . . . . . . . . . . 2
11--07
Transmission diagrams . . . 3
11--07
Tightening torque . . . . . . . . 4
11--07
Special Tools . . . . . . . . . . . 5÷6
11--07
Sections . . . . . . . . . . . . . . . 7--8
11--07
Description and operation
9
11--07
Fault diagnosis . . . . . . . . . . 9
11--07
Replacing clutch casing-reverser and creeper unit . 10÷15 End float adjustment between shaft and support . . 16÷17 Transmission longitudinal cutaway section view . . . . 18
11--07 11--07 11--07
CHAPTER 3 -- Power Shuttle Transmission (12X12) Summary . . . . . . . . . . . . . . . 1
11--07
Main Data . . . . . . . . . . . . . . 2--3
11--07
87679925A2 -- 02 -- 2010
CONTENTS
4 Page
Date
Transmission diagrams . . . 4
11--07
Tightening torque . . . . . . . . 5--6
11--07
Special Tools . . . . . . . . . . . 7--8
11--07
Sections . . . . . . . . . . . . . . . 9÷10
11--07
Description and operation . 11--12
11--07
Hydraulics . . . . . . . . . . . . . . 13÷16
11--07
Range and gear lever position sensor adjustment 17--18
Page
Date
Disassembly--Assembly -clutch (A) and (B) . . . . . . . . 42÷47
11--07
Calibrations . . . . . . . . . . . . . 48
11--07
HH MENU access . . . . . . . 48--49
11--07
Clutch calibration H1 menu transmission . . . . . . . . . . . . 50÷52
02--10
Transmission fault codes . 53÷55
02--10
11--07
Disassembly--Assembly -clutch casing with Power Shuttle units . . . . . . . . . . . . 19÷23
Transmission longitudinal cutaway section view . . . . 56
11--07
11--07
Disassembly--Assembly -driving shaft . . . . . . . . . . . . 24--25
CHAPTER 5 -- Power Shuttle transmission with creeper unit -- 20X20 version
11--07
Disassembly--Assembly -clutch (A) and (B) . . . . . . . . 25÷32
Summary . . . . . . . . . . . . . . . 1
02--10
11--07
Main Data . . . . . . . . . . . . . . 2--3
02--10
Calibrations . . . . . . . . . . . . . 33
11--07
Transmission diagrams . . . 4
02--10
HH MENU access . . . . . . . 33--34
11--07
Tightening torque . . . . . . . . 5--6
02--10
Clutch calibration H1 menu transmission . . . . . . . . . . . . 35÷37
Special Tools . . . . . . . . . . . 7--8
02--10
02--10
Sections . . . . . . . . . . . . . . . 9÷11
02--10
Transmission fault codes . 38÷40
02--10
Description and operation . 12
02--10
Transmission longitudinal cutaway section view . . . . 41
11--07
Creeper unit troubleshooting . . . . . . . . . . . . . . . . . . . . 13
02--10
Disassembly--Assembly -clutch casing with Power Shuttle and creeper units . 14÷17
02--10
Calibrations . . . . . . . . . . . . . 18
02--10
HH MENU access . . . . . . . 18--19
02--10
Clutch calibration H1 menu transmission . . . . . . . . . . . . 20÷22
02--10
Transmission fault codes . 23÷25
02--10
CHAPTER 4 -- Power Shuttle transmission with dual command (2 speed power shift) function Summary . . . . . . . . . . . . . . . 1
11--07
Main Data . . . . . . . . . . . . . . 2--3
11--07
Transmission diagrams . . . 4
11--07
Tightening torque . . . . . . . . 5--6
11--07
Special Tools . . . . . . . . . . . 7--8
11--07
Sections . . . . . . . . . . . . . . . 9÷11
11--07
23 -- DRIVE LINES
Description and operation . 12÷18
11--07
Summary . . . . . . . . . . . . . . . 1
11--07
Range and gear lever position sensor adjustment . . . 19--20
11--07
Main Data . . . . . . . . . . . . . . 2
11--07
Torque Specifications . . . . 3
11--07
Special Tools . . . . . . . . . . . 3
11--07
Sections . . . . . . . . . . . . . . . 4
11--07
Description and operation . 5
11--07
Fault diagnosis . . . . . . . . . . 6
11--07
11--07
Removal--Installation -- services control valve . . . . . . . 7÷9
11--07
11--07
Disassembly--Assembly -services control valve . . . . 10÷11
11--07
11--07
Removal--Installation -drive gear casing . . . . . . . . 12÷16
11--07
Removal--Installation -clutch casing with Power Shuttle and Dual Command (2 Speed Power Shift) units 21÷29 Disassembly--Assembly -clutch casing with Power Shuttle and Dual Command (2 Speed Power Shift) units 30÷36 Disassembly--Assembly -driving shaft . . . . . . . . . . . . 37--38 Disassembly--Assembly -driven shaft . . . . . . . . . . . . . 39÷41
87679925A2 -- 02 -- 2010
11--07
CONTENTS Page Disassembly--Assembly -drive gear casing . . . . . . . . 17÷20
Date 11--07
25 -- FRONT AXLE MECHANICAL TRANSMISSION Summary . . . . . . . . . . . . . . . 1
11--07
Main Data . . . . . . . . . . . . . . 2÷4
11--07
Torque Specifications . . . . 5÷7
11--07
Special Tools . . . . . . . . . . . 8--9
02--08
Sections . . . . . . . . . . . . . . . 10÷14
11--07
Description and operation . 15--16
11--07
Fault diagnosis . . . . . . . . . . 17
11--07
Rules for correctly fitting the axle support to the engine 18
11--07
Removal--Installation -front axle . . . . . . . . . . . . . . . 19÷22
5 Page
Date
Disassembly--Assembly -transmission--gearbox casing . . . . . . . . . . . . . . . . . 35÷42
11--07
Gearbox driving shaft end float adjustment . . . . . . . . . 43
11--07
Adjustments -- differential lock engagement sleeve position . . . . . . . . . . . . . . . . 44
11--07
Determining the bevel pinion positioning adjustment ring . . . . . . . . . . . . . . . . . . . . 45--46
11--07
Tapered roller bearings adjustment for pinion shaft
11--07
47
11--07
Adjusting the bevel crown wheel bearings and checking the clearance between the sides of the bevel drive teeth . . . . . . . . . . . . . . . . . . . 48÷50
02--10
Disassembly--Assembly -front axle . . . . . . . . . . . . . . . 23÷31
11--07
Adjusting the preloading on the bevel drive bearings . 51--52
02--10
Overhaul -- front differential 32
11--07
Differential pinion and side gear backlash adjustment . 53--54
02--10
Differential lock pedal travel adjustment . . . . . . . . . . . . . 55
11--07
Removal--Installation -- final drive . . . . . . . . . . . . . . . . 56÷59
11--07
Disassembly--Assembly -epicyclic final drive . . . . . . . 59
11--07
Disassembly--Assembly -drive wheel shaft . . . . . . . . 60--61
11--07
Overhaul -- front axle differential with LIM--SLIP . . . . . 33--34 Overhaul -- differential lock unit . . . . . . . . . . . . . . . . . . . . 35--36 Disassembly--Assembly -front epicyclic final drive without brake . . . . . . . . . . . 37÷40
11--07 11--07
11--07
Disassembly--Assembly -front epicyclic final drive with brake . . . . . . . . . . . . . . 41÷43
11--07
Replacing wheel hub seal with brake . . . . . . . . . . . . . . 44
11--07
Stub axle adjustments . . . . 45--46
11--07
Adjustments -- bevel drive
11--07
47÷51
27 -- REAR MECHANICAL TRANSMISSION Summary . . . . . . . . . . . . . . . 1
11--07
Main Data . . . . . . . . . . . . . . 2÷4
02--10
Torque Specifications . . . . 5--6
11--07
Special Tools . . . . . . . . . . . 7÷11
11--07
Sections . . . . . . . . . . . . . . . 12÷17
02--10
Description and operation . 18
02--10
Fault diagnosis . . . . . . . . . . 19--20
11--07
Removal--Installation -transmission--gearbox casing . . . . . . . . . . . . . . . . . 21÷34
11--07
31 -- POWER TAKE--OFF CHAPTER 1 -- Mechanical power take--off Summary . . . . . . . . . . . . . . . 1
11--07
Main Data . . . . . . . . . . . . . . 2--3
11--07
Special Tools . . . . . . . . . . . 3
11--07
Torque Specifications . . . . 4
11--07
Sections . . . . . . . . . . . . . . . 5÷9
11--07
Description and operation . 10--11
11--07
Fault diagnosis . . . . . . . . . . 11
11--07
Fitting cooler with mechanical transmission and power take--off . . . . . . . . . . . . . . . . 12--13
11--07
Cooling system description and operation . . . . . . . . . . 14
11--07
Removal--Installation -power take--off . . . . . . . . . . 15÷17
11--07
87679925A2 -- 02 -- 2010
CONTENTS
6 Page Disassembly--Assembly -power take--off . . . . . . . . . . 18÷20
Date 11--07
CHAPTER 2 -- Mechanical power take--off Summary . . . . . . . . . . . . . . . 1
02--10
Main Data . . . . . . . . . . . . . . 2--4
02--10
Special Tools . . . . . . . . . . . 5
11--07
Torque Specifications . . . . 6
11--07
Sections . . . . . . . . . . . . . . . 7÷14
11--07
Description and operation . 15÷24
11--07
Additional PTO controls for cab--version tractors with Power Shuttle transmissions . . . . . . . . . . . . . . . . . . 25--26
02--10
Rear PTO fault code listing 26
02--10
Fault diagnosis . . . . . . . . . . 27
11--07
Replacing the power take-off brake . . . . . . . . . . . . . . . 28--29
11--07
Removal--Installation -power take--off . . . . . . . . . . 30÷33
11--07
Disassembly--Assembly -power take--off . . . . . . . . . . 34÷40
11--07
Fitting cooler with mechanical transmission and electro--hydraulic power take-off . . . . . . . . . . . . . . . . . . . . . 41--42
11--07
Cooling system description and operation . . . . . . . . . . 43
11--07
33 -- BRAKES CHAPTER 1 -- Brakes
Page
Date
Service brake circuit air bleeding . . . . . . . . . . . . . . . . 14--15
11--07
Removal--Installation -service brake pump . . . . . . 16--17
11--07
Adjusting the height of the service brake pedals . . . . . 17
11--07
Removal--Installation -service brake . . . . . . . . . . . 18÷22
11--07
CHAPTER 2 -- Trailer air brakes (Italian and German version) Summary . . . . . . . . . . . . . . . 1
02--08
Main Data . . . . . . . . . . . . . . 1
02--08
Torque Specifications . . . . 2
02--08
Special Tools . . . . . . . . . . . 2
02--08
Sections . . . . . . . . . . . . . . . 3÷7
02--08
Description and operation . 8--9
02--08
Operation of single trailer brake circuit components . 10÷16 Fault diagnosis . . . . . . . . . . 17
02--08 02--08
Pressure tests . . . . . . . . . . 18÷22
02--08
35 -- HYDRAULIC SYSTEMS CHAPTER 1 -- Rear mechanical hydraulic lift Summary . . . . . . . . . . . . . . . 1
11--07
Main Data . . . . . . . . . . . . . . 2÷6
02--10
Torque Specifications . . . . 7--8
11--07
Special Tools . . . . . . . . . . . 9
11--07
Sections . . . . . . . . . . . . . . . 10--11
11--07
Description and operation . 12÷15
11--07
Fault diagnosis . . . . . . . . . . 16--17
11--07
Summary . . . . . . . . . . . . . . . 1
11--07
Main Data . . . . . . . . . . . . . . 2
11--07
Torque Specifications . . . . 3
02--10
Sections . . . . . . . . . . . . . . . 4--5
11--07
Description and operation . 6
11--07
Hydraulic diagram -brakes . . . . . . . . . . . . . . . . . 7
11--07
Pilot valve operation . . . . . 8
11--07
Fault diagnosis . . . . . . . . . . 9
11--07
Adjustments -- parking handbrake travel . . . . . . . . 10
LIFT--O--MATIC device upward travel adjustment . . . 23
02--08
11--07
Removal--Installation/Disassembly--Assembly parking brake casing . . . . . . . . . 11÷13
Disassembly--Assembly -external lift controls . . . . . . . 24
02--08
Removal--Installation -- lift . 25÷31
11--07
11--07
Disassembly--Assembly -lift . . . . . . . . . . . . . . . . . . . . . 32÷36
11--07
87679925A2 -- 02 -- 2010
Hydraulic lift pump components . . . . . . . . . . . . . . . . . . Replacing the set of pump seals . . . . . . . . . . . . . . . . . . Disassembly--Assembly -LIFT--O--MATIC control . . . Adjustments -- lift rod mechanism . . . . . . . . . . . . .
18--19
11--07
19
11--07
20
11--07
21--22
11--07
CONTENTS Page
Date
7 Page
Date
Adjusting the lift . . . . . . . . . 37÷42
11--07
Removal--Installation -- lift control valve . . . . . . . . . . . . 43--44
CHAPTER 4 -- Trailer brakes auxiliary control valves
11--07
Disassembly--Assembly -lift control valve . . . . . . . . . 45÷49
Summary . . . . . . . . . . . . . . . 1
11--07
11--07
Sections . . . . . . . . . . . . . . . 1
11--07
Lift pressure relief valve -removal/installation and setting . . . . . . . . . . . . . . . . . 50
Description and operation . 1÷5
11--07
02--10
Operating diagrams . . . . . . 6÷9
02--08
Fault diagnosis . . . . . . . . . . 10÷12
11--07
CHAPTER 5 -- Supplementary Cylinder
CHAPTER 2 -- Open centre system auxiliary control valves
Summary . . . . . . . . . . . . . . . 1
11--07
Summary . . . . . . . . . . . . . . . 1
11--07
Main Data . . . . . . . . . . . . . . 1
11--07
Main Data . . . . . . . . . . . . . . 1
11--07
Sections . . . . . . . . . . . . . . . 1
11--07
Special Tools . . . . . . . . . . . 1
11--07
Description and operation . 1
11--07
Torque Specifications . . . . 2
11--07
Sections . . . . . . . . . . . . . . . 3÷5
11--07
Description and operation . 6÷9
11--07
Removal--Installation/Disassembly--Assembly -supplementary cylinder . . . 2
11--07
Disassembly--Assembly -auxiliary control valves . . . 10--11
11--07
Rod hardening test . . . . . . 11
11--07
Blow--by test . . . . . . . . . . . . 12
11--07
Adjustment of the automatic detent release pressure . . . . . . . . . . . . . . . . . . . 12
11--07
CHAPTER 3 -- Auxiliary control valves (BOSCH) Summary . . . . . . . . . . . . . . . 1
11--07
Main Data . . . . . . . . . . . . . . 2
11--07
Special Tools . . . . . . . . . . . 2
11--07
Torque Specifications . . . . 3
11--07
View of BOSCH auxiliary control valve components . 4
11--07
Description and operation . 4--5
11--07
Control valve components
11--07
6÷9
Description and operation -Hydraulic system . . . . . . . . 10÷18
11--07
Removal--Installation -BOSCH auxiliary control valves . . . . . . . . . . . . . . . . . 19÷21
11--07
Disassembly--Assembly -BOSCH auxiliary control valves . . . . . . . . . . . . . . . . . 22÷26
11--07
Quick coupler maintenance 27--28
11--07
Fault diagnosis . . . . . . . . . . 29--30
11--07
87679925A2 -- 02 -- 2010
8
87679925A2 -- 02 -- 2010
CONTENTS
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.
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;
--
coat 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 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.
87679925A - 12 - 2007
SECTION 00 -- GENERAL -- CHAPTER 1
2
BEARINGS When installing bearings it is advised to: --
heat the bearings to 80 ÷ 90 °C before fitting on the shafts;
--
allow the bearings to cool before installing them.
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 solely genuine parts, which guarantee the same quality, duration and safety as the original parts as they are identical to the ones fitted 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. 87679925A - 12 - 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
--
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.
--
Operate the vehicle and use the implements exclusively from 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.
DANGER. Never carry out any cleaning, lubrication or maintenance operations when the engine is running.
--
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.
SAFETY REGULATIONS
--
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 if manually released for repair or maintenance purposes.
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.
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.
Use blocks or similar devices to secure the machine in these conditions. --
The fuel nozzle should always be in contact with the filling aperture. Maintain this position until filling operations are completed in order to avoid possible sparks caused by the accumulation of static electricity.
87679925A - 12 - 2007
SECTION 00 -- GENERAL -- CHAPTER 1
4 --
--
--
--
Only use specified towing points for towing the tractor, 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 tractor to the truck or trailer and lock the wheels in the position.
--
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 and 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.
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.
Maintenance and repair operations must be carried out in a CLEAN and DRY area, eliminate any water or oil spillage immediately.
--
--
Take extra care if bystanders are present.
Do not create piles of oil or grease--soaked rags as they represent a serious fire hazard; store them in a closed metal container.
--
Never pour gasoline or diesel oil into open, wide and 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 and wear protective equipment: helmets, goggles and special footwear.
--
When carrying out checks with the engine running, request the assistance of an operator in the driver’s seat. The operator must maintain visual contact with the service technician at all times.
87679925A - 12 - 2007
Before starting the vehicle or implements, make sure that the driver’s seat is locked in position and always check that the area is free of persons or obstacles. --
Empty pockets of all objects that may fall unobserved into the vehicle parts when disassembled.
--
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 carefully, do not put your hands or fingers between moving parts, wear suitable safety clothing -- safety goggles, gloves and shoes.
SECTION 00 -- GENERAL -- CHAPTER 1 START UP ---
Never start 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.
----
5
If any liquid penetrates skin tissue, call for medical aid immediately. Serious skin infections may result if medical attention is not given. Use the specific tools when checking pressure values on the hydraulic system.
ENGINE --
---
--
Always loosen the radiator cap slowly before removing it to allow any remaining pressure in the system to be discharged. Coolant should only be added when the engine is 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.
WHEELS AND TYRES --
---
--
ELECTRICAL SYSTEMS --------
--
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 to prevent explosion hazards. Before servicing operations, check for fuel or current leaks: Eliminate any eventual leaks before starting 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 battery before performing any kind of servicing on the electrical system.
----
---
REMOVAL AND RE--FITTING --
--
HYDRAULIC SYSTEMS --
A liquid leaking from a tiny hole may be almost invisible but, at the same time, be powerful enough to penetrate the skin. Check for leaks using a piece of cardboard, NEVER USE HANDS.
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 re--use parts of recovered wheels as incorrect welding or brazing may heat the material, causing it to weaken and eventually damage or break the wheel. Never cut or weld a rim mounted with an inflated tyre. When removing the wheels, lock both the front and rear vehicle wheels. Always position support stands when raising the vehicle, in order to conform to current safety regulations. Deflate the tyre before removing any object caught in the tyre tread. Never inflate tyres using inflammable gases; this could cause an explosion and put operator safety at risk.
--
Lift and handle all heavy parts using suitable lifting equipment and make sure that all slings and hooks are correctly secured. Handle all parts carefully during lifting operations, keep an eye on the personnel working near the load to be lifted. Never insert hands or fingers between parts, always wear approved accident prevention clothing (goggles, gloves and work boots). Avoid twisting chains or metal cables and always wear safety gloves when handling cables or chains.
87679925A2 - 02 - 2010
6
SECTION 00 -- GENERAL -- CHAPTER 1
CONSUMABLES COMPONENT TO BE FILLED OR TOPPED UP
QUANTITY RECOMMENDED dm3 NEW HOLLAND PRODUCT (litres)
NEW HOLLAND SPECIFICATION
INTERNATIONAL SPECIFICATION
Cooling system: less cab: . . . . . . . . . . with cab: . . . . . . . . . .
14 16
Water and AMBRA AGRIFLU 50% + 50%
NH 900 A
--
Windscreen wash reservoir .
2
Water & cleaning liquid
--
--
Decanted, filtered diesel fuel
--
--
NH 330H (SAE 15 -- 40) NH 324H (SAE 10W--30)
API CH--4 ACEA E5 SAE 15W--40 API CH--4 SAE 10W--30
Fuel tank -- all models . . . . . . . . . . . . . . -- mod.: 71/97, 78/106 and 83/113 KW/CV (suppl. tank) . . . . . . . . . .
127
40
Engine oil sump: without filter: . . . . . . . with filter: . . . . . . . . .
8,9 9,5
AMBRA MASTERGOLD HSP fluid
Brake control circuit without front brakes
0,4
AMBRA BRAKE LHM fluid
NH 610 A
ISO 7308
AMBRA MULTI G fluid
NH 410 B
API GL4 ISO 32/46 SAE 10W--30
AMBRA GR9 grease
NH 710 A
NLGI 2
Antifreeze fluid AMBRA SUPER FLUID
NH 202 A
--
Front axle: axle housing: -- all models . . . . . . . . . . . . . . final drives (each): -- with brakes . . . . . . . . . . . . . -- without brakes . . . . . . . . . . .
7,5 2,0 1.4
Rear transmission (bevel drive, final drives and brakes), gearbox, hydraulic lift, PTO and power steering -- Mech. transmissions . . . . . -- Power shuttle . . . . . . . . . . .
50 60
Front hubs . . . . . . . . . . . . . . .
--
Grease fittings . . . . . . . . . . . .
--
Antifreeze fluid reservoir for air brakes . . . . . . . . . . . . . . . .
0,5
87679925A2 - 02 - 2010
SECTION 10 -- ENGINE -- CHAPTER 1
7 (overleaf)
Head retaining bolts (*):
--
--
--
--
1st phase -- 2nd phase . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12x70
50
5.0
90°
1st phase -- 2nd phase -- 3rd phase . . . . . . . . . . . . . . . . .
M12x140
40
4.0
90° + 90°
1st
M12x180
70
7.0
90° + 90°
Rocker arm covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M8x1.25x65
24 ± 4
2.4 ± 0.4
--
Intake manifold fastening . . . . . . . . . . . . . . . . . . . . . . . . .
M8x1.25
24 ± 4
2.4 ± 0.4
--
Air intake union assembly . . . . . . . . . . . . . . . . . . . . . . . .
M8x1.25
24 ± 4
2.4 ± 0.4
--
Oil by--pass valve fastening on the filter head . . . . . . .
M22x1.5x10
80 ± 8
8.0 ± 0.8
--
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12x1.25x12
10 ± 1
1.0 ± 0.1
--
Exhaust manifold fastening . . . . . . . . . . . . . . . . . . . . . . .
M10x1.25x65
43 ± 6
4.3 ± 0.6
--
Coolant pump fastening . . . . . . . . . . . . . . . . . . . . . . . . . .
M8x1.25x25
24 ± 4
2.4 ± 0.4
--
Coolant inlet connector assembly . . . . . . . . . . . . . . . . . .
M8x1.25x35
24 ± 4
2.4 ± 0.4
--
M8x1.25x70
24 ± 4
2.4 ± 0.4
--
Fan hub fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M10x1.25x20
33 ± 5
3.3 ± 0.3
--
Fan pulley fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M6
10 ± 2
1.0 ± 0.2
M10
43 ± 6
4.3 ± 0.6
--
Rear lifting bracket fastening . . . . . . . . . . . . . . . . . . . . . .
M12x1.75x30
77 ± 12
7.7 ± 1.2
--
Crankshaft pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12x1.75 (10.9)
110 ± 5 11.0 ± 0.5
--
Flywheel casing fastening: . . . . . . . . . . . . . . . . . . . . . . . .
M12x120
85 ± 10
5.5 ± 1.0
--
M12x70
85 ± 10
5.5 ± 1.0
--
M12x140
49 ± 5
4.9 ± 0.5
--
M12x180
49 ± 5
4.9 ± 0.5
--
--
--
--
--
1st phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12x1.25
30 ÷ 4
3.0 ÷ 0.4
--
2nd
M12x1.25
--
--
60° ± 5°
Inlet pump gear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M8x1.25x16
24 ± 4
2.4 ± 0.4
--
Fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
60 ± 5
6.0 ± 0.6
--
Fuel priming pump fastening . . . . . . . . . . . . . . . . . . . . . .
--
24 ± 4
2.4 ± 0.4
--
Turbo--blower / exhaust manifold fastening . . . . . . . . . .
M10
43 ± 6
4.3 ± 0.6
--
Oil inlet pipe / filter fastening . . . . . . . . . . . . . . . . . . . . . .
--
24 ± 4
2.4 ± 0.4
--
Lubrication piping / turbo--blower fastening . . . . . . . . .
M12x1.5
35 ± 5
3.5 ± 0.5
--
Turbo--blower exhaust piping fastening . . . . . . . . . . . . .
M8x1.25x16
24 ± 4
2.4 ± 0.4
--
phase --
2nd
phase --
3rd
phase . . . . . . . . . . . . . . . . .
Flywheel fastening on the crankshaft phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(overleaf)
87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
8
(overleaf)
Alternator fastening on its support . . . . . . . . . . . . . . . . .
M8x1.25x30
24 ± 4
2.4 ± 0.4
--
Alternator support / thermostat cover fastening . . . . . .
M8x1.25x30
24 ± 4
2.4 ± 0.4
--
Alternator support / thermostat cover assembly . . . . . .
M8x1.25x30
24 ± 4
2.4 ± 0.4
--
Lower support assembly . . . . . . . . . . . . . . . . . . . . . . . . .
M10x1.25x25
24 ± 4
2.4 ± 0.4
--
Fastening of the top of the alternator on the support . .
M10
49 ± 5
4.9 ± 0.5
--
Alternator support fastening . . . . . . . . . . . . . . . . . . . . . . .
M12x1.75x120
43 ± 6
4.3 ± 0.6
--
Electrical connections on the alternator . . . . . . . . . . . . .
M6x1
10 ± 2
1.0 ± 0.2
--
Starter motor / flywheel cover casing fastening . . . . . .
M10
49 ± 5
4.9 ± 0.5
--
--
--
--
--
Crankshaft cap retaining bolts: 1st phase
.......................................
M12
50 ± 6
5 ± 0.6
--
2nd
phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12
80 ± 6
8 ± 0.6
--
3rd
phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12
--
--
90° ± 5°
Camshaft longitudinal retaining plate fixing bolt . . . . . .
M8
24 ± 4
2.4 ± 0.4
--
Camshaft gear retaining bolt . . . . . . . . . . . . . . . . . . . . . .
M8
36 ± 4
3.6 ± 0.4
--
--
--
--
--
.......................................
M11
60 ± 5
6 ± 0.5
--
phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M11
--
--
60° ± 5°
Connecting rod cap retaining bolt: 1st phase 2nd (*)
To tighten the head, proceed as follows: - 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 tightening to an angle of 90° for all the screws. - 3rd stage additional tightening to an angle of 90° for 140 and 180 mm long bolts only. A = fan side MIF1015A
1
87679925A - 12 - 2007
SECTION 10 -- ENGINE -- 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 Section X 380000216 380000220 X 380000221
380000301
X 380000302 380000304
380000362 X 380000364
380000569
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.
9
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
Crankshaft lifting tool. Dial gauge base for various measurements (use with 380000228). Movable tool for dismantling tractors with bracket 380000500 and adapter plate 380000844.
X 380000661
Engine mounting brackets for rotating stand 380000301.
X 380000663
Tool to extract crankshaft rear seal.
380000228
Dial gauge (0--5 mm).
X 380000914
Dial--gauge holder tool for rotary injection pump timing (use with 380000228).
X 380000732
Tool for engine flywheel rotation (use with 380000988).
X 380000988
Plate for engine flywheel rotation tool with flywheel timing pin (use with 380000732).
87679925A - 12 - 2007
10
SECTION 10 -- ENGINE -- CHAPTER 1 ENGINE VIEW
MIF1097A
2
87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
11
ENGINE 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. (overleaf)
87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
1
SECTION 10 -- ENGINE Chapter 1 -- Engine CONTENTS Description
Page
General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Engine R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Crankshaft front seal -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Crankshaft rear seal -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Valve tappet and rocker arm clearance -- Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Engine injector R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Bosch injection pump R.I. Valve Timing. Air bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Coolant pump R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Thermostat valve R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Radiator R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Coolant pump and generator drive belt. Tension adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
87679925A2 - 02 - 2010
SECTION 10 -- ENGINE -- CHAPTER 1
2
GENERAL SPECIFICATIONS
4--cylinder
Engine, technical type: --
mod. 56/76 KW/HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F4CE9484A*J600
--
mod. 63/86 KW/HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F4CE9484N*J601
--
mod. 71/97 KW/HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F4CE9484M*J601
--
mod. 78/106 KW/HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F4CE9484L*J600
--
mod. 83/113 KW/HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F4CE9484C*J600
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
diesel, 4--stroke
Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct
Number of cylinders in line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
mod. 56/76, 63/86, 71/97, 78/106 and 83/113 KW/HP --
Piston diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104 mm
--
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
132 mm
Total displacement: --
mod. 56/76, 63/86, 71/97, 78/106 and 83/113 KW/HP . . . .
4485 cm3
Compression ratio --
mod. 56/76, 63/86, 71/97, 78/106 and 83/113 KW/HP . . . .
16,5:1
Maximum Power Output: --
mod. 56/76 KW/hp -- type F4CE9484A*J600 . . . . . . . . . . . .
56 KW (76 hp)
--
mod. 63/86 KW/hp -- type F4CE9484N*J601 . . . . . . . . . . . .
63 kW (86 Hp)
--
mod. 71/97 KW/hp -- type F4CE9484M*J601 . . . . . . . . . . .
71 kW (97 Hp)
--
mod. 78/106 KW/hp -- type F4CE9484L*J600 . . . . . . . . . . .
78 KW (106 hp)
--
mod. 83/113 KW/HP -- type F4CE9484C*J600 . . . . . . . . . .
83 KW (113 hp)
Maximum power speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2300 rpm
Maximum torque --
mod. 56/76 KW/hp -- type F4CE9484A*J600 . . . . . . . . . . . .
324 (Nm)
--
mod. 63/86 KW/hp -- type F4CE9484N*J601 . . . . . . . . . . . .
366 (Nm)
--
mod. 71/97 KW/hp -- type F4CE9484M*J601 . . . . . . . . . . .
404 (Nm)
--
mod. 78/106 KW/hp -- type F4CE9484L*J600 . . . . . . . . . . .
425 (Nm)
--
mod. 83/113 KW/HP -- type F4CE9484L*J600 . . . . . . . . . .
445 (Nm)
Maximum torque speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1300 rpm
Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Sump pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
structural, cast iron
(continued)
87679925A2 - 02 - 2010
SECTION 10 -- ENGINE -- CHAPTER 1
3 (Continued)
GENERAL SPECIFICATIONS
4--cylinder
Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
forced, with lobe pump
Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft
Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . Oil filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mesh screen on oil pick--up and filter cartridge in delivery line
Normal oil pressure with motor warmed--up: at slow idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
> 0.7 bar (> 0.71 Kg/cm2)
at fast idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3,1 ± 0,9 (3,16 ± 0,91)
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
coolant circulation
Radiator on Mod. 56/76, 63/86, 71/97, 78/106 and 83/113 KW/HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
three--row vertical pipes
Fan, attached to the pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
intake, in plastic with 10 blades
Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
centrifugal vane--type
Coolant thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature ranges corresponding to each section: -- Initial blue section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- Middle green section (normal working conditions) . . . . . . . . . -- red end section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16° ± 30’
--
end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32° ± 30’
Exhaust: --
start: before B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48° ± 30’
--
end: after T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4° ± 30’
Clearance between valves and rocker arms with engine cold: --
intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.30 ± 0.05 mm
--
exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.55 ± 0.05 mm
(continued)
87679925A2 - 02 - 2010
SECTION 10 -- ENGINE -- CHAPTER 1
4
(Continued)
GENERAL SPECIFICATIONS Boost
4--cylinder With intercooler
Turbocharger type: --
Holset
HX25
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual cartridge dry air filter, with clogged filter indicator with centrifugal pre--filter and automatic dust ejector Charge 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 pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rotating distributor type
All--speed governor, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
centrifugal counterweights
Automatic advance regulator, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed advance (pump setting on engine for start of delivery before TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
hydraulic refer to the data given in the table for operation 14 page 53
Filling Oil sump
8.9 litres
Engine sump + filter
9.5 litres
Anti--pollution system Type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(*)
Exhaust gas recirculation system EGR (*)
Modification to the profile of the intake cam that permits partial opening of the valve simultaneously with the exhaust valve (exhaust gas recirculation EGR).
87679925A2 - 02 - 2010
SECTION 10 -- ENGINE -- CHAPTER 1
5
FUEL SYSTEM DATA Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rotating distributor with speed governor and advance variator incorporated
BOSCH pump: --
mod. 56/76 KW/hp -- type F4CE9484A*J600 . . . . . . . . . . . .
VE 4/12 F1150 L2042
--
mod. 63/86 KW/hp -- type F4CE9484N*J601 . . . . . . . . . . . .
VE 4/12 F1150 L2033
--
mod. 71/97 KW/hp -- type F4CE9484M*J601 . . . . . . . . . . .
VE 4/12 F1150 L2029
--
mod. 78/106 KW/hp -- type F4CE9484L*J600 . . . . . . . . . . .
VE 4/12 F1150 L2041
--
mod. 83/1113 KW/HP -- type F4CE9484C*J600 . . . . . . . . .
VE 4/12 F1150 L___
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
anticlockwise
Injection order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--3--4--2 (for all models)
56/76 KW/hp
63/86 KW/hp
71/97 KW/hp
78/106 KW/hp
83/113 KW/hp
BOSCH--type injectors: --
F4CE9484A*J600 . . . . . . . . . . . . . . . . . . . . .
--
F4CE9484N*J601 . . . . . . . . . . . . . . . . . . . . .
--
F4CE9484M*J601 . . . . . . . . . . . . . . . . . . . .
--
F4CE9484L*J600 . . . . . . . . . . . . . . . . . . . . .
--
F4CE9484C*J600 . . . . . . . . . . . . . . . . . . . . .
Number of nozzle holes . . . . . . . . . . . . . . . . . . .
DSLA 145 P 1441
6
Nozzle hole diameter mm. --
F4CE9484A*J600 . . . . . . . . . . . . . . . . . . . . .
--
F4CE9484N*J601 . . . . . . . . . . . . . . . . . . . . .
--
F4CE9484M*J601 . . . . . . . . . . . . . . . . . . . .
--
F4CE9484L*J600 . . . . . . . . . . . . . . . . . . . . .
--
F4CE9484C*J600 . . . . . . . . . . . . . . . . . . . . .
Setting pressure bar (kg/cm2) . . . . . . . . . . . . . .
0,226
260 ÷ 272 (265.13 ÷ 277.36)
NOTE: For more information on the engine and overhauling, refer to the specific manual: document no° 87664161A for Italian document no° 87659057A for English document no° 87659058A for French document no° 87659059A for German document no° 87659060A for Spanish.
87679925A2 - 02 - 2010
SECTION 10 -- ENGINE -- CHAPTER 1
6
PARTS TO BE TIGHTENED
Th d Thread
Cooling nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torque Nm
kgm
kgm
M 8X1.25X10
15 ± 3
1,5 ± 0,3
--
--
--
--
--
--
50 ± 6
5,0 ± 0,6
--
--
80 ± 6
8,0 ± 0,6
--
--
--
--
90° ± 5°
M 8X1.25X40
24 ± 4
2,4 ± 0,4
--
M 8X1.25X25
24 ± 4
2,4 ± 0,4
--
M 10x1.5
49 ± 5
4,9 ± 0,5
--
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 8X1.25X30
8±1
0,8 ± 0,1
--
Front box cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 8X1.25X45
24 ± 4
2,4 ± 0,4
--
M 8X1.25X30
24 ± 4
2,4 ± 0,4
--
--
--
--
--
M 11X1.25
30 ± 3
3,0 ± 0,3
--
M 11X1.25
60 ± 5
6,0 ± 0,5
--
M 11X1.25
--
--
60° ± 5°
Bracket assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 10X1.25X25
43 ± 5
4,3 ± 0,5
--
Plugs on the cylinder block . . . . . . . . . . . . . . . . . . . . . . .
M 10X1
6±1
0,6 ± 0,1
--
M 14x1.5
11 ± 2
1,1 ± 0,2
--
Oil inlet pipe assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 8X1.25X20
24 ± 4
2,4 ± 0,4
--
Oil sump installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 8X1.25X25
24 ± 4
2,4 ± 0,4
--
M 18x1.5
60 ± 9
6,0 ± 0,9
--
Timing system locking pin installation . . . . . . . . . . . . . .
M5 T25
5±1
0,5 ± 0,1
--
Fuel pump installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M8
24 ± 4
2,4 ± 0,4
--
M6
10 ± 1
1,0 ± 0,1
--
--
--
--
--
pre--tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 10x1.25
10÷15
1.0 ÷ 1.5
--
end torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 10x1.25
50÷55
5.0 ÷ 5.5
--
--
--
--
--
precision torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retaining nut
15÷20
1.5 ÷ 2.0
--
end torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retaining nut
85÷90
8.5 ÷ 9.0
--
Inspection cover on the gearbox . . . . . . . . . . . . . . . . . . .
--
30÷35
3.0 ÷ 3.5
--
Fixing the rocker arm on the head . . . . . . . . . . . . . . . . .
M8
24 ± 4
2,4 ± 0,4
--
Main bearings: 1st phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3rd phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Big--end cap bolts: 1st phase
.......................................
2nd phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3rd phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel pump retaining bolts:
Fuel pump gear:
(continued)
87679925A2 - 02 - 2010
SECTION 10 -- ENGINE -- CHAPTER 1
12
ENGINE TROUBLESHOOTING (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.
(overleaf)
87679925A - 12 - 2007
and
calibrate
Disconnect fuel lines from injection pump and clean thoroughly. If necessary clean and dry the fuel tank.
SECTION 10 -- ENGINE -- CHAPTER 1
13
ENGINE TROUBLESHOOTING (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 anomalous knocking noises.
1. Injectors partially obstructed or Clean, overhaul 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.
(overleaf)
87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
14
ENGINE TROUBLESHOOTING (overleaf)
Problems The engine produces abnormal smoke: black or d k grey. dark
Possible Problem
Solutions
1. Maximum delivery of injection Calibrate pump on test bench to pump too high. values specified in calibration tables. 2. Injection pump delivery excess- Adjust injection pump timing or check ively retarded or automatic ad- automatic advance regulator. vance regulator damaged. 3. Injection pump delivery Adjust injection pump timing on the excessively advanced. engine. 4. Injectors partially obstructed or adjusted.
or totally Clean, overhaul and calibrate incorrectly injectors; if necessary, replace.
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; -- ylinder liner wear; -- worn or incorrectly adjusted -- valves. 7. High--pressure damaged. Blue, grey--blue or grey--white smoke.
fuel
if
lines Inspect and replace if necessary.
1. Injection pump delivery excess- Adjust injection pump timing or check ively retarded or automatic ad- automatic advance regulator. vance 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 on after switching off.
1. Engine stop damaged.
electromagnet Replace electromagnet.
2. All--speed governor damaged.
87679925A - 12 - 2007
Overhaul injection pump and adjust on test bench to values specified in calibration table.
SECTION 10 -- ENGINE -- CHAPTER 1
15
ENGINE 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 Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
1. Remove the bonnet (1) as described, see section 90. 2. Disconnect the battery negative cable. 3. Drain the oil from the transmission--gearbox housing. 4. Remove the retaining bolts (1) and the guard (2) on the right--hand side of the fan, then remove the four bolts retaining the mechanical battery cut--out switch (1) from the guard.
1
2 5. Unscrew the control unit memory fuse power cable (1) with the related positive cables (2) from the battery cut--out switch.
87679925A - 12 - 2007
16
SECTION 10 -- ENGINE -- CHAPTER 1
6. Detach the fitting (3) of the return pipe (2) for the coolant from the cab heater radiator connected to the underside of the coolant pump (1) and drain off the engine coolant.
3 7. Remove the catch (2) and detach the toolbox (1).
4 8. Remove the split pins, retaining pin and front ballast assembly (1) from the support.
5
9. Unscrew the front central and rear retaining bolts on the front axle shaft guard, then remove the guard (1).
1 25038
6 87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
10. Remove the circlip (2) and move the front sleeve (1) in the direction indicated by the arrow until it is released from the groove on the front axle.
17
2
1
25039
7 11. Remove the circlip (2) and move the rear sleeve (1) in the direction indicated by the arrow until it is released from the groove on the drive.
1
2 25040
8 12. Remove the propeller shaft central support (1) retaining bolts and extract the shaft together with the support.
1
25041
9
87679925A - 12 - 2007
18
SECTION 10 -- ENGINE -- CHAPTER 1
13. Remove the retaining bolts (1) of the draw pipe (2) of the lift pump. On the same side of the machine, on the left, unscrew the underlying oil pipes and, if there are clamps on them screwed onto the frame, unscrew them to free the pipes from the frame. -- Unscrew the nozzle oil delivery pipe on the high--pressure pump. -- On the power steering pump, unscrew the oil hose delivering oil to the power steering control valve. -- Again on the left--hand side behind the connection between the clutch casing and engine, on the control valve of the gearbox (if there is a hydraulic gearbox) or on the services control valve, unscrew the delivery and return pipes to the cooler and the supply pipe to the control valve. -- Still in the area of the latter, unscrew the second part of the front differential lock pipe. 14. Remove the two metal clamps (2) and the rigid pipe (1) for drawing oil from the transmission via the pumps of the lift and power steering, remove the pipe. On the same side of the machine, on the right, unscrew the underlying oil pipes and, if there are clamps on them screwed onto the frame, unscrew them to free the pipes from the frame. -- High pressure user supply pipe, remove the pipe. -- On the gearbox filter, remove the delivery to the gearbox control valve and extract the pipe, then remove the filter too. -- Again on the gearbox filter, remove the power steering outlet hose to the filter (in the case of the hydraulic transmission) or remove the supply pipe to the services control valve (in the case of the mechanical transmission) then remove the pipe.
10
11
15. Extract the plastic fasteners (2) and detach the diesel recovery pipe (3) and delivery pipe (4) to the diesel pump (1).
12
87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
19
16. Disconnect the electrical connections (1) of the engine main cable from the cab cable.
17. Disconnect all the electrical connections (1) located on the cab main cable and connect on the engine users.
13
14 18. Disconnect the two power steering oil delivery and return hoses (1), remove the pipe.
19. Remove the front differential lock union (1) and the hose (2) together with the pipe disconnected in the operation 13.
15
16 87679925A - 12 - 2007
20
SECTION 10 -- ENGINE -- CHAPTER 1
20. Remove the retaining clips (1) and detach the flexible cables governing the hand throttle (5) and pedal throttle (4). 21. Remove the retaining clip (3) and detach the throttle control tie--rod (2) connected to the injection pump.
22. Detach the clamp (1) and the cab heater delivery pipe (2).
17
18 23. Take out the three exhaust silencer rear retaining bolts (1).
24. Remove the clamp (1), the air filter dust ejector pipe (2) and the four nuts (3) securing the silencer to the exhaust manifold.
19
20 87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
21
25. Remove the silencer (2) together with the exhaust pipe (1).
26. Remove the two clips (2) for retaining to the support (3) and the brake fluid reservoir (1).
21
22 27. Remove the two retaining bolts (1) and the support (2) together with the relays (3) protecting the system.
28. Remove the two retaining bolts (1) and the support together with the fuse--holder box (2).
23
24 87679925A - 12 - 2007
22
SECTION 10 -- ENGINE -- CHAPTER 1
29. Remove the four rear retaining bolts (1) of the bonnet support (2).
30. Remove the three front retaining bolts (1) of the bonnet support (2).
25
26 31. Detach the bonnet support (1).
32. Disconnect the clogged filter sensor, loosen the clamps and detach the pipes on the air filter: -- air delivery to the turbo (1), (remember also to disconnect the pipe on the oil vapour recovery filter that will remain connected to the delivery pipe) -- pneumatic braking compressor intake (2), (if installed) -- ejector (3) then recovery it take out the screws (4), remove the air filter.
27
28 87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
23
33. Loosen the air delivery retaining clamp (1) on the turbo and extract the pipe.
34. Loosen the air delivery pipe clamp (1) from the turbo to the air / air exchanger; perform the same operation on the left--hand air supply pipe, from the cooler to the intake manifold.
29
30 35. Loosen the clamp on the turbo then extract the pipe, on the left--hand side loosen the one on the intake manifold recovering the pipe.
36. Remove the coolant compensation box from the support. Unscrew the retaining bolts (1) on the right and left, then remove the cooler.
31
32 87679925A - 12 - 2007
24
SECTION 10 -- ENGINE -- CHAPTER 1
37. Remove the two retaining bolts (2) and detach the support (3) together with the dryer filter (1) and pipes.
1
3 38. Unhook the top pin (1) retaining the condenser.
2 33
34 39. Turn the steering wheel fully to the left, remove the radiator of the condenser (1) from the same side of the tractor.
40. Remove the compressor (1) as described in section 50 without detaching pipes (2) and (3) so as not to then have to recover, evacuate and charge the gas in the air conditioning system.
35
36 87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
25
41. Remove the condenser radiator (1) the dryer filter (2) with its support and the compressor (3), resting them alongside the right--hand rear wheel with the associated piping.
42. Loosen the corresponding retaining clamps and extract the top pipe between the radiator and the thermostatic valve on the engine.
37
38 43. Loosen the retaining clamp (2) and extract the pipe (1) joining the coolant pump to the bottom of the radiator.
44. Remove the two retaining bolts (1) and the brake piping support (2).
39
40 87679925A - 12 - 2007
26
SECTION 10 -- ENGINE -- CHAPTER 1
45. Remove the three retaining bolts (2) and the left--hand side guard (1) of the engine fan.
41
46. Working from the side of the starter motor (1), remove the retaining nut (2) and the protective cable housing (3).
42 47. Remove the retaining nut (1) and the electrical cable (2) connected to the fuse--holder box and the positive cable between the motor and battery cut--out. Disconnect all the connections of the engine main cable (on the brake pump pressure switches, on the brake oil cup, on the coolant temperature sensor, engine speed, engine oil pressure, grid heater, ........) cut the plastic clamps and remove the metal ones, recover the electrical system.
43
48. Remove the four knobs (1) and take off the two right-- and left--hand dashboard panels (2).
1
2
MDD2562A
44 87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
27
49. Extract the differential lock pedal retaining pin (in the case of standard machines) from the drive shaft (1), remove the pedal and footboard (2).
2 1
25043
50. Remove the four plugs (1) in order to gain access to the engine upper retaining bolts.
45
46 51. Using the wrench (1), remove the two nuts and two bolts fastening the engine to the transmission, gaining access via the four slots in the platform (2).
52. Hitch the engine to the hoist with the chains (1) anchoring it to the attachments (2) on the engine.
47
48 87679925A - 12 - 2007
28
SECTION 10 -- ENGINE -- CHAPTER 1
53. Position a fixed stand (2) under the clutch housing (1) near the engine attachment flanging and apply the handbrake.
49
54. Position the movable tool for dismantling tractors 380000569 (2) with the bracket 380000500 and adapter plate 380000844 under the engine and place a wooden block (1) in between the points of contact between the tool and tractor.
1
2 MODD1771A
50 55. Remove the two bolts fastening the engine to the transmission on the tank side using the 19 mm wrench (1) shown alongside.
56. Remove the remaining six retaining bolts (1) at the bottom and side.
51
52 87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
29
57. Separate the engine (1) from the transmission with the tool 380000569 (2).
1
2
25050
53
58. Insert the fixed stand (1) under the ballast support and secure the front wheels with wooden blocks (2).
25056
1
2 54
59. Position a fixed stand (3) under the support of the groove (1) of the front axle drive placing a wooden plug (2) between the parts (3) and (1).
60. Fit the lifting eyelet (1) in the threading on the support (2).
55
56 87679925A - 12 - 2007
30
SECTION 10 -- ENGINE -- CHAPTER 1
61. Insert the hooks of the lifting chains (1) in the eyelets shown in the figure, afterwards tensioning the chains with the hoist.
62. Remove the four bolts (2) fastening the front axle support (1) to the engine (3).
57
58 63. Detach the engine (2) from the front axle (3), trying to avoid incorrect operations with the hoist so as not to let the engine fan damage the fins of the radiator (1), left on the axle (3). 64. Then rest the engine (2) on a platform support.
59
87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1 65. To refit the engine, proceed as follows:
ATTENTION
to move the engine/front axle assembly close to the clutch casing. --
In the phase of installing the engine/front axle assembly to the clutch casing, it is necessary to push on the front wheels, taking great care in the end phase of coupling over both the pipes and the cables/electrical connections to prevent crushing between the two bodies. During this phase, it is moreover necessary to turn the crankshaft with the aid of the radiator cooling fan to help the coupling between the sleeve and the drive shaft.
--
Secure both assemblies by tightening all the bolts locking the engine to the clutch casing.
--
Disconnect the hoist chains, remove the U--bolt previously fitted under the clutch casing and recover the movable tool for dismantling tractors 380000569.
--
Refit the 4 plugs on the platform and refit the footboard and, in the case of standard machines, refit the lock pedal.
--
Refit the two cabinets under the instrument panel with the 4 knobs.
--
Refit the specific electric cable of the engine, bind it with the plastic clamps and with the related metal clamps, refit the related plastic guards on the starter motor too.
--
Refit the fan guard on the left--hand side.
--
Refit the brake pipe support.
--
Refit the two cylinder block / radiator connecting pipes, top and bottom, with the metal clamps.
--
Install the compressor as described in section 50 together with the pipes.
--
Refit the condenser radiator together with the pipes and reconnect the top condenser retaining pin.
--
Refit the dryer filter together with its support and piping, tightening the two retaining bolts.
--
Refit the air / air cooler with the metal pipes and sleeves, tightening them with the metal clamps.
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
Respect the tightening torques prescribed on page 6.
--
Insert the three hooks of the chain in the eyelets on the engine and, using the hoist, lift the assembly off the platform support.
--
Position the engine on the front axle, trying to avoid incorrect operations with the hoist so as not to let the engine fan damage the fins of the radiator, then join the two assemblies together with the four retaining bolts.
--
Reposition the movable tool for dismantling tractors 380000569 under the engine and place a wooden block in between the point of contact between the tool and engine.
--
--
--
--
--
--
--
With the aid of the hoist, place the engine on the tool 380000569 and remove the lifting eyelet previously fitted on the front of the engine. Remove the fixed stand previously positioned under the support of the groove of the drive of the front axle and the wooden plug. Remove the fixed U--bolt fitted beforehand under the ballast support and the two wooden wedges locking the front wheels. Remove the old sealing paste from the two surfaces between the engine and clutch casing. Apply LOCTITE sealing compound on the engine/clutch casing contact surfaces. Position wooden blocks under the rear wheels, make sure that the handbrake is fully applied and that all fixed and mobile stands are safely positioned. The installation phase described here requires the presence of two or three workers to use the movable tool for dismantling tractors 380000569
31
87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
32 --
Refit the air filter, ejector pipe, delivery pipe to the turbo with the pipe on the oil vapour recovery filter, and the air brakes compressor intake pipe (if installed), tighten the metal clamps, reconnect the electrical system to the clogged filter sensor.
--
Reconnect all the pins of the cab main electrical system to the users on the engine.
--
Reconnect the engine cable main connection to the cab.
--
Refit the bonnet support, tightening the retaining bolts.
--
Reconnect the diesel recovery and delivery pipes to the pump.
--
Refit the support with the fuse--holder box on the bonnet support, tightening the two retaining bolts.
--
Position and reconnect the oil pipes (described in operation 14.) on the right--hand side, taking care to tighten the clamps to the frame.
--
Refit the support together with the relays protecting the system on the bonnet support, fitting the two retaining bolts.
--
Position and reconnect the oil pipes (described in operation 13.) on the left--hand side, taking care to tighten the clamps to the frame.
--
Refit the propeller shaft with its central support and the retaining bolts.
--
Refit the front axle drive shaft guard, tightening the front, central and rear retaining bolts.
--
Refit the front ballast together with the support and insert the retaining pin and the split pins.
--
Refit the toolbox and the catch.
--
Refit the positive cables and the control unit memory cable on the mechanical battery cut--out switch.
--
Refit the battery cut--out switch on the guard on the right--hand side of the fan, refit the guard tightening the three retaining bolts.
--
Refill the oil from the transmission/gearbox and the coolant in the radiator.
--
Install the bonnet as described, see section 90.
--
Reconnect the battery negative cable.
--
---
Refit the brake fluid reservoir onto the support and the two retaining clips. Refit the silencer together with the exhaust pipe. Secure the silencer to the exhaust manifold with the four nuts and connect the air filter dust extractor pipe to the silencer exhaust, inserting the retaining clamp.
--
Refit the three rear retaining bolts of the exhaust silencer.
--
Fit the cab heater delivery and return pipes and insert the associated clamps.
--
Install the flexible cables governing the hand and pedal throttle, inserting the retaining clips.
--
Reconnect the throttle control tie--rod to the injection pump, inserting the retaining clip.
--
Refit the hose together with the front differential lock pipe.
--
Reconnect the right and left steering hoses to the front axle.
87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
33
CRANKSHAFT FRONT SEAL Renew
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 (1) as described, see section 90, and disconnect the battery negative cable.
2. Remove the radiator of the condenser (1), see section 50, without however removing the condenser gas delivery/return pipes so as not to recover/recharge the system refrigerant gas.
60
61 3. Remove radiator (1), as described in this section on page 59.
62
87679925A - 12 - 2007
34
SECTION 10 -- ENGINE -- CHAPTER 1
4. Loosen the pivot screws (2) and lock screws (1) of the tightener (3).
63
5. Loosen the bolt (2) tensioning the belt (1) and remove the belt.
64 6. Remove the six retaining bolts (1), the pulley (2) governing the accessory assemblies and the fan--alternator--coolant pump pulley (3).
65
7. Apply tool 380000665 (4) on the front tang (2) of the crankshaft. 8. 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. 9. Secure the tool 380000665 (4) to the seal (1) by screwing down the screws (3) supplied. 10. Extract the seal (1) by screwing down the screw (5). 87679925A - 12 - 2007
MIF0916A
66
SECTION 10 -- ENGINE -- CHAPTER 1
35
11. 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).
12. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
MIF0917A
67
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).
MIF1001A
68 --
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 the operation in this section on page 59.
--
Refit the condenser radiator, see section 50.
--
Reconnect the battery negative cable and close the bonnet.
87679925A - 12 - 2007
36
SECTION 10 -- ENGINE -- CHAPTER 1
CRANKSHAFT REAR SEAL Renew
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 section 18.
69
2. Remove the eight screws (1) fixing the engine flywheel (2).
70 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 put down in a specific wooden container with the hoist.
MIF1116A
4. Apply tool 380000663 (3) on the rear shank (1) of the crankshaft.
87679925A - 12 - 2007
71
SECTION 10 -- ENGINE -- CHAPTER 1
37
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
72
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
73 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
74
87679925A - 12 - 2007
38
SECTION 10 -- ENGINE -- CHAPTER 1
11. Manually tighten the bolts (2) retaining the flywheel (1) to the crankshaft.
MIF1115A
75
12. Tighten the bolts (1) securing the engine flywheel (2) in two successive stages as described on page 6: -- 1st phase, tightening with torque wrench to a torque of 30 ± 5 Nm; -- 2nd stage, angle closed 605 ± 5°. NOTE: Angle closing is performed with tool 380001001.
MIF1146A
76 13. Install the clutch as described in section 18.
87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
39
VALVE TAPPET AND 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, see section 90. 2. Disconnect the battery negative cable.
77 3. Remove the plastic retaining clamps, from the cab heater water delivery--return pipes (2) and those of the electric cables (1), moving the pipes and cables on the compressor as described in the figure.
4. Remove the retaining bolt and the front tappet inspection cover (1) together with the cover base seal.
78
79
87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
40
5. Remove the two retaining bolts (3) and the central tappet inspection cover (2) together with the engine vapour intake pipe (1) and the cover base seal.
80 6. Remove the retaining bolt and the rear tappet inspection cover (1) together with the cover base seal.
81 7. 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.
8. 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. ---
The symmetrical cylinders are 1 -- 4 and 3 -- 2. FIRING ORDER 1 -- 3 -- 4 -- 2
87679925A - 12 - 2007
MIF1016A
82 Balancing valves of cylinder no.
1
3
4
2
Adjust valve clearance of cylinder no.
4
2
1
3
SECTION 10 -- ENGINE -- CHAPTER 1
41
For assembly operations proceed as follows: --
Fit the rear tappet inspection cover together with the cover base seal and tighten the retaining bolt to the torque stated on page 6.
--
Fit the central tappet inspection cover together with the engine vapour inlet pipe and the cover base seal, then tighten the retaining bolts to the torque stated on page 6.
--
Fit the front tappet inspection cover together with the cover base seal and tighten the retaining bolt to the torque stated on page 6.
--
Reposition the cab water delivery--return pipes and those of the electric cables, inserting new plastic retaining clamps.
--
Install the bonnet as described in section 90.
--
Reconnect the battery negative cable.
87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
42 ENGINE INJECTOR R.I.
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. Lift the bonnet and disconnect the battery negative cable. 2. Install the bonnet (1) as described in section 90.
3. Take out the three exhaust silencer rear retaining bolts (1).
83
84 4. Remove the clamp (1), the air filter dust ejector pipe (2) and the four nuts (3) securing the silencer to the exhaust manifold.
85
87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
43
5. Remove the silencer (2) together with the exhaust pipe (1).
86
6. Remove the diesel delivery (1) and recovery (2) fittings from the injectors, then remove the relevant pipes.
87 7. Remove the injectors (2) with tool 380000671 (1) and extract them from the cylinder head. 8. Remove the threaded parts retaining the injectors from the cylinder head. 9. To refit, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Fit the threaded parts retaining the injectors on the cylinder head.
--
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 6.
--
MIF1062A
88
MIF1063A
89 87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
44 --
Fit the new seals on the fuel manifolds.
--
Fit the diesel delivery and recovery pipes and fittings on the injectors.
--
Fit the silencer and exhaust pipe.
--
Fit the air filter dust ejector pipe, its clamp and the four rear nuts retaining the silencer to the exhaust manifold.
--
Fit the three rear retaining bolts of the exhaust silencer.
--
Install the bonnet as described in section 90.
--
Lower the bonnet and reconnect the battery negative cable.
87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
45
BOSCH INJECTION PUMP R.I.
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. Lift the bonnet and disconnect the battery negative cable. 2. Install the bonnet (1) as described in section 90.
3. Remove the accelerator retaining spring (1) and extract the lever (2).
90
91 4. Disconnect the engine stop electromagnet wire (1).
92
87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
46
5. Remove the quick couplers (1) on the filter and (2) on the injection pump, remove the injection pump supply pipe. Remove the pipe (3) coming from the tank.
ATTENTION Make the vehicle safe and put the gear into neutral.
MIF1161A
93
6. Remove the quick couplers and pipe (1) installed between the fuel filter and fuel pump.
94 7. Remove the fittings of the pipes (2) connecting the injection pump--injectors, the pipe (1) connected to the thermostarter device and the electrical connection of the engine stop device (3).
MIF1163A
95
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SECTION 10 -- ENGINE -- CHAPTER 1
47
8. Disconnect the electrical connection (1) for measuring the engine oil pressure.
9. Remove the four fittings (2) connecting the injection pump / injectors and the pipes (1).
96
97 10. Remove the retaining bolts (1) and the three brackets (2) retaining the pipes, inserted on the injection pump/injector connection line.
11. Remove the fittings (1) of the injector diesel delivery pipes and the fittings (2) of the injection pump diesel return pipe, then detach the pipes. 12. Lock the engine flywheel with appropriate means.
98
99 87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
48
13. 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 52, 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
100
14. Remove the three nuts (2) (3) (5) securing the injection pump (1) to the engine flywheel casing (4) and extract it from its housing.
MIF0922A
101 15. To refit the injection pump, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Respect the tightening torques prescribed on page 6.
--
When refitting the BOSCH injection pump, insert the stud bolts in the engine flywheel casing into the mating holes on the pump flanging.
--
Do the timing for the injection pump in relation to the drive gear, proceeding as described on page 52.
--
Then loosen the retaining and safety bolt of the injection pump timing.
87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
49
L spacer and tighten the retaining
--
Reinsert the bolts.
--
Free the engine flywheel, take out the tools 380000988 and 380000732 and refit the starter motor.
--
Reconnect the pipes and the fittings of the diesel delivery pipes to the injectors and the fittings of the diesel return pipe to the injection pump.
--
Fit the three retaining brackets, insert the pipes on the line that connect the injection pump to the injectors, tightening the retaining bolts.
--
Reconnect the four pipes connecting the injection pump / injectors, tightening their fittings.
--
Reconnect the electrical connection measuring the engine oil pressure.
--
Install the fittings of the pipes connecting the injection pump--injectors, the pipe connected to the thermostarter device and the electrical connection of the engine stop device.
--
Reconnect the pipe installed between the fuel filter and the fuel pump and reinsert the quick couplers.
--
Fit the pipe supplying the injection pump, connecting the quick couplers on the filter and on the injection pump.
--
Fit the pipe coming from the tank.
--
Reconnect the engine stop electromagnet cable.
--
Fit the throttle control lever and its retaining clip.
--
Install the bonnet as described in section 90.
--
Reconnect the battery negative cable and lower the bonnet.
for
87679925A - 12 - 2007
50
SECTION 10 -- ENGINE -- CHAPTER 1
INJECTION PUMP Renewal -- Checking timing Free the injection pump from the fuel circuit and from the delivery pipes to the injectors, remove the electrical system on the engine stop and on the advance cut--out (see preceding operation). NOTE: When replacing the injection pump, bear in mind that it is supplied as a spare part already set for cylinder No. 1 to T.D.C. Disassembly Proceed as follows: MIF1172A
102
1. Take out the bolts (1) and remove the starter motor (2). 2. Fit the bracket tool 380000988 (1), retaining the gear for turning the engine flywheel tool 380000732 (2). 3. Slowly turn the engine flywheel (3) and at the same time press on the pin (4), supplied with tool 380000988, in order to insert the pin (4) into the seat in the engine flywheel (3).
2
3 MIF1173A
103 4. Take out the retaining bolts (2) and remove the priming pump (1) from the crankcase (3).
MIF1174A
104
5. Check through the opening accommodating the priming pump that the camshaft (1) has the reference marks (2) indicating cylinder No. 1 to T.D.C. If there are no marks, extract the pin (4, fig. 103) from the flywheel and turn the latter through 360° so that the marks (2) are visible as shown in the figure alongside, afterwards re--inserting the locking pin (4, fig. 103).
MIF1175A
105 87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
51
Take the injection pump out of its seat.
Using a wrench, unscrew the ribbed driving gear (1) then take it out of the pump.
106
107 Assembling Proceed as follows:
Take a pump with the plunger on cylinder No. 1 already pre--set. Remove the splining key, insert the ribbed gear (1, fig. 107) onto the pump’s tapered shaft, then slightly tighten the gear with a wrench. Insert the ribbed gear into the central seat of the timing gear by turning the tapered shaft, in the middle of the ribbed gear, so as to insert the stud bolts (2) in the middle of the slot (1). Remove the pump from its seat. Using a torque wrench (1) tighten the ribbed gear check nut to a torque of 95 Nm (9.69 kgm), after clamping the gear in a vice fitted with lead jaws.
108
109 87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
52
6. Fit the injection pump casing (1), already set, in the seat of the gear box (2) without tightening the retaining bolts (3). With the injection pump fitted in its seat and cylinder No. 1 at T.D.C. the plunger travel must be as prescribed. In order to check this, proceed as follows:
ATTENTION The seal removed at the time of pump disassembly must not be reused. Always use genuine spare parts.
MIF0981A
110
7. Loosen the screw (1) blocking rotation of the pump spindle and insert the L spacer (2). 8. Tighten the screw (1), locking part (2) so that the spindle of the fuel pump can turn freely.
MIF1176A
111 9. Remove the plug on the pump cover. 10. Fit the dial gauge 380000228 (2) and the associated tool 380000914 (1), pre--loading the shaft by 2.5 mm. 11. This operation makes it possible to use the dial gauge (2) to check that the plunger in the pump moves to the bottom limit equivalent to the lowest indication of the dial gauge pointer.
MIF1165A
112
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SECTION 10 -- ENGINE -- CHAPTER 1
53
12. Extract the pin (4, fig.103) of tool 380000988, turn the flywheel slowly anticlockwise (seen from fan side), with a wrench with a 1/2” shank (1) on tool 380000732, so that the plunger reaches its BDC (the dial gauge pointer will stop).
113 13. Zero--set the dial gauge.
114 14. Slowly turn the engine flywheel clockwise (seen from fan side) with the wrench (1) and at the same time press on the pin (4, fig.103), supplied with tool 380000988, to insert the pin (4, fig.103) into the seat in the engine flywheel (3, fig.103). The dial gauge stem should travel: -- Engine 56 / 76, 63 /86 and 71 / 97 KW / HP 0.8 ± 0.05 mm --
Engine 78 /106 KW / HP 0.7 ± 0.05 mm
115 --
Engine 83 /113 KW / HP 0.88 ± 0.05 mm
87679925A2 - 02 - 2010
54
SECTION 10 -- ENGINE -- CHAPTER 1
15. Turn the pump (1) anticlockwise if the stroke is any less, or clockwise if the stroke is any greater in order to obtain the prescribed stroke. 16. Verifying these conditions, lock the pump by tightening the nuts to the torque shown on page 6.
116 17. Fit the priming pump (1) on the crankcase (3) and tighten the retaining bolts (2) to the prescribed torque. Reconnect the various pipes and the electrical system. 18. Remove the tools 380000988 and 380000732 for retaining/rotating the flywheel and place the starter motor in its seat.
MIF1174A
117
BOSCH INJECTION PUMP Fuel circuit air bleeding 19. Loosen the injector delivery unions (1), make the engine turn with the starter motor and, after having checked that there are no air bubbles, tighten the unions (1).
1
MIF1167A
118
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SECTION 10 -- ENGINE -- CHAPTER 1
55
COOLANT PUMP 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. 1. Raise the bonnet (1). 2. Disconnect the battery negative cable.
3. Remove the three retaining bolts (1) and the guard (2) on the right--hand side of the fan.
119
120 4. Detach the fitting (3) of the return pipe (2) for the coolant from the cab heater radiator connected to the underside of the coolant pump (1) and drain off the engine coolant.
121
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SECTION 10 -- ENGINE -- CHAPTER 1
56
5. Loosen the screws (2) and (3) retaining and pivoting the tightener to the cover (5). 6. Loosen the screw (4) for tensioning the belt (1) and remove the belt.
122
7. Remove two retaining screws and the coolant pump (1).
8. 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 6 and on page 66.
--
Fit a new seal (2) onto the coolant pump (1).
--
Fit the coolant pump, tightening the two retaining bolts.
--
Fit the belt and adjust it with the tensioning screw.
--
Tighten the screws retaining and pivoting the tightener to the cover.
--
Reconnect the fitting of the cab heater radiator coolant return pipe to the bottom of the coolant pump and refill the engine coolant.
--
Fit the guard on the right--hand side of the fan and tighten the three retaining bolts.
--
Reconnect the battery negative cable.
--
Close the bonnet.
87679925A - 12 - 2007
MIF0997A
123
SECTION 10 -- ENGINE -- CHAPTER 1
57
THERMOSTAT VALVE R.I.
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 (1). 2. Disconnect the battery negative cable.
3. Remove the three retaining bolts (1) and the guard (2) on the right--hand side of the fan.
124
125 4. Detach the fitting (3) of the return pipe (2) for the coolant from the cab heater radiator connected to the underside of the coolant pump (1) and drain off the engine coolant.
126
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SECTION 10 -- ENGINE -- CHAPTER 1
58
5. Remove the clamp (2) and extract the sleeve (1) connecting the radiator and thermostat valve.
127
6. Take out the bolts (1) retaining the thermostat valve body (2).
128 7. Remove the thermostat valve body (2), seal (3) and thermostat valve (4). 8. 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 6.
--
Refit the thermostatic valve, after positioning the thermostat valve seal. Fit the thermostat valve body and the retaining bolts. Fit the radiator--thermostat valve connecting sleeve and the clamp. Install the fitting of the cab heater radiator coolant return pipe connected to the bottom of the coolant pump and refill the engine coolant. Fit the guard on the right--hand side of the fan and tighten the three retaining bolts. Reconnect the battery negative lead. Close the bonnet.
----
----
87679925A - 12 - 2007
MIF1169A
129
SECTION 10 -- ENGINE -- CHAPTER 1
59
RADIATOR 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. 1. Remove the bonnet (1) as described in section 90.
2. Remove the three retaining bolts (1) and the guard (2) on the right--hand side of the fan.
3. Detach the fitting (3) of the return pipe (2) for the coolant from the cab heater radiator connected to the underside of the coolant pump (1) and drain off the engine coolant.
130
131
132
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60
SECTION 10 -- ENGINE -- CHAPTER 1
4. Disconnect the air filter clogged sensor wires (1).
5. Disconnect the clogged filter sensor, loosen the clamps and detach the pipes on the air filter: -- air delivery to the turbo (1), (remember also to disconnect the pipe on the oil vapour recovery filter that will remain connected to the delivery pipe) -- pneumatic braking compressor intake (2), (if installed) -- ejector (3) then recovery it take out the screws (4), remove the air filter.
133
134 6. Loosen the air delivery retaining clamp (1) on the turbo and extract the pipe.
7. Remove the coolant recovery cup from the support. Loosen the air delivery pipe clamp (1) from the turbo to the air / air exchanger; perform the same operation on the left--hand air supply pipe, from the cooler to the intake manifold.
135
136 87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
61
8. Loosen the clamp on the turbo then extract the pipe, on the left--hand side loosen the one on the intake manifold recovering the pipe.
137
9. Unscrew the retaining bolts (1) on the right and left, then remove the cooler.
138 10. Remove the two retaining bolts (2) and detach the support (3) together with the dryer filter (1) and pipes.
1
3 11. Unhook the top pin (1) retaining the condenser.
2 139
140 87679925A - 12 - 2007
62
SECTION 10 -- ENGINE -- CHAPTER 1
12. Turn the steering wheel fully to the left, remove the radiator of the condenser (1) from the same side of the tractor.
141
13. Remove the compressor (1) as described in section 50 without detaching pipes (2) and (3) so as not to then have to recover, evacuate and charge the gas in the air conditioning system.
142 14. Remove the two retaining bolts (2) and detach the support (3) together with the dryer filter (1) and pipes.
1
3 15. Remove the condenser radiator (1) the dryer filter (2) with its support and the compressor (3), resting them alongside the right--hand rear wheel with the associated piping.
2 143
144 87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
63
16. Unhook the bottom pin (1) retaining the air / transmission oil cooler.
17. Turn the steering wheel fully to the left, remove the cooler (1) from the same side of the tractor.
145
146 18. Loosen the corresponding retaining clamps and extract the top pipe between the radiator and the thermostatic valve fitted on the engine.
19. Loosen the retaining clamp (2) and extract the pipe (1) joining the coolant pump to the bottom of the radiator.
147
148 87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
64
20. Remove the radiator / bonnet support bracket retaining bolts (1).
21. Take out the two radiator retaining bolts installed under the front axle support, removing the bolts, washers and lower rubber blocks. 22. Remove the radiator (1).
149
150 23. Remove the rubber blocks (1), washers and upper rubber blocks (2).
24. To refit the radiator, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Respect the tightening torques prescribed on page 6.
--
Fit the upper rubber blocks, washers and the rubber block at the base of the radiator.
87679925A - 12 - 2007
151
SECTION 10 -- ENGINE -- CHAPTER 1 --
Fit the radiator.
--
Fit the lower rubber blocks, the washers and the radiator retaining bolts installed under the front axle support.
--
Fit the pipes between the radiator and the thermostatic valve, top, and the lower one, tighten the clamps.
--
Fit the transmission cooler and secure it with the lower pin.
--
Fit the dryer filter with its support. Refit the compressor as described in section 50.
--
Fit the dryer filter and secure it with the upper pin.
--
Fit the air / air cooler and tighten the relevant bolts. Reposition the coolant recovery cup.
--
Reposition the turbo exchanger connection pipes on the right--hand side and the intake manifold exchanger on the left--hand side, then tighten the metal clamps.
--
Fit the air filter with the bolts. Reposition the air delivery pipe to the turbo and tighten the metal clamps.
--
Reconnect the pneumatic braking compressor intake pipe (if mounted) and the ejector, then tighten the clamps. Reconnect the pins on the filter clogging switch.
--
Install the fitting of the cab heater radiator coolant return pipe connected to the bottom of the coolant pump.
--
Refill the engine radiator with coolant.
--
Refit the guard on the right--hand side of the fan and tighten the three retaining bolts.
--
Reconnect the battery negative cable and refit the bonnet as described in section 90.
65
87679925A - 12 - 2007
SECTION 10 -- ENGINE -- CHAPTER 1
66
COOLANT PUMP AND GENERATOR DRIVE BELTS Adjusting tension (Disassembly operation 2 รท 5)
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 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).
152 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 following torque settings: --
With the standard cooling fan
--
3.8 รท 4.4 Nm.
--
With the coupling
--
4.3 รท 4.9 Nm.
cooling
87679925A - 12 - 2007
fan
with
viscostatic
SECTION 10 -- ENGINE -- CHAPTER 1
67
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 154 below, using the CLAVIS frequency meter 380001268, bearing in mind that the data measured must remain within the following tolerances:
153
--
With the standard cooling fan.
--
Assembly tension 1100 รท 1300 Nm
--
Frequency measured with CLAVIS 158 รท 170 Hz
--
With the coupling.
--
Assembly tension 1250 รท 1450 Nm.
--
Frequency measured with CLAVIS 177 รท 191 Hz.
cooling
fan
with
viscostatic
154
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.
87679925A - 12 - 2007
68
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SECTION 10 -- ENGINE -- CHAPTER 1
SECTION 18 -- CLUTCH -- CHAPTER 1
1
SECTION 18 -- CLUTCH Chapter 1 -- Clutch CONTENT Description
Page
Clutches. General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Checks, measurements and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Main transmission clutch release -- Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Clutch R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Dual Clutch 12”/12” -- Test bench overhaul and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Adjusting the coplanarity of the single--plate / dual--plate clutch release levers . . . . . . . . . . . . . . . . . . . . . . 17
87679925A - 12 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
2
LUK 12” CLUTCH -- GENERAL SPECIFICATIONS (see fig. 1) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
single dry plate clutch
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
operation with pedal
Work Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mechanical transmissions (12X12 mechanical shuttle and 20X12 creeper unit shuttle ) with hydraulic PTO
Engagement and release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belleville spring disk
--
main clutch (for model 56/76 and 63/86 kW/HP with hydraulic power take--off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
no. 6 plugs with pads in Cerametallic
--
main clutch (for models 71/97 and 78/106 kW/HP with hydraulic power take--off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
no. 7 plugs with pads in Cerametallic
Driven plate thickness for main clutch (1, fig. 1) . . . . . . . . . . . . . . --
Driven plate wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
9.6 ÷ 10.4
”
see page 17
Clutch control adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
see page 8
LUK 12”/12” CLUTCH -- GENERAL SPECIFICATIONS (see fig. 2) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
single disk, dry plate dual clutch unit
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical: pedal operated for main transmission clutch; hand lever operated PTO clutch
Work Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mechanical transmissions (12X12 mechanical shuttle and 20X12 creeper unit shuttle ) with mechanical PTO
Engagement and release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
single Belleville spring
Driven plates lining material --
main clutch (for model 56/76 and 63/86 kW/HP with mechanical no. 6 plugs with pads in ceramepower take--off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tallic
--
main clutch (for models 71/97 and 78/106 kW/HP with mechanical no. 7 plugs with pads in ceramepower take--off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tallic
--
PTO clutch (for all models noted above) . . . . . . . . . . . . . . . . . . . . . . .
organic agglomerate
Driven disc thickness: --
main clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
9.6 ÷ 10.4
--
PTO clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
7.3 ÷ 7.9
--
wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
see page 6
Release lever coplanarity adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
see page 17
Clutch control adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
see page 8
87679925A - 12 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
3
BOLT TORQUES
Tightening torque PARTS TO BE TIGHTENED
Thread Nm
kgm
Engine / flywheel retaining bolts * . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12x1.25
30 ± 4
3 ± 0,4
LUK 12” clutch / flywheel retaining bolts . . . . . . . . . . . . . . . . . . . . .
M8x30
25 ÷ 30
2.54 ÷ 3.06
LUK 12” clutch / flywheel retaining bolts . . . . . . . . . . . . . . . . . . . . .
M10x45
57 ÷ 63
5.81 ÷ 6.42
Flexible coupling / flywheel retaining bolts** . . . . . . . . . . . . . . . . . .
M10x20
67
8,83
Release command fork lever securing bolt . . . . . . . . . . . . . . . . . . .
M16x1.5
157
16
12”/12” clutch/flywheel retaining bolts . . . . . . . . . . . . . . . . . . . . . . .
M10x1.25
59
6
Clutch housing/engine retaining nuts . . . . . . . . . . . . . . . . . . . . . . . .
M12x1.25
98
10
Nut for sleeve cover fixing stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M8x1.25
17
1,7
* After tightening the bolts to the prescribed torque, tighten all the bolts with a wrench to an angle of 60° ± 5°. ** Before tightening the bolts to the prescribed torque, apply a few drops of Loctite 270 onto the bottom of the bolts.
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. 380000569
Movable tool for dismantling tractors with bracket 380000500 and adapter plate 380000844.
380000292
Pin for centring and adjustment of 12” and 12”/12” clutches.
380000293
Clutch adjustment gauge (with 380000292).
380000256
Set of wrenches for adjustment of levers in 12”/12” LUK clutches.
87679925A - 12 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
4
Longitudinal section of 12” LUK clutch”. Electrohydraulic power take--off 1.
Main transmission clutch plate.
2. 3. 4. 5. 6. 7. 8.
Diaphragm Spring. Main clutch disengagement lever. Sleeve bearing. Sleeve support retaining bolt. Sleeve operating clevis. Sleeve support. Power take--off shaft flexible coupling.
1
2
3
4
45x75x16
NOTE: When refitting the clutch, check that the clutch disks are positioned as in the drawing.
8
7
6
5
MDM1514A
Longitudinal section of 12”/12” LUK clutch. Mechanical Power take--off 1. 2.
Power take--off clutch plate. PTO clutch pressure plate auto--adjuster spring.
3. 4. 5.
Power take--off clutch engagement lever. Power take--off clutch engagement control sleeve. Gear clutch release sleeve.
6. 7.
Sleeve support. Sleeve support retaining bolt.
1 1
2
3
A
4
5
6
8. Main clutch sleeve control clevis. 9. Power take--off clutch sleeve control clevis. 10. Main clutch release lever. 11. Main clutch plate. 12. Clutch control spring. 13. Power take--off shaft support bearing.
A. 144 mm. Nominal distance of release levers
(4) from clutch contact surface on flywheel. B. 103 mm. Nominal distance of release levers (8) from clutch contact surface on flywheel.
13 12
NOTE: When refitting the clutch, check that the clutch disks are positioned as in the drawing.
87679925A - 12 - 2007
11
B
10
9
8
7
MDM1515A
2
SECTION 18 -- CLUTCH -- CHAPTER 1 Longitudinal section through flexible coupling. Power Shuttle unit 1.
Flywheel.
2. 3. 4.
Flexible coupling. Shuttle clutch driving shaft. Engine / flywheel retaining bolts.
1
4
5
2
3
MDM1516A
3
87679925A2 - 02 - 2010
SECTION 18 -- CLUTCH -- CHAPTER 1
6
CLUTCH TROUBLESHOOTING Problems The clutch slips
Possible Problem
Solutions
1. Worn disks (1 and 11, fig. 2) Check and compare the data given on pressure plates and on the pages indicated, replace any flywheel (1--2--3--4, page 7). parts which are worn up to or over the limit and adjust levers and clutch control linkage. 2. Belleville spring disk (12, Replace the Belleville spring. fig. 2) stretched or damaged. 3. Oil or grease contaminating Replace the disks, identify and the disks friction material (1 eliminate the source of the lubricant inside the clutch housing and and 11, fig. 2). thoroughly clean the friction surfaces.
The clutch jerks
1. Partial seizure of the external Check rod pivots and lubricate. control linkage. 2. Clutch disk deformed.
(11,
fig. 2) Replace the disk and adjust the clutch control lever.
3. Clutch disk (11, fig. 2) with Replace disk. spring drive damaged or with hub rivets loose. 4. Oil or grease contaminating Replace the disks, identify and the disks friction material (1 eliminate the source of the lubricant inside the clutch housing and and 11, fig. 2). thoroughly clean the friction surfaces. Clutch sticks and drags
1. Clutch disks (1 and 11, fig. 2) Replace and adjust disks. deformed. 2. Seizure of external control Check, replace faulty parts and lubricate. linkage. 3. Controls incorrectly adjusted. Adjust the controls (see page 9).
Clutch noisy y when engaged g g and/or d/ disengaged di d
1. Thrust bearing worn.
Clutch pedal too stiff
1. Partial seizure of the external Check rod pivots and lubricate. control linkage.
2. Clutch disk (11, fig. 2) with Replace disk. spring drive faulty.
2. Partial seizure of pedal pivot.
87679925A2 - 02 - 2010
Replace bearing.
Check pivot and lubricate.
SECTION 18 -- CLUTCH -- CHAPTER 1
7
CHECKS, MEASUREMENTS AND REPAIRS -- 12”/12” DUAL 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. Check all parts carefully. --
Check for wear on the Power take--off (11, fig. 4) and main (9) clutch disks and replace if the retaining rivets are worn or approaching the friction material.
1
--
Replace the disc when the oil has soaked into the organic agglomerate surfaces.
--
Check the friction surface conditions of the pressure plates (2 and 3 fig. 5) and the clutch cover (4).
Generally, by means of turning, up to 0.75 mm of material can be removed from the cast iron friction surfaces of the clutch cover (4) and pressure plate rings (2 and 3), therefore the Minimum permissible dimensions after refacing of parts subject to wear in the 12”/12” dual clutch are: 1. 2. 3. 4.
B A
2
3
4
5
12
11
10
9
8
7
6
MDD3226A
4
1
2
3
4
D
Engine flywheel. PTO clutch pressure plate. Main transmission clutch pressure plate. Supporting housing.
A. ≥ 13.25 mm. B. ≥ 28.85 mm. C. ≥ 21.95 mm. D. = (14--A)+0.5 mm.
A
B
C
26164
5 87679925A - 12 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
8
When parts (1), (2), (3) and (4, fig. 5) are to be repaired by removing material, proceed as follows:
--
If it is necessary to reface the friction surfaces on the flywheel (1, fig. 5), remember that the maximum amount that can be removed in relation to the nominal thickness* (see figs. 6 and 7) is 1 mm.
∅ 360
--
For flywheels of 12”/12” dual clutches (see fig. 7) it is moreover necessary, after refacing the friction surface of the p.t.o. clutch pressure plate, to restore the external surface D according to the formula:
73,5 0,2 ± (*)
∅ 186
26165
6
D = (14--A) + 0.5 mm. ∅ 352 E8
± (*) 73,5 0,2
D
∅ 313 NOTE: Figure 6 corresponds to the flywheel relative to a 12” single disk clutch. Figure 7 corresponds to the flywheel relative to a 12”/12” dual disk clutch.
26167
7 NOTE: When the main transmission clutch disk starts to slip, after several refacing operations on the parts (3 and 4 fig. 5), the entire clutch assembly will need to be replaced. --
To reassemble the 12”/12” dual clutch, proceed as described on page 16.
87679925A - 12 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1 MAIN TRANSMISSION CLUTCH RELEASE Adjustment
1
When the position of the clutch pedal (2) is misadjusted or the clutch is overhauled, check that distance “A”, of the main clutch pedal in relation to the flooring, is 185 mm for tractors without cabs and 162 mm for tractors with cabs. If not adjust as follows: 1. Remove the knobs (1) and the two lateral panels on the instrument panel to access the adjusting parts.
9
2
A 23751
8
2. Unscrew the locknut near the clevis and turn the nut to adjust the clutch tie rod (2). 3. According to the tractor type, check that distance (A), corresponds to the value noted above, then tighten the locknut. Key fig. 8. A Height of clutch pedal in relation to level of mat. 185 mm tractors without cab 162 mm tractors with cab B Total travel of clutch pedal 159 mm C Pedal travel with shuttle locked 114÷124 mm D Pedal travel with shuttle released 35÷45 mm 4. Adjust the shuttle interlock tie rod (1), similarly to tie rod (2), so that the shuttle is released after a travel C of the clutch pedal equal to 114÷124 mm, before 35÷45 mm from the limit stop 5. Push the pedal down a few times, then check that the travel (A) of the clutch pedal (2) is as prescribed and that the shuttle interlock tie rod has the above--mentioned characteristics. 6. Refit the two lateral panels on the instrument panel and tighten the knobs (1). NOTE: The shuttle interlock is a mechanical device, mounted on manual gearboxes, thanks to which it is not possible to change direction of travel unless the clutch pedal has been pressed down fully. After fully pressing down the clutch pedal, the shuttle lever is released and it is possible to change direction of travel.
9
1
2
A 23751
10 NOTE: As opposed to the main clutch pedal, the PTO clutch lever and tie--rods are self--adjusting.
87679925A1 - 02 - 2008
SECTION 18 -- CLUTCH -- CHAPTER 1
10 CLUTCH R.I.
To gain access to the clutch the engine must be separated with the axle or front axle from the transmission.
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 operations 1 รท 56 relative to engine removal, see (Sect. 10, page 15). 2. Separate the engine (1) from the transmission with the tool 380000569 (2).
1
2
25050
11
3. Insert tool (2) 380000292 in the hole in the middle of the clutch, take out the six screws (1) securing the clutch to the engine flywheel and remove the clutch.
12
87679925A1 - 02 - 2008
SECTION 18 -- CLUTCH -- CHAPTER 1
11
4. To install the engine with the front axle, proceed as follows:
--
Refit the 4 plugs on the platform and refit the footboard and, in the case of standard machines, refit the lock pedal.
ATTENTION
--
Refit the two cabinets under the instrument panel with the 4 knobs.
--
Refit the specific electric cable of the engine, bind it with the plastic clamps and with the related metal clamps, refit the related plastic guards on the starter motor too.
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Respect the tightening torques prescribed on page 3.
--
Assemble the clutch using pin 380000292 and secure the clutch to the engine flywheel with the bolts
--
Refit the fan guard on the left--hand side.
--
Refit the brake pipe support.
--
Adjust the coplanarity of the clutch disengagement levers, as described on page 17.
--
Refit the two cylinder block / radiator connecting pipes, top and bottom, with the metal clamps.
--
Remove the old sealing paste from the two surfaces between the engine and clutch casing.
--
Install the compressor as described (sect. 50, page 27) together with the pipes.
--
Apply LOCTITE sealing compound on the engine/clutch casing contact surfaces.
--
Refit the condenser radiator together with the pipes and reconnect the top condenser retaining pin.
--
Position wooden blocks under the rear wheels, make sure that the handbrake is fully applied and that all fixed and mobile stands are safely positioned.
--
Refit the dryer filter together with its support and piping, tightening the two retaining bolts.
---
The installation phase described here requires the presence of two or three workers to use the movable tool for dismantling tractors 380000569 to move the engine/front axle assembly close to the clutch casing.
Refit the air / air cooler with the metal pipes and sleeves, tightening them with the metal clamps.
--
Refit the air filter, ejector pipe, delivery pipe to the turbo with the pipe on the oil vapour recovery filter, and the air brakes compressor intake pipe (if installed), tighten the metal clamps, reconnect the electrical system to the clogged filter sensor.
--
Refit the bonnet support, tightening the retaining bolts.
--
Refit the support with the fuse--holder box on the bonnet support, tightening the two retaining bolts.
--
Refit the support together with the relays protecting the system on the bonnet support, fitting the two retaining bolts.
--
Refit the brake fluid reservoir onto the support and the two retaining clips.
--
Refit the silencer together with the exhaust pipe.
--
In the phase of installing the engine/front axle assembly to the clutch casing, it is necessary to push on the front wheels, taking great care in the end phase of coupling over both the pipes and the cables/electrical connections to prevent crushing between the two bodies. During this phase, it is moreover necessary to turn the crankshaft with the aid of the radiator cooling fan to help the coupling between the sleeve and the drive shaft.
--
Secure both assemblies by tightening all the bolts locking the engine to the clutch casing.
--
Disconnect the hoist chains, remove the U--bolt previously fitted under the clutch casing and recover the movable tool for dismantling tractors 380000569.
87679925A - 12 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
12 --
Secure the silencer to the exhaust manifold with the four nuts and connect the air filter dust extractor pipe to the silencer exhaust, inserting the retaining clamp.
--
Refit the three rear retaining bolts of the exhaust silencer.
--
Fit the cab heater delivery and return pipes and insert the associated clamps.
--
Install the flexible cables governing the hand and pedal throttle, inserting the retaining clips.
--
Reconnect the throttle control tie--rod to the injection pump, inserting the retaining clip.
87679925A - 12 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
13
DUAL CLUTCH 12”/12”
Test bench overhaul and adjustment 1. Unscrew the three PTO clutch lever adjustment nuts (1).
1
24791
13
2. Recover the pressure plate (1) with the three coil springs (2) and the three washers.
1
2 24792
14 3. Position three clamps (1) at intervals of 120° on the clutch body and gradually and carefully squeeze the Belleville spring disk.
1
24793
15
4. Extract the six spring retaining pins (1) from their seats.
1
24794
16 87679925A - 12 - 2007
14
SECTION 18 -- CLUTCH -- CHAPTER 1
5. Remove the three clamps and extract the Belleville spring disk (1).
1
24975
6. Loosen the three locknuts (1) on the main clutch lever adjustment screws.
17
1
24976
18 7. Remove the three main clutch lever adjustment screws (1).
1
24977
19
8. Extract the main clutch pressure plate (1).
1
24978
20 87679925A - 12 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
15
9. Extract the main clutch disk (1).
1
24979
21
10. Remove the springs (1) on the PTO clutch control levers.
1
24980
22 11. Extract the pivot pins (1) on the PTO clutch control levers.
1 24981
23
12. Remove the springs (1) on the main clutch control levers.
1
24982
24 87679925A - 12 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
16
13. Extract the pivot pins (1) on the main clutch control levers.
1 24983
14. In order to assemble the 12�/12� dual 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.
87679925A - 12 - 2007
25
SECTION 18 -- CLUTCH -- CHAPTER 1 COPLANARITY ADJUSTMENT OF DUAL CLUTCH RELEASE LEVERS
17
2
1
1. After overhauling the clutch, fit centering pin 380000292 (3) and fit the entire clutch assembly with PTO disk to the flywheel, then tighten the bolts (1) to the torque value given on page 3. Fit gauge 380000293 (2) and, using a feeler gauge, adjust the clutch release levers (4) to obtain a clearance of 0.1 mm.
3
4 25366
26
2. Rotate the gauge 380000293 (1) and, using a feeler gauge, adjust the PTO clutch release levers (2) to obtain a clearance of 0.1 mm. Remove tools no. 380000293 and 380000292.
1
2 MDD3228A
27
SINGLE DISK CLUTCH
1
1. Insert centering pin 380000292 (2), unscrew the flywheel retaining bolts (1) and remove the clutch unit.
2 MDD3229A
2. Check the disk (2) for wear and replace the linings if they have worn down (or are nearly worn down) to the plate. In the event of pressure plate (1) breakdown replace the entire part.
28
29 87679925A - 12 - 2007
18
87679925A - 12 - 2007
SECTION 18 -- CLUTCH -- CHAPTER 1
SECTION 21 -- TRANSMISSIONS -- CHAPTER 1
1
SECTION 21 -- TRANSMISSIONS Chapter 1-- Shuttle CONTENT Description
Page
Transmission with range gear and reverser. Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Transmission diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Clutch--shuttle casing. Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 1
2
REVERSER DATA
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mechanical type with spur gearing, located between the main clutch and the gearbox. Composed of no. 1 driving gear, no. 1 intermediate gear and no. 1 idler gear
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
hand lever located on left--hand side of operator
TRANSMISSION AND RANGE GEAR DATA
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 speed, constant--mesh, with synchronisers on all gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
helical
Reduction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ordinary gear train with 3 ranges for a total of 12 gears
--
gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox and reduction unit controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
spur
independent, by means of two hand levers located on the right--hand side of the operator
For missing data see Chapter 1 Section 27.
87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 1
3
TRANSMISSION DIAGRAMS
36
43 33 27 21 17
40
26
A
27
23
d
44 28
d
23 50 39 4652
38 33 13
36
b
12 29 72
34
10
b
23
34--4wd 37--2wd
c
13 25
c
65
a 36
45
26
B
43 37 30 24
17
27
23 44 38 29
28
d
13 36 12 29 72
b c
35 42
23 50 50
34
10
d
b
23
34--4wd 37--2wd
13 25
c
65
a MDM1517A
1 A. Transmission diagram 30 km/h. B. Transmission diagram 40 km/h.
a. Front axle with 4--wheel drive. b. Bevel drive. c. Final reduction gears. d. Differential lock.
87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 1
4
2
BOLT TORQUES Tightening torque PARTS TO BE TIGHTENED
Thread Nm
kgm
Bolts or nuts securing clutch--reverser casing to the engine (C1)
M12x1.25
98
10
Sleeve cover retaining nuts (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M8x1.25
17
1.7
Reverser driven shaft support cover retaining bolts (C3) . . . . . . .
M8x1.25
28
2,9
Reverser driven shaft plate retaining bolt (C4) . . . . . . . . . . . . . . . .
M10x1.25
64
1.5
Clutch--reverser casing/rear transmission--gearbox casing retaining bolt (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12x1.25
98
10
87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 1
5
List of specific tools required for the various operations described in this Section.
SPECIAL TOOLS
CAUTION 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.
1
2
380000236 Tractor disassembly trolley. 380000227 Clutch casing lift hook. 380000301 Rotating stand for overhaul operations. 380000271 Front bracket (with 380000301). 380000272 Rear bracket (with 380000301).
4
3
5
6
7
X
26181
10
9
8 3
Reverser longitudinal section
1. 2. 3. 4. 5.
Reverser shaft. Seal. Needle bearing. Reverser drive gear unit. Needle bearing.
6. 7. 8. 9. 10.
Reverser control synchroniser. Seal. Reverser driven gear unit. Driven gear pin (8). Seal.
NOTE: When fitting apply sealing compound to surfaces X as shown on page 12, Chap. 4. 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 1
6
4 Reverser cross--sectional views 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Reverser control fork. Reverser control synchroniser. Reverser control external lever. Seal. Circlip. Thrust washer. Reverser intermediate gear unit. Needle bearing. Thrust washer. Seal. Intermediate gear journal (7).
87679925A - 12 - 2007
12. Stop plate for journals (11 and 13). 13. Reverser driven gear pin. 14. Reverser control rod. 15. Spacer. 16. Reverser control synchroniser. 17. Poppet ball. 18. Ball spring (17). 19. Poppet ball retaining screw (the screw must be smeared with one of the sealing compounds listed in Section 00).
SECTION 21 -- TRANSMISSIONS -- CHAPTER 1
7
DESCRIPTION AND OPERATION The reverser is a mechanical device making it possible to obtain 12 forward gears and 12 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.
REVERSER TROUBLESHOOTING
Problems
Spontaneous shuttle disengagement
Possible Problem
Solutions
1. External levers and relay rods Adjust correctly. incorrectly adjusted.
2. Synchroniser teeth damaged. Remove the clutch casing and replace the synchroniser.
3. Engagement stroke incomplete. Difficulty in engaging the reverser
Eliminate the cause and restore full engagement travel.
1. External levers and relay rods Adjust correctly. incorrectly adjusted. 2. Stiffness and/or seizure of Check rod pivots and lubricate. external levers and rods. 3. Main clutch dragging.
see page 5, Section 18.
4. Synchroniser damaged.
Remove the clutch casing and replace the synchroniser.
5. Internal controls do not slide Overhaul the controls. easily: rods, forks and sleeves. Reverser is noisy
1. Worn or damaged internal Remove the clutch casing and parts. replace the damaged parts.
87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 1
8
CLUTCH--REVERSER CASING 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. In order to work on the reverser, detach the cab or platform as described in Section 90 and the clutch casing as described in Section 4. Then proceed as follows: 1. Secure the clutch--reverser casing (1) on the stand 380000301 (2) using the two brackets 380000271 and 380000272.
1
2
24984
5 2. Take off the retaining pin, remove the relay rod (2) and the internal lever (1).
1
2
26185
6
3. Take out the grub screw (1), remove the spring and poppet ball.
1 24989
7
87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 1
9
4. Remove the circlip (1) and retrieve: The bearing and the thrust washers. The synchroniser unit together with the control fork and rod. The reverser driven gear (2) with its needle bearings and spacer.
1 2
26186
5. Extract the reverser driving gear (1) and needle bearings.
8
1
24994
9 6. Remove the circlip (1) retaining the bearing and fixing the reverser driving shaft.
1
24995
7. Operating from the front of the clutch--reverser casing and using an aluminium punch (2), remove the reverser driving shaft (1) from the rear of the casing.
10
1
2
24997
11 87679925A - 12 - 2007
10
SECTION 21 -- TRANSMISSIONS -- CHAPTER 1
8. Release the retaining clips and extract the sliding sleeves (1).
1
24999
9. Remove the nuts and washers then remove the sleeve support cover (1).
12
1
25000
13 10. Take out the two bolts (1) retaining the sliding sleeve forks (2).
1
2
25001
14
11. Extract the two clutch external levers (1) and remove the relative forks (2).
1
2 25002
15 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 1 12. Straighten out the notching, remove the bolt (1) retaining the reverser driven shaft pin locking plate (2) and the intermediate gear pin, extracting the parts from the rear of the casing.
11
1
2 25004
13. To refit the reverser proceed as follows.
16
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Study the illustrations in figs. 3 and 4 for the positioning of the various parts.
--
Respect the tightening torques prescribed on page 4.
--
Fit the intermediate gear pin, complete with all parts, and the reverse driven gear pin and secure with the plate and bolt.
--
Fit the sliding sleeve forks on the clutch levers and secure with the bolts.
--
Fit the sliding sleeve support cover and secure with the nuts.
--
Assemble the sliding sleeves unit on the support and secure to the fork with the clips.
--
Working from the rear of the clutch--reverser casing, fit the reverser driving shaft and secure to the casing with the support bearing snap ring.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 1
12 --
Fit the shuttle driving gear and bearings on the driving shaft.
--
Fit the reverser driven gear and bearings on the driven shaft.
--
Assemble the synchroniser unit (control forks, rods, thrust washers and bearing) and insert the relative snap ring.
--
Fit the poppet ball, spring and bolt smeared with one of the sealing compounds listed in Section 00.
--
Position the internal lever, insert the drive lever and secure with the relative circlip.
--
Detach the clutch--shuttle casing from stand 380000301.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 1
13
26188
Longitudinal section of transmission with reverser, dual disk clutch and mechanical PTO
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16
14
SECTION 21 -- TRANSMISSIONS -- CHAPTER 1
Longitudinal view of transmission with shuttle, single disk and electro--hydraulic PTO
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17
SECTION 21 -- TRANSMISSIONS -- CHAPTER 2
1
SECTION 21 -- TRANSMISSIONS Chapter 2 -- Reverser and creeper unit CONTENT Description
Page
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Transmission diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Reverser--clutch casing and creeper unit D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 End float adjustment between shaft and support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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2
SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 REVERSER DATA
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mechanical type with spur gearing,located between the main clutch and the gearbox. Composed of no. 1 driving gear, no. 1 intermediate gear and no. 1 idler gear
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
hand lever located on left--hand side of the operator
End float adjustment between gearbox main shaft and clutch casing output shaft synchronizer support Spacer thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
3 -- 3.25 -- 3.50 -- 4
CREEPER UNIT DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cascading with spur gearing, located between the main clutch and the gearbox, in series with the reverser. Providing 20 forward gears and 12 reverse gears
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with lever located on right--hand side of operator
TRANSMISSION DATA
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 speed, constant--mesh, with synchronisers on all gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
helical
Reduction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ordinary gear train with 3 ranges providing a total of 12 gears
-- gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
spur
Gearbox and reduction unit controls . . . . . . . . . . . . . . . . . . . . . . . . .
independent, by means of two handlevers located on right--hand side of operator
For missing data see Chapter 1 Section 27.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 2
3
TRANSMISSION DIAGRAMS
49 18
A
16
36
40
43 33 27 21 17
27
b
31
d 44
24
57
16
d
38 33 13
36
23 50 39 4652
b
12 29
23
34--4wd 37--2wd
c
72
10
34
c
13 25 65
a 49
B
18
16
36
45
37 30
43 24
17
27
b
31
d 44
16
24
57
38 29 13
d 36 12 29
35 42
23 50 50
34
10
23
b c
34--4wd 37--2wd 13 25
72
c
65
a MDM1518A
1 A. Transmission diagram 30 km/h. B. Transmission diagram 40 km/h.
a. Front axle with 4--wheel drive. b. Bevel drive. c. Final reduction gears. d. Differential lock.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 2
4
C1 --98 Nm
C2 --17 Nm
C3 --17 Nm C4 --28 Nm
26189
2 BOLT TORQUES
PARTS TO BE TIGHTENED
Thread
Bolts or nuts securing reverser--clutch casing and creeper unit to the engine (C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torque Nm
kgm
M12x1.25
98
10
Sleeve cover retaining nuts (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M8x1.25
17
1,7
Reverser--creeper driven shaft cover retaining nuts (C3) . . . . . . .
M8x1.25
17
1,7
Gearbox driving and driven shafts bearing cover screws (C4) . . .
M8x1.25
28
2,9
Creeper and reverser--clutch casing/rear transmission--gearbox casing retaining bolt (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12x1.25
98
10
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 2
5
SPECIAL TOOLS
CAUTION The operations described in this section can only be carried out with the 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.
380000227
Clutch casing lift hook.
380000301
Rotating stand for overhaul operations.
380000271
Front bracket (with 380000301).
380000272
Rear bracket (with 380000301).
List of specific tools required for the various operations described in this Section.
380000236
Tractor disassembly trolley.
26191
3 Support bracket for fitting the transmission driving shaft seal (Mark tool with no. 50043) (Measurements in mm) Make in UNI C40 material
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6
SECTION 21 -- TRANSMISSIONS -- CHAPTER 2
26192
4 Striker for transmission driving shaft seal assembly (Mark tool with no. 50137) (Measurements in mm) Make in UNI C40 material
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 2
1
2
3
10
4
9
7
5
6
7
8
26193
5 Longitudinal section of reverser--creeper 1. 2. 3. 4. 5.
Reverser and creeper shaft. Seal. Retaining snap ring. Creeper gear unit. Reverser--creeper synchroniser.
6. 7. 8. 9. 10.
Reverser--driven shaft gear unit. Creeper unit driven gear. Thrust washer. Reverser driven shaft. Seal.
NOTE: When fitting apply sealing compound to surfaces X as shown on page 12, Chap. 4.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 2
8
6 Cross--sectional views of reverser--creeper 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Reverser control fork. Poppet ball. Reverser control synchroniser. Seal. Reverser control external lever. Creeper fork. Poppet ball. Creeper unit external control lever. Seal. Creeper gear unit.
87679925A - 12 - 2007
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Reverser intermediate gear. Needle bearing. Gear journal (11). Seal. Pin retaining bolt (13). High gears pawl. Reverser and creeper control rod. Reverser control synchroniser. Creeper gear unit. Rod retaining bolt (17) (the bolt must be smeared with one of the sealing compounds listed in Section 00.
SECTION 21 -- TRANSMISSIONS -- CHAPTER 2
9
DESCRIPTION AND OPERATION The reverser--creeper unit is a mechanical device providing 20 forward speeds and 12 reverse speeds.
The creeper unit only intervenes in slow and medium slow 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 synchroniser control gear and a driven gear. The synchroniser is the same for the reverser.
The creeper unit is installed in series with the reverser and is controlled by a lever located on the right--hand side of the operator. The reverser is composed of a group of three spur gears: shuttle driving gear, intermediate gear and shuttle driven gear, engagement is by means of a synchroniser located in the gear unit. The reverser--creeper unit is installed inside the clutch casing, between the clutch and the gearbox. Lubrication is by means of the oil in the rear transmission/gearbox.
REVERSER--CREEPER TROUBLESHOOTING Problems
Possible Problem
Solutions
Spontaneous reverser--creeper 1. External levers and relay rods Adjust correctly. disengagement. incorrectly adjusted. 2. Synchroniser teeth damaged. Remove the clutch casing and replace the synchroniser. 3. Engagement stroke incomplete.
Eliminate the cause and restore full engagement travel.
The reverser--creeper engages 1. External levers and relay rods Adjust correctly. with difficulty. incorrectly adjusted. 2. Stiffness and/or seizure of Check rod pivots and lubricate. external levers and rods. 3. Main clutch dragging.
See page 5, Sect. 18.
4. Synchroniser damaged.
Remove the clutch casing--gearbox and replace the synchroniser.
5. Internal controls do not slide Overhaul the controls. easily: rods, forks and sleeves. The reverser--creeper is noisy.
1. Worn or damaged internal Remove the clutch casing and replace the damaged parts. parts.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 2
10
REVERSER--CLUTCH CASING AND CREEPER UNIT Renew
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 work on the reverser creeper unit, detach the cab or platform as described in Section 90 and the clutch casing as described in Section 4. Then proceed as follows: 1. Position the casing on the rotating stand 380000301 using the brackets 380000271 and 380000272.
22893
7
2. Remove the retaining ring (1) and extract the gear (2).
1 2
22894
8 3. Remove the circlip (1).
1
26198
9
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 2
11
4. Remove the fork sliding rod retaining bolt (1).
26199
10 5. Remove the synchroniser unit (1) together with the sliding rod, forks and gears.
26200
11 6. Extract the gear unit (1) and the roller bearings then remove the thrust washer.
26201
12
7. Working from the opposite side of the casing, remove the retaining clips (2) and extract the clutch pressure plate bearing unit (1).
26202
13 87679925A - 12 - 2007
12
SECTION 21 -- TRANSMISSIONS -- CHAPTER 2
8. Remove the retaining bolts (2) and the control forks (1).
26203
14 9. Take out the retaining bolt (15, fig. 6) and remove the reverser intermediate assembly (1).
26204
15 10. Remove the nuts, washers and cover (1).
22902
16
11. Working from the rear remove the snap ring and shaft (1) with relative bearing.
26205
17 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 2
13
12. Remove the nuts and washers and the clutch sleeves support (1), together with the bearing.
26206
18
13. Take off the circlip (2) and remove the shaft (1) together with the bearing.
26207
19 14. Take off the circlip (1) left in its seat.
26208
20
15. Using a suitable tool, extract the seal (1).
26209
21 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 2
14
16. To refit all the shuttle and creeper parts in the casing proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Study the illustrations in figs. 5 and 6 for the positioning of the various parts.
--
Respect the tightening torques prescribed on page 4.
--
To fit the seal (1, fig. 21) observe the instructions of operations 17. รท 24.
--
Assemble the drive shaft, complete with bearing and circlips.
--
Fit the snap ring in the sleeves support, position the spacer then fit the clutch sleeves support cover.
--
Assemble the reverser and creeper driven gear unit shaft.
--
Fit the driven gear shaft cover and secure in position with the bolts.
--
Assemble the reverser intermediate gear unit and secure with the relative bolt.
--
Fit and secure the clutch forks to the relative levers.
--
Assemble the pressure plate bearings and secure with relative clips.
--
Assemble the driven gear unit, bearing and thrust washer.
--
Assemble the synchroniser unit and all gears and forks then secure in position with the circlip.
--
Fit the rod retaining bolt smearing the thread with one of the sealing compounds listed in Section 00.
--
Assemble the gear on the shuttle driven shaft and secure with the snap ring.
--
Remove the clutch--shuttle and creeper casing from stand 380000301.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 17. Fit the circlip, seal side (1, fig. 20), in its seat. 18. Make the bracket for tool 50043 (3, fig. 22) and drift 50137 (4, also see figs. 3 and 4). 19. Fit the bracket (3) on the clutch casing (2), insert the striker (4, see fig. 4) in the seal seat touching the circlip (1, fig. 20). 20. Tighten the nut (1, fig. 22) until the distance (H) between the bracket and the nut is 3.3 รท 3.6 mm then secure the nut with a locknut (5).
15
1 5
2 3
4
26210
22 21. Extract the punch (1), remove the bracket (2) and the circlip (1, fig. 20). 22. Insert a new seal (2, fig. 5), in its seat, fit the bracket (2, fig. 23) back on the clutch casing and insert the punch (1) on the bracket.
26211
23 23. Force the seal in until the nut (1, fig. 22) is flush against the bracket (2). 24. Remove the bracket (2), extract the punch (1) and then proceed to assemble the other parts. NOTE: Leave the drift (1) and nut in this position even when replacement operations are terminated. For future replacements just check that the distance (H, fig. 22) is as prescribed.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 2
16
END FLOAT ADJUSTMENT BETWEEN GEARBOX MAIN SHAFT AND CLUTCH CASING OUTPUT SHAFT SYNCHRONIZER SUPPORT
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
In the mating between the clutch casing (1) and the related gearbox (2), the gearbox main shaft (4), and the support (5) of the reverser synchronizer (3) there should be a certain endfloat between the two (G, fig. 26): G = 0.2 ÷ 0.45 mm
24 Take the vertical machined wall of the transmission as reference and, with the aid of a depth gauge, measure the stand--out (distance “X”) of the gearbox main shaft.
25 Take the vertical machined wall of the clutch casing as reference and, with the aid of a depth gauge, measure the stand--in (distance “Y”) between the slot of part (5, fig. 24) and the surface. The difference between the distances: (Y -- X) gives the free distance.
26 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 2
17
The maximum thickness (Smax) to be added will be: Smax = Y - X - 0.2 The minimum thickness (Smin) to be added will be: Smin = Y - X - 0.45 Choose a shim (S) from the ones listed in the table on page 2. Smax > S > Smin
26
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18
SECTION 21 -- TRANSMISSIONS -- CHAPTER 2
26212
Longitudinal section of the reverser and creeper
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27
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
1
SECTION 21 -- TRANSMISSIONS Chapter 3 -- Power Shuttle transmission -- Version 12X12 CONTENT Description
Page
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Transmission diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Range and gear lever position sensor adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Clutch casing with Power Shuttle. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Driving shaft. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Clutch (A) D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Clutch (B) D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Transmission fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
2
TRANSMISSION DATA Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 speed, constant--mesh, with synchronisers on all gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
helical
Reduction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ordinary gear train with 3 ranges providing a total of 12 gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
spur
Gearbox and reduction unit controls . . . . . . . . . . . . . . . . . . . . . . . . .
independent, by means of two hand levers located on the right-hand side of the operator
Range and gear position sensor adjustment: available spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
0.5 -- 1.0 -- 1.5
POWER SHUTTLE UNIT MAIN DATA Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Shuttle gears and services working pressure . . . . . . . . . . .
mounted on the outer left--hand side of the clutch casing, comprising: -- no. 2 proportional solenoid valves controlling clutches A and B; -- no. 1 discharge solenoid valve -- one pressure regulating valve; -- no. 2 unions for checking the pressure of the various clutches. bar
15.7 ÷ 16.7 (16 ÷ 17 kg/cm@)
By--pass valve spring (11, fig. 7): --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
20.5
--
spring length under load of 41.2 ÷ 45.2 N (4.2 ÷ 4.6 kg)
mm
16
Mating clearance between: --
pressure control valve and relative seat on hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
0.025 ÷ 0.035
Pressure control valve spring (9, fig. 7): --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
127
--
spring length under load of 279 ÷ 304 N (28.5 ÷ 31 kg) . . . . .
mm
102.5
bar
2.9 ÷ 3.7 (3 ÷ 3.8 kg/cm@)
Power Shuttle transmission lubrication pressure . . . . . . Lubrication pressure control valve spring (1, fig. 10): --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
38
--
spring length under load of 29 ÷ 31 N (3 ÷ 3.2 kg) . . . . . . . . .
mm
24.5 (overleaf)
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
3 (overleaf)
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)
Power Shuttle unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
to reverse without having to stop the tractor or use the clutch pedal.
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of hand lever located under the steering wheel, to the left--hand side of the operator.
Number of driven plates in each clutch . . . . . . . . . . . . . . . . . . . . . .
no.
5
Driven disc thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
2.65 รท 2.75
Driven plate material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
N 401--2
Number of driving plates in each clutch . . . . . . . . . . . . . . . . . . . . . .
no.
5
Drive disc thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
2.15 รท 2.25 or 2.35 รท 2.45
Driving plate material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thickness of clutch assembly under a load of 1600 N (163.1 kg)
steel mm
25.3 รท 25.5 (1)
Power Shuttle clutch pistons return spring (13, fig. 6): --
number of springs for each clutch . . . . . . . . . . . . . . . . . . . . . . .
no.
7
--
spring free height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
4,2
--
spring height under a load of 2108 N (215 kg) . . . . . . . . . . . . .
mm
3,3
(1) Value to obtain by varying the thickness of the driving plates.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
4
TRANSMISSION DIAGRAMS 40 39
34
43 33 27 21
17
27
b
31
d
A
44
42
33
36
13
d 36 12 29
39 4652
23 50
23
b
34--4wd 37--2wd
c
72
34
10
c
13 25 65
a 45 39
34
43 37 30 24
17
27
b
31
d
B
44
42
29
36
13
d 36 12 29
b c
23 50 35 4250
34
10
23
34--4wd 37--2wd 13 25
72
c
65
a MDM1519A
1 A. Transmission diagram 30 km/h. B. Transmission diagram 40 km/h.
87679925A - 12 - 2007
a. b. c. d.
Front axle with 4--wheel drive. Bevel drive. Final reduction gears. Differential lock.
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
5
2
BOLT TORQUES PARTS TO BE TIGHTENED
Thread
Tightening torque Nm
kgm
For missing data see Chapter 1. Driven shaft manifold cover retaining nut (C1) . . . . . . . . . . . . . . . .
--
22 ÷ 25
2.24 ÷ 2.55
Lubrication manifold retaining screw (C2) . . . . . . . . . . . . . . . . . . . .
--
22 ÷ 25
2.24 ÷ 2.55
Clutch A bell housing retaining nut (C3) . . . . . . . . . . . . . . . . . . . . . .
--
22 ÷ 25
2.24 ÷ 2.55
Flexible coupling retaining nut (C4) (•) . . . . . . . . . . . . . . . . . . . . . . .
--
87
8,84
Control valve cap (C1, fig. 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
70 ÷ 90
7.1 ÷ 9.2
Clutch pressure control union (C2, fig. 3) . . . . . . . . . . . . . . . . . . . . .
--
22 ÷ 29
2.24 ÷ 3
Oil delivery union (C3, fig. 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
70 ÷ 90
7.1 ÷ 9.2
Oil delivery T union (C4, fig. 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
48 ÷ 66
4.9 ÷ 6.7
(•) Apply 1 or 2 drops of LOCTITE 270 before tightening.
87679925A - 12 - 2007
6
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
3
87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
7
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.
380000227
Clutch casing lift hook.
X 380000290
Tool for fitting internal hub seals on A and B clutches.
380000301
Rotating stand for overhaul operations.
X 380000296
Tool for fitting clutch driving shaft seal (with 380000258).
380000271
Front bracket (with 380000301).
380000278
380000272
Rear bracket (with 380000301).
X 380000289
Limp home device.
X 380000291
Tool for A and B clutch springs.
X 380000843
Connector to access HH diagnostic programs.
Hydraulic pressure testing kit (use with union 295032).
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
8
27893
Tool to make for clutch casing--engine removal--installation (mark tool with no. 50169 -- Measurements in mm) Make in UNI C40 material
4
MDB1753A
Guide pin to be made for clutch A cover removal--installation (mark tool with no. 50223 -- Measurements in mm) Make in UNI C40 material
87679925A - 12 - 2007
5
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
9
POWER SHUTTLE CLUTCH CASING SECTION
MDM0339A
6
Longitudinal cross--sectional view of Power Shuttle gearbox 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Forward gear clutch bell housing A. Clutch A piston. Clutch A. Clutch A bottom / clutch B driving gear. Clutch B bottom. Reverse gear clutch B. Clutch B piston. Reverse driving gear / shaft. Reverse driving gear. Forward gear drive shaft. Gearbox main shaft driving gear.
12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Flexible coupling. Piston return springs in the neutral phase. Lubrication manifold. Transmission shaft lubrication line. Reverse intermediate gears. Keying ball. Clutch casing transmission shaft. Reverse idler gear shaft retaining pin. Reverse idler gear. Reverse idler gear shaft. Bearing.
NOTE: When fitting apply sealing compound to surfaces X as shown on page 11.
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10
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3 POWER SHUTTLE CONTROL VALVE
7 Power Shuttle transmission control valve 1. Transmission oil temp sensor.
7. Heat exchanger hot oil delivery union.
2. Unions for diagnostic tests on clutch lines.
8. Connections to the forward and reverse gear clutches.
3. Reverse proportional solenoid valve.
9. Pressure relief valve spring.
4. Forward proportional solenoid valve.
10. Pressure relief valve spool.
5. Dump solenoid valve.
11. Lubrication by--pass valve.
6. Power shuttle control valve supply union / oil delivery to the services control valve.
12. Cold oil lubrication line to the clutch casing.
87679925A - 12 - 2007
13. Connection to the discharge.
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
11
DESCRIPTION AND OPERATION Speed Transmission 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 3 gear ranges. The gearbox and the range gears are controlled by two independent levers located on the right--hand side of the operator. Lubrication is by means of the oil in the rear transmission/gearbox.
Power Shuttle unit (see fig. 6) The Power Shuttle unit is composed of two multi--disk clutches in an oil bath located in the front part of the clutch casing, and is controlled by a control valve attached to the left--hand side of the clutch casing. This provides hydraulic control of 4 gears for each range, both forward and in reverse. Gear and range selection is carried out by means of the clutch pedal and operating the control levers, located on the right--hand side of the operator. The front clutch (A) commands the forward gears and the rear clutch (B) commands the reverse gears. Forward or reverse gear is selected by means of the lever under the steering wheel to the left of the operator; there is no need to use the clutch pedal. The Power Shuttle unit provides 12 forward gears and 12 reverse gears.
MDB1772A
Sealing compound application diagram for clutch A cover. The types of sealing compounds to be applied are specified in Section 00.
8
87679925A - 12 - 2007
12
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3 DESCRIPTION AND OPERATION
Main hydraulic circuit (see fig. 9) The power steering pump draws filtered oil from the filter on the intake (17) it sends the oil to the power steering control valve (6), the oil returning from the orbitrol goes to the transmission control valve (15) where it finds the pressure regulating valve governing the clutches and services (1, fig. 10). The valve regulates the oil at a pressure of 15.7 รท 16.7 bar (16 รท 17 kg/cm@), afterwards the oil reaches the discharge solenoid valve that, finding it closed, does not continue, on the other side it reaches the services control valve (13) through the outlet (b). Power Shuttle transmission -- Lubrication circuit (see fig. 10) The excess oil goes into the lubrication circuit, the valve regulating the lubrication pressure is on the manifold of the main shaft and sets the pressure to 2.9 รท 3.7 bar (3 รท 3.8 kg/cm@). Depending on the temperature of the oil it takes two specific routes: cold and therefore dense oil passes with difficulty through the cooler (1, fig. 9) then it opens the by--pass valve (11, fig. 7) and goes straight to lubrication. Hot fluid oil passes easily through the cooler so it leaves the control valve through the pipe (e, fig. 10) it reaches the cooler (1, fig. 9) then returns to the control valve on the pipe (h, fig. 10) and goes straight to lubrication passing inside the by--pass valve; a portion crosses the pipe (i, fig. 10) reaches the power take--off (11, fig. 9). The oil from the lubrication manifold lubricates the two clutches and the main shafts and, through the pipe (15, fig. 6), reaches the transmission shafts of the transmission and clutch casing and lubricates everything as far as the pinion.
87679925A - 12 - 2007
Power Shuttle transmission -- Clutch A at rest / engaged (see fig. 11 and 12) With the machine stationary and the tractor running, the oil under pressure reaches the base of the discharge solenoid valve (see fig. 11). Since this solenoid valve is normally on discharge all the rest of the control valve is kept in this condition via the pipe (c, fig. 11 and 12). On deciding to start driving the tractor, either by using the clutch pedal and moving the shuttle lever into forward or reverse gear or by using only the shuttle lever, a signal is sent to the control unit that opens immediately energizing the discharge solenoid valve that opens and sends the oil under pressure into the pipe connected with the end portion of the clutch control solenoid valves. If forward gear is selected the control unit sends a signal to the solenoid valve of clutch A that modulates making the oil pass gradually and packing the clutch A moving the tractor forwards (see fig. 12). In a similar manner it works in reverse gear as soon as the control unit controls the discharge solenoid valve and proportionally controls the reverse gear solenoid valve.
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
13
HYDRAULIC CIRCUIT
Pressurised oil Intake and discharge oil Lubricating oil Oil at static rest
3
4
6
7
8
9
10
2 11 1
5
17
16
15
14
13
12
MDM0341A
9 Power Shuttle transmission -- Main hydraulic circuit
1. Heat exchanger.
10. PTO brake.
2. Steering pump.
11. Electrohydraulic PTO unit.
3. Steering cylinders. 4. Low pressure switch. 5. Front differential lock. 6. Power steering control valve. 7. Power take--off solenoid valve.
12. Rear differential lock. 13. User control valve. 14. Four wheel drive release solenoid valve. 15. Gearbox hydraulic control valve.
8. Differential lock solenoid valve.
16. Oil filter on delivery.
9. Four--wheel drive pipe.
17. Oil filter on suction.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
14
Pressurised oil Discharge oil
c
d
b
Lubricating oil 82.9 3.7 bar
a
e f a
g i
h
1 MDM0342A
10 Power Shuttle transmission -- Lubrication circuit
1. Lubricating pressure regulating valve. a. Oil from the power steering pump to the pressure regulating valve. b. Oil to the services control valve. c. Discharge oil. d. Discharge oil. 87679925A - 12 - 2007
e. Hot oil to the cooler. f. Lubricating oil (if hot it does not open the by--pass valve and goes to the cooler, if cold it goes straight to lubrication). g. Cold oil straight to lubrication. h. Oil from cooler. i. Oil to power take--off lubrication.
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
15
Pressurised oil Discharge oil
5
Lubricating oil
1
c
2
6 4 3 2
1
b
a
MDM0343A
Power Shuttle transmission -- Clutch A at rest 1.
Dump solenoid valve.
2.
Forward solenoid valve (proportional).
3.
Reverse solenoid valve (proportional).
4.
Reverse gear pipe diagnosis connector.
5.
Temperature sensor.
6.
11
Pipe to the reverse gear clutch.
a. Oil from the power steering pump to the pressure regulating valve. b. Oil to the services control valve. c. Discharge oil.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
16
Pressurised oil Discharge oil
5
Lubricating oil
1
c
2
6 4 3 2
1
b
a
MMM0344A
Power Shuttle transmission -- Clutch A engaged. 1.
Dump solenoid valve.
2.
Forward solenoid valve (proportional).
3.
Reverse solenoid valve (proportional).
4.
Reverse gear pipe diagnosis connector.
5.
Temperature sensor.
87679925A - 12 - 2007
6.
12
Pipe to the reverse gear clutch.
a. Oil from the power steering pump to the pressure regulating valve. b. Oil to the services control valve. c. Discharge oil.
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
17
RANGE AND GEAR POSITION SENSOR ADJUSTMENT Define the process of adjustment of the range (2 and 3) and gear (1) position sensor on Power Shuttle transmissions.
Gear lever status switch Put the gear lever into neutral, using a gauge measure the distance D between the end of the feeler (2) and the plane of the box (3). With the sensor (1) in your hand and the button at rest, measure the distance D1, between the inner face of the hexagon and the end of the button. For the sensor button to travel C = 2.4 รท 2.8 mm the adjustment thickness will be: S = D1 -- (D + C)
13
14 Range lever status switches Put the range lever onto fast, on both range lever status switches (2 and 3, fig. 13) using a gauge measure the distance D, between the end of the feeler (2) and the inner face of the recess where the sensor will be housed in the supporting box (3). With the sensor (1) in your hand, measure the distance D1, between the end of the button and the inner face of the hexagon. For the sensor button to travel C = 2.4 รท 2.8 mm the adjustment thickness will be: S = D1 -- (D + C)
15
NOTE: General Considerations: a) Check that the distance: D + S = 19.8 รท 20.2 mm b) Round down the value
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
18
Adjustment check In figure 16 there is a diagram of the lever status switches. If the adjustment is made during the phase of overhauling the gearbox, with the cab detached and with the aid of a tester switched onto ohmmeter, putting the rods at the ends of the switch, there must be the values in Ω listed in the following table with the gear levers in their various positions.
16
With the range lever in.........
Gearbox sensor G
With the gear lever in.........
Switch status
Ω
Analog--digital conversion H9 (Channel 16)
Neutral
Closed
560
67
1st
Open
2760
30
2nd
Open
2760
30
3rd
Open
2760
30
4th
Open
2760
30
Range sensor R1
Range sensor R2
Switch status
Ω
Analog--digital conversion H9 (Channel 17)
Switch status
Ω
Analog--digital conversion H9 (Channel 18)
Neutral
Open
2760
30
Open
2760
30
Medium
Closed
560
67
Open
2760
30
Fast
Closed
560
67
Closed
560
67
Low
Open
2760
30
Closed
560
67
If the check must be made with the cab down, it is then difficult to use the tester at the ends of the various buttons, in the diagnostic programs HH MENU in H9 at channels Ch 16 (G), Ch 17 (R1) and Ch 18 (R2), it is perfectly possible to test the lever status buttons and the display will show the digital conversion of the above--mentioned tables. NOTE: With program H9 it is possible to move the tractor. It is wise to test in motion and on ground that is not level but rather broken. The jolting produced and the vibration of the gear levers must not be enough to accidentally switch over the switches, even for a short time, thus causing fault code 2040.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
19
CLUTCH CASING WITH POWER SHUTTLE 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. In order to work on the reverser--creeper unit first detach the cab or platform as described in Sect. 90 and remove the clutch casing as described in Chapter 4. Then proceed as follows: 1. Fix the gearbox to the rotating stand 380000301 (1) using front 380000271 and rear 380000272 brackets. 2. Unscrew the retaining screws and remove the control valve (1).
17
18 3. Extract the oil drainage union (1).
4. Take out the screws fastening the cover of the clutch (1, fig. 6) screw three screws into the extraction holes (2) and remove the cover (1) and clutch A.
19
20 87679925A - 12 - 2007
20
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
5. Remove the circlip (1) locking clutch B on the related shaft.
6. Extract clutch B (1) from the shaft and remove.
21
22 7. Unscrew the retaining screws and the lubrication manifold (1) together with the transmission shaft unit lubrication line (15, fig. 6).
8. Take off the nuts fastening the transmission shaft lubrication cover (1) and then remove it.
23
24 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
21
9. Remove the circlip (1), transmission shaft fastener (18, fig. 6), together with the washer.
10. Extract the gearbox main shaft driving gear (1) (11, fig. 6).
25
26 11. Using a suitable punch, tap the transmission shaft (1) and extract it from the related bearing.
12. From the back, remove the transmission shaft (1) together with the reverse intermediate gear and the keying ball (16, fig. 6) between the two.
27
28 87679925A - 12 - 2007
22
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
13. Remove the grub screw (1) on the reverse idler gear unit pin.
14. Working from the back of the clutch casing, extract the reverse idler gear together with the pin (1) and the related bearing and thrust washer.
29
30 15. Using a suitable punch, tap the driving shaft (1).
16. Remove the driving shaft (1), working from the rear side of the clutch casing.
31
32 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
23
17. 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 in fig. 6 page 9 and fig. 33 page 24.
--
Before refitting the casings, supports and covers clean and de--grease the mating surfaces and apply sealing compound (approx. 2 mm in diameter) as shown in figure 8.
--
Respect the tightening torques prescribed on page 5.
--
Mount the driving shaft.
--
Fit the thrust washer, gear unit and reverse pin, securing in position with the screw.
--
Mount the clutch casing transmission shaft and lock it from the front with the washer and circlip.
--
Mount the transmission shaft lubrication cover and then screw on the retaining nuts.
--
Assemble and secure the lubrication manifold, complete with the transmission shaft lubrication line.
--
Position clutch B on the shaft and secure with the circlip.
--
Assemble and secure the cover and clutch A.
--
Insert the oil drainage union.
--
Re--fit the control valve.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
24
Longitudinal section of the main shaft. 1. 2. 3. 4. 5. 6. 7. 8. 9.
Gearbox driving gear thrust circlip. Reverse driving gear rear thrust circlip. Reverse driving gear. Reverse gear shaft internal bearing retaining circlip. Reverse driving gear / shaft. Forward gear shaft. Bearing. Circlip. Forward gear clutch driven hub A.
DRIVING 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. For the correct orientation of the various parts, refer to the picture 33. To remove the gearbox, proceed as follows. 1. 2. 3. 4.
Remove the circlips (1 and 2, fig. 33). Extract the reverse driving gear (3, fig. 33). Take out the circlip (4, fig. 33). Grip the forward gear shaft (6, fig. 33) from the back and tap on the reverse gear / shaft (5, fig. 33) on the back and extract it.
87679925A - 12 - 2007
33
Bearing. Circlip. Reverse gear clutch hub retaining circlip B. Circlip. Forward gear clutch A bottom / reverse gear clutch B driving hub. 15. Retaining circlip part 14. 16. Forward gear clutch A bell housing circlip. 10. 11. 12. 13. 14.
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
25
5. Remove the bearing (7, fig. 33) from the forward gear shaft. 6. Remove the circlip (8, fig. 33). 7. Remove the main shaft, proceeding as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Fit the circlip (8, fig. 33).
--
Mount the bearing (7, fig. 33) inserting it from the back of the forward gear shaft, make it flush against the ring.
--
Insert the forward gear shaft (6, fig. 33), from the front, into the reverse gear shaft (5, fig. 33), on the back, until the latter reaches the position reaching the bearing.
--
Insert the bearing retaining circlip (4, fig. 33) into the reverse shaft.
--
Insert the gear (3, fig. 33) from the back of the forward gear shaft, make it flush with the bearing.
--
Insert the circlips (2 and 1, fig. 33).
CLUTCH 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. Proceed as follows. 1. Remove the circlip (1) retaining the forward gear clutch A bottom / reverse gear clutch driving hub B (3, fig. 6).
34
87679925A - 12 - 2007
26
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
2. Recover the unit (1) composed of: -- forward gear clutch A bottom / reverse gear clutch driving hub B (14, fig. 33) -- bearing (10, fig. 33) -- clutch A driven hub (9, fig. 33) -- circlip retaining bearing on the hub (11, fig. 33) -- circlip retaining bearing on part 14 (13, fig. 33)
3. Remove the clutch A disk assembly (1), the separating springs and the anti--rotation pin.
35
36 4. Using a screwdriver (1) remove the seal and the circlip (16, fig. 33), with an appropriate pair of pliers.
5. Using a brass punch, tap on the hub (1) on clutch casing A.
37
38 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
27
6. Extract the cover (1) and remove the clutch casing A (2).
7. Position the clutch casing A (1) under a press and, using tool 380000291 (2) and adapter, compress the springs, remove the stop ring (3) and remove the Belleville washer.
39
40 Replacing the seal on the clutch casing internal hub 8. Position the O--Ring seal (1) in the relative seat on the clutch casing internal hub.
9. Position the external ring (1) of the seal on the guide on tool 380000290 (2).
41
42 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
28
10. Position the guide (2) on tool 380000290 on the clutch casing internal hub and push the ring (3) into position using the press (1) on tool 380000290.
11. Refit the clutch A, and proceed as follows:
ATTENTION
43
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 12. Position the clutch casing A (1) under a press and, using tool 380000291 (2) and adapter, compress the Belleville springs and fit the spring stop ring.
44 13. Fit the casing (1) of the clutch A on its cover (2) and secure it with the circlip, then fit the seal.
14. Assemble the clutch disk assembly on the clutch casing A as described here: --
45
Insert the first metal disk (2) on the casing (1) of the clutch A.
46 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
29
15. On the casing (1) of the clutch A, make a reference mark (2) to time the splits of the springs during the assembly operation.
16. Do the timing of the swings (1) and splits (2) of the springs as shown in the figure.
47
48 17. Insert the first spring on the casing (1) of the clutch A, keeping the split of the spring (2) timed with the reference mark (3) made beforehand.
18. Insert the first clutch disk (2) on the casing (1) of the clutch A, centring the spring (3) previously mounted on the outer edge of the disk (2).
49
50 87679925A - 12 - 2007
30
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
19. Insert the second metal disk (2) on the casing (1) of the clutch A.
20. Insert the second spring (3) on the casing (1) of the clutch A, keeping the split timed with the reference mark (2) made beforehand.
51
52 21. Insert the second clutch disk (2) on the casing (1) of the clutch A, centring the spring (3) previously mounted on the outer edge of the disk (2). -- Complete fitting the disk assembly and clutch springs A on the casing following the above method.
22. Inside the split in the separating springs, insert a pin (1) into the space between the teeth of the disks keyed onto the clutch bell housing. This is to prevent some springs from turning and not respecting the timing.
53
54 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
31
23. Refit the unit (1) composed of: -- forward gear clutch A bottom / reverse gear clutch driving hub B (14, fig. 33) -- bearing (10, fig. 33) of clutch A driven hub (9, fig. 33) -- circlip retaining bearing on the hub (11, fig. 33) -- circlip retaining bearing on part 14 (13, fig. 33).
24. Fit the circlip (1) retaining the unit previously fitted inside the clutch A.
55
56 --
Clutch B 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. Proceed as follows. 1. Remove the circlip (1), the disk assembly, separating springs and the anti--rotation pin.
2. Carry out operations no. 3. and from no. 7. to no. 21. described above for clutch A to correctly disassemble/assemble the disks and the springs of the clutch B.
57
87679925A - 12 - 2007
32
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
3. In a similar manner to operation 22 of clutch A assembly, insert the pin into the space between the teeth of the metal disk keyed onto the clutch B bell housing, left free by the split in the springs.
4. Take great care over positioning the disk of clutch B. One tooth up it has a retaining pin (1), the position of this tooth must be very far from the space where the pin is inserted described in the preceding operation.
58
59 5. Insert the retaining circlip with the pliers. Keep the tooth with the pin in the middle of the split in the ring. The pin will prevent the ring from turning and therefore the pin from coming out that was inserted in operation 3.
60
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
33
CALIBRATIONS Fault codes If the Faults Detection Logic reads a fault condition, the code will flash on the information monitor. In this manner, the fault condition can be displayed whilst in HH mode. During calibration, certain faults may be masked.
ATTENTION
2024
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.
61
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 á 50 °C. Unless otherwise specified, the levers: - Shuttle control; - gear control; - range gear control; - creeper lever; are in the NEUTRAL position.
HH MENU ACCESS 1. Turn the starter switch (1, fig. 63) to A (OFF) and connect the tool 380000843 (2) to the diagnostics socket (1).
62
87679925A - 12 - 2007
34
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
2. Turn the starter switch (1) to B, the information monitor will show HH MENU plus HO, or HP, or RJ, or JB; two arrows are displayed at the bottom showing the possibility of passing from one option to another. HP = Standard control panel. HO= Advanced control panel. RJ = Transmission, Differential Lock, Four--Wheel Drive and Power Take--Off. JB = Advanced keypad. MDB1669A
63
3. By using the clock adjustment buttons: minutes adjustment (1) and hours adjustment (2) it is possible to pass between the options.
0 x100
1 3
2
64 4. Select the HH menu of the control unit RJ by pressing the push--button (3, fig. 64) and access the sub--system, using the clock adjustment buttons: minutes adjustment (1, fig. 64) or hours adjustment (2, fig. 64) it is possible to access the H1 menu of the control unit RJ of the gearbox, then pressing the push--button (3, fig. 64) to go into calibration.
5. The menu of the selected control unit appears on the information monitor. If the control unit gives a negative response to the ADIC message for menu access the attention sign will appear, in this case you need to turn the switch (1, fig. 63) to A (OFF) and repeat the HH MENU access procedure after checking the supply and connection of the relevant control unit are correct. A. Correct access. B. Module responds incorrectly.
HHMENU RJ
RJ H1
RJ H1
65
RJ HH
HHMENU
A
B 66
87679925A - 12 - 2007
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3
35
CLUTCH CALIBRATION H1 MENU TRANSMISSION Access the HH MENU RJ as described on page 18 and proceed as follows. --
Select the H1 MENU with buttons (1) and (2), press key (3) to access the above--mentioned H1 MENU.
--
To calibrate the clutches the operator must be seated in the driving seat.
--
Press the clutch pedal, start up the engine and take it to a speed of 1250 ÷ 1350 rev/min;
--
0 x100
1 3
2
Engage the 1st gear and III range, move the Power Shuttle control lever onto forward travel and release the clutch pedal.
67
NOTE: The clutches can also be calibrated without the tool 380000843, just keep the buttons (1 and 2, fig. 22) for minutes adjustment or hours adjustment pressed simultaneously while starting the machine. --
If you have selected the H1 MENU you need to do the calibrations or turn the switch (1, fig. 18) to A (OFF).
--
The central display will show CAL then the transmission oil temperature 50 °C.
NOTE: Clutch calibration is possible with both high and low oil temperatures, even if the display signals two alarm conditions to the driver: CL -- in the case of cold oil (under 20 °C) CH -- in the case of hot oil (over 100 °C)
RJ
CAL
H1
50C 68 --
--
--
Using button (2 or 1, fig. 22) select clutch A or B then keep the button (1, fig. 22) pressed to do the calibration. The display will show in sequence: A = clutch to calibrate; I = vertical bar that, blinking, moves from the left to the right: 280 = progressive calibration value: A / 295 = end calibration value that alternates with the clutch. Release the button (1, fig. 22).
A RJ
H1
I 280 320
A 69
87679925A2 - 02 - 2010
36 --
--
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3 Using the button (2 or 1, fig. 22) select the clutch B and keep the button (1, fig. 22) pressed to calibrate the clutches. If a fault is found during calibration, the display will show the relevant error code U (see table on page 22).
b RJ
H1
I 280 A
320
70
NOTE: After selecting the clutch to calibrate with the button (2 or 1, fig. 22) it is possible to start automatic calibration by pressing button (2, fig. 22) for a few seconds, then automatically, both clutches will calibrate and, at the end, the central display will show End.
RJ
H1
A b End 71
--
After calibrating all the clutches turn the switch (1) to A (OFF) to save the calibrations.
MDB1669A
72
87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
37
Calibration error code Code
Meaning
U19
Oil temperature < 10 °C, calibration is not possible
U20
Wrong sequence, operate the Power Shuttle control lever and the clutch control pedal
U21
Engine speed too low
U22
Engine speed too high
U23
Power Shuttle control lever on neutral
U24
Wrong range selection (the III range is not engaged)
U25
Gear lever in neutral
U26
Clutch pedal pressed
U31
Tractor moving
U33
Parking brake disengaged
U34
Operator not seated in driving seat
U36
Calibration value too high
U37
Calibration value too low
CL
Low oil temperature < 20 °C
CH
High oil temperature > 100 °C
NOTE: For resolution of the error codes, refer to Section 55, Chapter 10.
87679925A - 12 - 2007
38
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
TRANSMISSION FAULT CODES The fault codes are shown on the dot--matrix display (1) of the analog--digital control panel (ADIC) and on the lower central display (2).
The disabling errors will be shown on the dot--matrix display of the control panel and will be visible for the driver.
73
74 Hidden and saved fault codes can be displayed by using the fault diagnosis mode of the “H” menus and are not visible for the driver. The “H” menu diagnostic mode can be used to access and clear the fault codes which may be stored in the various controllers. The H--menu diagnostic mode also contains many other useful functions which may be used to assist with diagnostics.
75 NOTE: To access the MENU HH to view the codes and, if necessary, clear them, refer to Section 55, Chapter 10.
87679925A - 12 - 2007
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3
39
TRANSMISSION FAULT CODE LISTING E.C.R. (*)
Code
Description of Fault
2011
Clutch pedal potentiometer signal too low
YES
2012
Clutch pedal potentiometer signal too high
YES
2014
Voltage from the gear neutral position switch is high
YES
2015
Voltage from the gear neutral position switch is low
YES
2016
Voltage from the range position switch (R1) is high
YES
2017
Voltage from the range position switch (R1) is low
YES
2018
Voltage from the range position switch (R2) is high
YES
2019
Voltage from the range position switch (R2) is low
YES
2021
Transmission harness disconnected
YES
2024
All the clutches must be calibrated
NO
2025
Engine speed (rpm) high
YES
2028
Clutch B not calibrated
NO
2029
Clutch A not calibrated
NO
2030
Critical code on transmission
NO
2035
Wheel speed too high
YES
2036
Engine speed (rpm) low
YES
2037
Clutch disconnect switch open circuit
YES
2038
Clutch B solenoid valve short to + 12 volts
NO
2039
Clutch B solenoid valve open circuit or short to ground
NO
2040
Inconsistent gear lever status switches.
YES
2041
Clutch A solenoid valve open circuit or short to ground
NO
2042
Clutch A solenoid valve short to + 12 volts
NO
2047
Clutch disconnect switch set too high
YES
2048
Clutch disconnect switch set too low
NO
2049
Wheel speed sensor too high
YES
2051
Oil temperature sensor open circuit
YES
2052
Oil temperature sensor short circuit
YES
2053
5 volt reference voltage too high
NO
2054
5 volt reference voltage too low
NO
2055
Shuttle lever forward switch voltage high
YES
2056
Shuttle lever forward switch voltage low
YES
2057
Shuttle lever reverse switch voltage high
YES
87679925A2 - 02 - 2010
40
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3
2058
Shuttle lever reverse switch voltage low
YES
2059
Shuttle Lever sw. disagree
YES
2061
No seat safety switch transition in the last 25 hours of work
NO
2069
Wheel speed sensor voltage too low
YES
2097
Short circuit to +12V to the discharge (dump) solenoid valve.
NO
2098
Short circuit to ground or circuit open to the discharge (dump) solenoid valve.
NO
2450
Configuration error
NO
(*) Enter the HH programs of the control panel select the H3 program, enter the ECR, then select the options: E -- show only severe codes, F -- show all codes for 6 minutes of power then pass to â&#x20AC;&#x153;Eâ&#x20AC;?. With option E selected, the word: YES -- means that the code will not be shown on the display but only kept in memory, NO -- means the code will not be shown on the display. NOTE: For resolution of the error codes, refer to Section 55, Chapter 9.
87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
41
Longitudinal section of Power Shuttle transmission
87679925A - 12 - 2007
42
87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
1
SECTION 21 -- TRANSMISSIONS Chapter 4 -- Power Shuttle transmission with dual command (2 Speed Power Shift) function CONTENT Description
Page
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Transmission diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Range and gear lever position sensor adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Clutch casing with Power Shuttle unit and Dual Command (2 Speed Power Shift) function D.A. . . . . . . . 21 Clutch casing with Power Shuttle and Dual Command (2 Speed Power Shift) units D.A. . . . . . . . . . . . . . . 30 Driving shaft D. A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Driven shaft D. A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Clutch (A) D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Clutch (B) D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Transmission fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
2
TRANSMISSION DATA Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 speed, constant--mesh, with synchronisers on all gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
helical
Reduction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ordinary gear train with 3 ranges providing a total of 12 gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
spur
Gearbox and reduction unit controls . . . . . . . . . . . . . . . . . . . . . . . . .
independent, by means of two hand levers located on the right-hand side of the operator
Range and gear position sensor adjustment: available spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
0,5 -- 1,0 -- 1,5
POWER SHUTTLE AND DUAL COMMAND (2 SPEED POWER SHIFT) DATA Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Shuttle gears and services working pressure . . . . . . . . . . .
mounted on the outer left--hand side of the clutch casing, comprising: -- no. 4 control solenoid valves; -- one pressure regulating valve; -- no. 1 accumulator; -- no. 4 unions for checking the pressure of the various clutches. bar
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.7 ÷ 16.7 (16 ÷ 17 kg/cm@) with diaphragm
By--pass valve spring (18, fig. 8): --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
20.5
--
spring length under load of 41.2 ÷ 45.2 N (4.2 ÷ 4.6 kg) . . . .
mm
16
Mating clearance between: --
pressure control valve and relative seat on hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
0.025 ÷ 0.035
Pressure control valve spring (15, fig. 8): --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
127
--
spring length under load of 279 ÷ 304 N (28.5 ÷ 31 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
102.5
Power Shuttle transmission lubrication pressure . . . . . . . . . . . . . .
bar
2.9 ÷ 3.7 (3 ÷ 3.8 kg/cm@)
Lubrication pressure control valve spring (1, fig. 7): --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
38
--
spring length under load of 29 ÷ 31 N (3 ÷ 3.2 kg) . . . . . . . . .
mm
24,5
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
paper cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
fixed to the pump body on suction side (overleaf)
87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
3 (overleaf)
Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
the same as used for the hydrostatic steering system (see Section 41)
Power Shuttle unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
to reverse without having to stop the tractor or use the clutch pedal.
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of hand lever located under the steering wheel, to the left--hand side of the operator.
Number of driven plates in each clutch . . . . . . . . . . . . . . . . . . . . . .
no.
5
Driven disc thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
2.65 ÷ 2.75
Driven plate material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
N 401--2
Number of driving plates in each clutch . . . . . . . . . . . . . . . . . . . . . .
no.
5
Drive disc thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
2.15 ÷ 2.25 or 2.35 ÷ 2.45
Driving plate material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thickness of clutch assembly under a load of 1600 N (163.1 kg)
steel mm
25.3 ÷ 25.5 (1)
Power Shuttle clutch pistons return spring (11, fig. 6): --
number of springs for each clutch . . . . . . . . . . . . . . . . . . . . . . .
no.
7
--
spring free height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
4.2
--
spring height under a load of 2108 N (215 kg) . . . . . . . . . . . . .
mm
3.3
Dual Command (2 Speed Power Shift) . . . . . . . . . . . . . . . . . . . .
provides two speeds (HIGH and LOW) within the same gear. The two speeds can be engaged under load by means of two clutches in oil baths.
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of push--buttons located on the gear lever
Number of driven plates in each Dual Command (2 Speed Power Shift) clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
no.
5
Driven disc thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
1.75 ÷ 1.85 or 1.95 ÷ 2.05
Driven plate material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
steel
Number of driving plates in each Dual Command (2 Speed Power Shift) clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
no.
5
Drive disc thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
1.95 ÷ 2.05
Driving plate material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thickness of clutch assembly under a load of 1600 N (163.1 kg)
N 401--4--20 mm
19.1 ÷ 19.3 (1)
Dual Command (2 Speed Power Shift) clutch pistons return springs (9, fig. 6): --
length of free springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
61
--
length of springs under load of 954 ÷ 1052 N (97.3 ÷ 107.3 kg) mm
34
(1) Value to obtain by varying the thickness of the driving plates.
87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
4
TRANSMISSION DIAGRAMS
39
34 34
34
40
43 33 27 21
17
27
b
31
d
A
44
42
41 36 33 39 52 46
36
23 50
23
13
d 36 12 29
b
34--4wd 37--2wd
c
72
34
10
c
13 25 65
a
39
34 34
34
45
43 37 30 24
17
27
b
31
B
d 44
42
41 36 29
36
13
d 36 12 29
b c
35 42
50 23 50
34
10
23
34--4wd 37--2wd 13 25
72
c
65
a MDM1520A
1 A. Transmission diagram 30 km/h. B. Transmission diagram 40 km/h.
87679925A - 12 - 2007
a. b. c. d.
Front axle with 4--wheel drive. Bevel drive. Final reduction gears. Differential lock.
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
C1 --22÷25Nm
C4 --87Nm
5
C2 --22÷25Nm C3--22÷25Nm
MDE0030A
2
BOLT TORQUES PARTS TO BE TIGHTENED
Thread
Tightening torque Nm
kgm
For missing data see Chapter 1. Clutch A cover retaining screw (C1, fig. 2) . . . . . . . . . . . . . . . . . . . .
--
22 ÷ 25
2.24 ÷ 2.55
Lubrication manifold retaining screw (C2) . . . . . . . . . . . . . . . . . . . .
--
22 ÷ 25
2.24 ÷ 2.55
Driven shaft manifold cover retaining nut (C3) . . . . . . . . . . . . . . . .
--
22 ÷ 25
2.24 ÷ 2.55
Flexible coupling retaining nut (C4) (:) . . . . . . . . . . . . . . . . . . . . . .
--
87
8,84
Control valve cap (C1, fig. 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
70 ÷ 90
7.1 ÷ 9.2
Control valve retaining screw (C2) . . . . . . . . . . . . . . . . . . . . . . . . . .
--
51 ÷ 62
5.2 ÷ 6.3
Control valve retaining screw (C3) . . . . . . . . . . . . . . . . . . . . . . . . . .
--
136 ÷ 165
13.9 ÷ 16.8
Accumulator union (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
70 ÷ 90
7.1 ÷ 9.2
Accumulator (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
70 ÷ 90
7.1 ÷ 9.2
Solenoid valve pin retaining screw (C6) . . . . . . . . . . . . . . . . . . . . . .
--
15 ÷ 21
1.53 ÷ 2.14
Solenoid valve retaining nut (C7) (•) . . . . . . . . . . . . . . . . . . . . . . . . .
--
2÷3
0.2 ÷ 0.3
Clutch pressure control union (C8) . . . . . . . . . . . . . . . . . . . . . . . . . .
--
22 ÷ 29
2.24 ÷ 3
Oil delivery T union (C9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
48 ÷ 66
4.9 ÷ 6.7
Oil delivery union (C10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
70 ÷ 90
7.1 ÷ 9.2
(•) Apply 1 or 2 drops of LOCTITE 542 before tightening.
(:) Apply 1 or 2 drops of LOCTITE 270 before tightening. 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
6
C1 --70÷90Nm
C10 --70÷90Nm
C2 --51÷62Nm
C9 --48÷66Nm
C3 --136÷165Nm
C8 --22÷29Nm
C4 --70÷90Nm
C5 --70÷90Nm
C7 --2÷3Nm
C6 --15÷21Nm
MDE0031A
3
87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
7
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.
380000227
380000301
380000278
Hydraulic pressure testing kit (use with union 295032).
X 380000243
Press for Dual Command (2 Speed Power Shift) hydraulic clutch springs.
X 380000244
Dual Command (2 Speed Power Shift) hydraulic clutch shaft stop and support.
X 380000245
Tool for fitting seals on Dual Command (2 Speed Power Shift) hydraulic clutch hub.
X 380000289
Limp home device.
Clutch casing lift hook.
Rotating stand for overhaul operations.
380000271
Front bracket (with 380000301).
380000272
Rear bracket (with 380000301).
X 380000291
Tool for A and B clutch springs.
X 380000290
Tool for fitting internal hub seals on A and B clutches.
X 380000296
Tool for fitting clutch driving shaft seal (with 380000258).
87679925A - 12 - 2007
8
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
27893
Tool to make for clutch casing--engine removal--installation (mark tool with no. 50169 -- Measurements in mm) Make in UNI C40 material
4
MDB1753A
Guide pin to be made for clutch A cover removal--installation (mark tool with no. 50223 -- Measurements in mm) Make in UNI C40 material 87679925A - 12 - 2007
5
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
1
2
X B
3
4
5
11 B
6
9
7
10 B
8
9 B
MDE0875A
1. 2. 3. 4. 5. 6.
Longitudinal cross--sectional view of Power Shuttle with Dual Command (2 Speed Power Shift) function Clutch A cover. 7. Clutch C. Clutch A piston. 8. Clutch D. Clutch A. 9. Clutches C and D springs. Clutches A and B hub. 10. Lubrication line. Clutch B. 11. Clutches A and B springs. Clutch B piston.
6
NOTE: When fitting apply sealing compound to surfaces X as shown on page 12.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
10
1
2
3
MDB1767A
4 MDB1766A
5 6 7 MDB1768A
8
MDB1769A
7 Cross--sectional view of Power Shuttle with Dual Command (2 Speed Power Shift) function 1. 2. 3. 4.
Lubrication oil pressure control valve. Lubrication oil union. Dual Command (2 Speed Power Shift) clutches (C and D) oil lines. Reverse intermediate gear.
87679925A - 12 - 2007
5.
Gear pin (4).
6.
Needle bearing.
7.
Pin retaining screw (5).
8.
Power Shuttle clutches (A and B) oil lines.
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
4
3
2
11
5
1
14
MDB1770A
13
12
11
9
10
8
7
6
15 16
18 17 MDB1771A
8 Cross--sectional view of Power Shuttle and Dual Command (2 Speed Power Shift) control valve 1. 2.
Heat exchanger oil delivery union--line. Clutch A line pressure gauge.
10. Clutch D control solenoid valve. 11. Clutch C control solenoid valve.
3. 4. 5. 6. 7. 8. 9.
Clutch B line pressure gauge. Control valve body. Accumulator. Clutch D pressure control union. Clutch C pressure control union. Clutch B pressure control union. Clutch A pressure control union.
12. 13. 14. 15. 16. 17. 18.
Clutch B solenoid valve. Clutch A solenoid valve. Pump delivery oil union. Pressure control valve spring (16). Oil pressure control valve. By--pass valve. By--pass valve spring.
87679925A - 12 - 2007
12
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4 DESCRIPTION AND OPERATION
Speed Transmission 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 3 gear ranges. The gearbox and the range gears are controlled by two independent levers located on the right--hand side of the operator. Lubrication is by means of the oil in the rear transmission/gearbox.
Forward or reverse gear is selected by means of the lever under the steering wheel to the left of the operator; there is no need to use the clutch pedal. The Power Shuttle unit provides 12 forward gears and 12 reverse gears. Dual Command (2 Speed Power Shift) unit (see fig. 6) The Dual Command (2 Speed Power Shift) is composed of two multi--disk clutches in an oil bath located on the driven shaft in the rear part of the clutch casing, and is controlled by the same control valve as the Power Shuttle.
Power Shuttle unit (see fig. 6)
The Dual Command (2 Speed Power Shift) provides two speeds within the same gear.
The Power Shuttle unit is composed of two multi--disk clutches in an oil bath located in the front part of the clutch casing, and is controlled by a control valve attached to the left--hand side of the clutch casing.
The two speeds (HIGH or LOW) are selected by means of two push--buttons located on the gearshift lever.
This provides hydraulic control of 4 gears for each range, both forward and in reverse.
The HIGH speeds are commanded by the front clutch (C), whereas the LOW speeds are commanded by the rear clutch (D).
Gear and range selection is carried out by means of the clutch pedal and operating the control levers, located on the right--hand side of the operator.
The Dual Command (2 Speed Power Shift) provides 24 forward gears and 24 reverse gears.
The front clutch (A) commands the forward gears and the rear clutch (B) commands the reverse gears.
87679925A - 12 - 2007
For a more thorough understanding of its operation, here we give the hydraulic diagrams and the relevant sequences.
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
13
Static rest oil (Neutral)
MDE0876A
Power Shuttle transmission with Dual Command (2 Speed Power Shift) function (24+24), 30 km/h version (Neutral)
9
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
14
Pressurized oil Discharge oil Lubricating oil (2.9รท3.7 Bar)
1
2
3
4
5 10
6
9 7
8
MDE0877A
10 1. 2. 3. 4. 5.
Power Shuttle transmission with Dual Command (2 Speed Power Shift) function (24+24) -- Lubrication circuit Discharge oil 6. Pump pressure oil Oil to solenoid valves 7. Power take--off lubrication Oil to the differential lock, four--wheel drive, power 8. Cold oil from the heat exchanger take--off and p.t.o. brake 9. Cold oil to lubrication Pump pressure oil Hot oil to the heat exchanger 10. Cold oil to the by--pass valve
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
15
Pressurized oil Discharge oil Lubrication oil
1
2
3 MDE0878A
11
Power Shuttle transmission with Dual Command (2 Speed Power Shift) function (24+24) -- Clutch A under pressure 1. Discharge oil 3. Oil from the pump 2. Oil to the differential lock, four--wheel drive, power take--off and p.t.o. brake
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
16
Pressurized oil Discharge oil Lubrication oil
1
2
3 MDE0879A
12
Power Shuttle transmission with Dual Command (2 Speed Power Shift) function (24+24) -- Clutch A in discharge 1. Discharge oil 3. Oil from the pump 2. Oil to the differential lock, four--wheel drive, power take--off and p.t.o. brake
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
17
Pressurized oil Discharge oil Lubrication oil
1
2
3 MDE0880A
13
Power Shuttle transmission with Dual Command (2 Speed Power Shift) function (24+24) -- Clutch C under pressure 1. Discharge oil 3. Oil from the pump 2. Oil to the differential lock, four--wheel drive, power take--off and p.t.o. brake
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
18
Pressurized oil Discharge oil Lubrication oil
1
2
3 MDE0881A
14
Power Shuttle transmission with Dual Command (2 Speed Power Shift) function (24+24) -- Clutch C in discharge 1. Discharge oil 3. Oil from the pump 2. Oil to the differential lock, four--wheel drive, power take--off and p.t.o. brake
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
19
RANGE AND GEAR POSITION SENSOR ADJUSTMENT Define the process of adjustment of the range (2 and 3) and gear (1) position sensor on Power Shuttle transmissions.
Gear lever status switch Put the gear lever into neutral, using a gauge measure the distance D between the end of the feeler (2) and the plane of the box (3). With the sensor (1) in your hand and the button at rest, measure the distance D1, between the inner face of the hexagon and the end of the button. For the sensor button to travel C = 2.4 รท 2.8 mm the adjustment thickness will be: S = D1 -- (D + C)
15
16 Range lever status switches Put the range lever onto fast, on both range lever status switches (2 and 3, fig. 15) using a gauge measure the distance D, between the end of the feeler (2) and the inner face of the recess where the sensor will be housed in the supporting box (3). With the sensor (1) in your hand, measure the distance D1, between the end of the button and the inner face of the hexagon. For the sensor button to travel C = 2.4 รท 2.8 mm the adjustment thickness will be: S = D1 -- (D + C)
17
NOTE: General Considerations: a) Check that the distance: D + S = 19.8 รท 20.2 mm b) Round down the value.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
20
Adjustment check In figure 18 there is a diagram of the lever status switches. If the adjustment is made during the phase of overhauling the gearbox, with the cab detached and with the aid of a tester switched onto ohmmeter, putting the rods at the ends of the switch, there must be the values in Ω listed in the following table with the gear levers in their various positions.
18
With the range lever in.........
Gearbox sensor G
With the gear lever in.........
Switch status
Ω
Analog--digital conversion H9 (Channel 16)
Neutral
Closed
560
67
1st
Open
2760
30
2nd
Open
2760
30
3rd
Open
2760
30
4th
Open
2760
30
Range sensor R1
Range sensor R2
Switch status
Ω
Analog--digital conversion H9 (Channel 17)
Switch status
Ω
Analog--digital conversion H9 (Channel 18)
Neutral
Open
2760
30
Open
2760
30
Medium
Closed
560
67
Open
2760
30
Fast
Closed
560
67
Closed
560
67
Low
Open
2760
30
Closed
560
67
If the check must be made with the cab down, it is then difficult to use the tester at the ends of the various buttons, in the diagnostic programs HH MENU in H9 at channels Ch 16 (G), Ch 17 (R1) and Ch 18 (R2), it is perfectly possible to test the lever status buttons and the display will show the digital conversion of the above--mentioned tables. NOTE: With program H9 it is possible to move the tractor. It is wise to test in motion and on ground that is not level but rather broken. The jolting produced and the vibration of the gear levers must not be enough to accidentally switch over the switches, even for a short time, thus causing fault code 2040.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
21
CLUTCH CASING WITH POWER SHUTTLE UNIT AND DUAL COMMAND (2 SPEED POWER SHIFT) FUNCTIONS 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. To detach the clutch casing with the Power Shuttle unit remove the cab and the platform (see Sect. 90) then proceed as follows. 1. Disconnect the negative battery cable, unscrew the plug (1) and drain the oil from the gearbox--transmission casing.
1
25622
19 2. Extract the pins (1) after having removed the split pins, detach the vertical tie--rods (2) on the lift arms and the lower lift arms, then remove the anti--swing tie--rods (3).
1
2
3
25531
3. Raise the rear part of the tractor, positioning two fixed stands (1) under the final drive casings (2).
20
1
2
25501
21
87679925A - 12 - 2007
22
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
4. Remove the rear wheels.
25646
5. Take out the screws (2) and remove the steps (1) providing access to the cab (on both sides), take out the related fixing screws and remove the bracket (3) supporting the cab (left side).
22
1
2
3
25660
23 6. Take out the screws (2) and remove the bracket (1) supporting the cab (right side).
1
25661
2 24
7. Unscrew the front, central and rear bolts securing the drive shaft guard.
25038
25 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4 8. Take off the circlip (2) and extract the sleeve (1) from the front axle.
23
2
1
25039
9. Take off the circlip (2) and extract the sleeve (1) from the drive.
26
1
2
25040
27 10. Take out the retaining bolts of the propeller shaft central support (1) and remove the shaft together with its support.
1
25041
11. Remove the plug (1) and drain off the fuel into a suitable container (the tank capacity is 127 l).
28
1
25518
29 87679925A - 12 - 2007
24
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
12. Detach the timing gear pump diesel pipes (1) and the hot water delivery/return pipes (2) to the cab heater. 13. Detach the pipe (3) connecting the rear pump (5) to the trailer brake/timing gear/lift valve, then the rear transmission/oil filter pipe (4). (The front pump (5) is connected via the pipes to the power steering control valve).
14. Remove the clamps (1) and detach the fuel delivery three--way union (2).
30
1
2
25663
31 15. Disconnect the electrical connections (1) and the fuel return line (2) located on the fuel gauge unit (4) and detach the breather pipe (3).
1
2
3
4
26138
16. Take off the clamp (1) and remove the injection pump supply pipe (2).
32
1
2
25520
33 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4 17. Position a hydraulic jack (1) under the central part of the tank (2) and slightly raise to facilitate disassembly operations.
1
25
2
25665
18. Take out the two bolts (1) retaining the rear bracket (2) supporting the tank.
34
1
2
25522
35 19. Remove the nut (1) securing the clamp (2) and extract it from the support bracket (3), detach the front clamp and remove the tank.
1
2
3
25666
36
20. Remove the unions and disconnect the pipes delivering oil to the Power Shuttle control valve (1) to the cooler, the oil return (2), delivery to the services control valve (3) and lubrication to the PTO unit (4).
MDM877B
37 87679925A - 12 - 2007
26
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
21. Remove the union (2) and disconnect the front axle differential lock pipe (1).
1
2
25668
22. Disconnect the electrical connection (1) of the Power Shuttle control solenoid valve.
38
39 23. Position the fixed stand (1) on tool 380000236 under the transmission casing, insert a wooden block between the stand and the transmission casing.
24. Unscrew the bolts (1) and remove the bracket (2) on the tank front support.
40
41 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4 25. Position the mobile trolley (1) on tool 380000236 under the clutch casing (2), inserting a wooden block (3) between the trolley and the clutch casing then place a support column under the towbar.
27
1
2 3 25670
42
26. Unscrew the clutch casing (1) retaining bolts from the rear transmission casing and separate the two casings.
43 27. Move the mobile trolley (3) under the sump, connect the chains on hook 380000227 (1) to the clutch casing (2) and take up the strain with a hoist.
1
2
3 25672
28. Unscrew the bolts and nuts securing the clutch casing (1) and Power Shuttle unit to the engine (2) and remove the casing (1).
44
1
2
25673
45 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
28
29. Re--assemble the clutch casing with the Power Shuttle unit, taking the following precautions.
--
Assemble the gearbox--transmission oil heat exchanger piping and secure with the relative bracket.
--
Fit the Power Shuttle control valve feed line.
--
Fit the tank, resting it on the two support brackets.
--
Secure the tank with the two metal clamps. Insert the fuel return hose in the union on the tank cap.
--
Connect the fuel pump hose.
--
Tighten all the unions and clamps and secure the various pipes and hoses with clamps.
Respect the tightening torques prescribed on page 5.
--
Connect the fuel gauge unit connections.
Using hook 380000227 and a hoist refit the clutch casing to the engine and secure by tightening the relative bolts or nuts to the prescribed torque value.
--
Connect the transmission--gearbox oil breather pipe.
--
Connect the 3--way union to the various fuel return lines.
--
Straighten the brake control lines and secure with the bracket.
--
Connect the two hydraulic pump pipes and the hydraulic lift delivery line.
--
Fit the trailer brake control valve pipe to the 4WD casing.
--
Fit the drive shaft and relative guard.
--
Assemble the RH cab support bracket and secure to the clutch casing with the retaining bolts.
--
Fit the two cab access steps.
--
Fit the rear wheels, raising the tractor with a hoist and a nylon sling. Extract the two fixed stands from under the final drives and the column from under the towbar.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
---
--
--
Before refitting the clutch casing to the engine carefully clean the mating surfaces and apply sealing compound (2 mm diameter), according to the diagram shown in fig. 46.
Position the mobile trolley on tool 380000236 under the clutch casing. Smear the splining grooves on the transmission and PTO drive shafts with AMBRA GR 9 GREASE. Move the engine--clutch casing unit towards the gearbox--transmission casing using tool 380000236 and acting on the front wheels.
--
Tighten the retaining bolts to the prescribed torque value and release hook 380000227.
--
Remove the mobile trolley from under the clutch casing and the fixed stand from under the transmission--gearbox casing.
--
Connect the clutch tie--rod and secure the sheath in the relative bracket.
--
Connect the solenoid valve electrical connection to the Power Shuttle control valve.
--
Fit the two lift vertical tie--rods and the two anti--swing rods.
--
Refit the lines on the Power Shuttle control valve and the solenoid valve support, then refit the front differential lock piping.
--
Make sure that all the transmission--gearbox drainage plugs are tightened and fill up with the quantities described in Section 00.
--
Assemble the tank support front bracket and cab support.
--
Fill up the fuel tank.
--
Connect the negative cable to the battery.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
29
46 Sealing compound application diagram for clutch casing--engine and rear transmission--gear casing assembly
The types of sealing compounds to be applied are specified in Section 00.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
30
Clutch casing with Power Shuttle and Dual Command (2 Speed Power Shift) units 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. Proceed as follows. 1. Fix the gearbox to the rotating stand 380000301 (1) using front 380000271 and rear 380000272 brackets. 2. Unscrew the retaining screws and remove the control valve (1).
47
48 3. Extract the oil drainage union (1).
4. Unscrew the retaining screw, detach the bracket (1) and remove the control valve/internal manifold connecting lines (2).
49
50 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
31
5. Remove the seal and the snap ring (1).
6. Take out the screws fastening the cover (1) of the clutch (A, fig. 6) screw three screws into the extraction holes (2) and remove the cover (1).
51
52 7. Remove the retaining ring (1) fastening the clutch (B, fig. 6).
8. Extract clutch B (1) from the shaft and remove.
53
54 87679925A - 12 - 2007
32
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
9. Unscrew the retaining screws and the lubrication manifold (1) together with the Dual Command (2 Speed Power Shift) clutch unit lubrication lines.
10. Unscrew the retaining screws and remove the Dual Command (2 Speed Power Shift) clutch shaft manifold cover (1).
55
56 11. Remove the Dual Command (2 Speed Power Shift) clutch shaft bearing (1).
12. Position and secure tool 380000244 (1) on the clutch casing.
57
58 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
33
13. Remove the nut on the Dual Command (2 Speed Power Shift) clutch shaft.
14. Extract the manifold ring (1) from the dual command clutches shaft. 15. Disassemble tool 380000244 (1, fig. 58).
59
60 16. Take out the retaining bolts and remove the bracket (1).
17. Remove the snap ring (1) on the driving shaft.
61
62 87679925A - 12 - 2007
34
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
18. Using a puller (1) extract the gear (2) with its bearing.
19. Using a suitable punch, tap the dual command clutches shaft (1) and extract the bearing.
63
64 20. Remove the shaft together with the Dual Command (2 Speed Power Shift) clutches (1).
21. Remove the grub screw (1) on the reverse gear unit pin.
65
66 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
35
22. Working from the front side of the clutch casing, tap the reverse gear unit pin (1) with a punch and remove the unit from the rear side, together with the thrust washer (2).
23. Using a suitable punch, tap the driving shaft (1).
67
68 24. Remove the driving shaft (1), working from the rear side of the clutch casing. Driving shaft Disassembly--Assembly (see page 37) Driven shaft Disassembly--Assembly (see page 39) 25. 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 in figs. 6, 7 and 7.
--
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 8.
--
Respect the tightening torques listed on pages 5 and 5.
69
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
36 --
Mount the driving shaft.
--
Fit the thrust washer, gear unit and reverse pin, securing in position with the screw.
--
Assemble the Dual Command (2 Speed Power Shift) shaft and lock in position with tool 380000244.
--
Assemble and secure the bracket with guard on the Dual Command (2 Speed Power Shift) clutch shaft.
--
Fit the manifold ring on the dual command clutches shaft, tighten and secure the nut.
--
Remove tool 380000244 and fit the bearing in the seat on the Dual Command (2 Speed Power Shift) clutch shaft.
--
Assemble and secure the manifold cover on the Dual Command (2 Speed Power Shift) clutch shaft.
--
Assemble and secure the lubrication manifold, complete with Dual Command (2 Speed Power Shift) clutch unit lubrication line.
--
Position clutch (B, fig. 6) on the shaft and secure with the snap ring.
--
Assemble and secure the cover and clutch (A, fig. 6).
--
Fit the seal and the snap ring on the clutch A cover.
--
Insert the control valve--internal manifold connecting lines, position and secure the relative bracket.
--
Insert the oil drainage union.
--
Position and secure the control valve.
--
Fit the driving shaft rear gear and related bearing and hold it with the circlip.
87679925A - 12 - 2007
70
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
Longitudinal section of the main shaft 1. 2. 3. 4. 5. 6. 7. 8. 9.
Gearbox driving gear thrust circlip. Reverse driving gear rear thrust circlip. Reverse driving gear. Reverse gear shaft internal bearing retaining circlip. Reverse driving gear / shaft. Forward gear shaft. Bearing. Circlip. Forward gear clutch driven hub A.
37
71
Bearing. Circlip. Reverse gear clutch hub retaining circlip B. Circlip. Forward gear clutch A bottom / reverse gear clutch B driving hub. 15. Retaining circlip part 14. 16. Forward gear clutch A bell housing circlip. 10. 11. 12. 13. 14.
DRIVING 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. For the correct orientation of the various parts, refer to the picture 71. To remove the gearbox, proceed as follows. 1. 2. 3. 4.
Remove the circlips (1 and 2, fig. 71). Extract the reverse driving gear (3, fig. 71). Take out the circlip (4, fig. 71). Grip the forward gear shaft (6, fig. 71) from the back and tap on the reverse gear / shaft (5, fig. 71) on the back and extract it.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
38
5. Remove the bearing (7, fig. 71) from the forward gear shaft. 6. Remove the circlip (8, fig. 71). 7. Remove the main shaft, proceeding as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Fit the circlip (8, fig. 71).
--
Mount the bearing (7, fig. 71) inserting it from the back of the forward gear shaft, make it flush against the ring.
--
Insert the forward gear shaft (6, fig. 71), from the front, into the reverse gear shaft (5, fig. 71), on the back, until the latter reaches the position reaching the bearing.
--
Insert the bearing retaining circlip (4, fig. 71) into the reverse shaft.
--
Insert the gear (3, fig. 71) from the back of the forward gear shaft, make it flush with the bearing.
--
Insert the circlips (2 and 1, fig. 71).
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
39
DRIVEN SHAFT. Disassembly--Assembly Proceed as follows:
2
1
1. Remove the reverse driven gear (1) / gear (3) governing clutch C, together with the bearings and the thrust washer.
MDD3181A
72 2. Remove the clutch assembly (1) by extracting it from the driven shaft (2).
1
2
MDD3182A
73 3. Remove the retaining ring (3), the clutch reaction disc (2) and extract the clutch discs (1). Repeat the operation on the other clutch.
1
2
3
MDD3183A
4. Position tool 380000243 (2) on the clutch body (1) and secure in a vice, then compress the spring by tightening nut (3).
74
1
2 3
MDD3184A
75 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
40
5. Remove the circlip (1) retaining the cup (2), unscrew the nut of tool 380000243 and remove the spring (3) together with the above--mentioned parts.
1
2
3
MDD3185A
76 6. Remove piston (1) using a compressed air jet. 7. Repeat operations no. 5. and 6. on the opposite side and remove the snap ring, cup, spring and piston.
1
MDD3186A
77
8. Fit the driven shaft following the disassembly operations in reverse; proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. ---
--
Check the wear on the various components, especially the seals, replacing if necessary. Position the guide on tool 380000245 (1) on the clutch casing hub (3), fit the seal (2) and push it into its seat using the press of tool 380000245 (1). Repeat the same operation for the seal on the hub on the opposite side too.
1
NOTE: After having positioned the two seals (2) on the hubs, allow to settle in the seats for at least 15 minutes before fitting the clutch control pistons.
2 3 MDD3187A
78
87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4 -----
--
41
Refer to the illustrations in fig. 6 for the correct orientation of the various parts. Using tool 380000243 perform operations no. 6. and 5. on both sides. Insert the clutch plates, reaction disk and circlip on both sides. Insert the clutch output gear D in the clutch assembly, insert the toothed thrust washer on the driven shaft, then insert the clutch assembly onto the driven shaft. Insert the thrust washer on the driven shaft, then insert the reverse driven gear / the gear governing the clutches C, together with the bearings on the driven shaft.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
42 CLUTCH 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. Proceed as follows. 1. Remove the circlip (1) retaining the forward gear clutch A bottom / reverse gear clutch driving hub B (14, fig. 71).
79 2. Recover the unit (1) composed of: -- forward gear clutch A bottom / reverse gear clutch driving hub B (14, fig. 71) -- bearing (10, fig. 71) -- clutch A driven hub (9, fig. 71) -- circlip retaining bearing on the hub (11, fig. 71) -- circlip retaining bearing on part 14 (13, fig. 71)
3. Remove the clutch A disk assembly (1) and the separating springs.
80
81
87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
43
4. Using a brass punch, tap on the hub (1) on clutch casing A after removing the circlip (16, fig. 71), with an appropriate pair of pliers.
5. Extract the cover (1) and remove the clutch casing A (2).
82
83 6. Position the clutch casing A (1) under a press and, using tool 380000291 (2) and adapter, compress the springs, remove the stop ring (3) and remove the Belleville washer.
Replacing the seal on the clutch casing internal hub
84
7. Position the O--Ring seal (1) in the relative seat on the clutch casing internal hub.
85 87679925A - 12 - 2007
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
44
8. Position the external ring (1) of the seal on the guide on tool 380000290 (2).
9. Position the guide (2) on tool 380000290 on the clutch casing internal hub and push the ring (3) into position using the press (1) on tool 380000290.
86
10. Refit the clutch A, and proceed as follows:
ATTENTION
87
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 11. Position the clutch casing A (1) under a press and, using tool 380000291 (2) and adapter, compress the Belleville springs and fit the spring stop ring.
12. Fit the casing (1) of the clutch A on its cover (2) and secure it with the circlip.
88
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
45
13. Assemble the clutch disk assembly on the clutch casing A as described here: --
Insert the first metal disk (2) on the casing (1) of the clutch A.
14. On the casing (1) of the clutch A, make a reference mark (2) to time the splits of the springs during the assembly operation.
90
91 15. Do the timing of the swings (1) and splits (2) of the springs as shown in the figure.
16. Insert the first spring on the casing (1) of the clutch A, keeping the split of the spring (2) timed with the reference mark (3) made beforehand.
92
93 87679925A - 12 - 2007
46
SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
17. Insert the first clutch disk (2) on the casing (1) of the clutch A, centring the spring (3) previously mounted on the outer edge of the disk (2).
18. Insert the second metal disk (2) on the casing (1) of the clutch A.
94
95 19. Insert the second spring (3) on the casing (1) of the clutch A, keeping the split timed with the reference mark (2) made beforehand.
20. Insert the second clutch disk (2) on the casing (1) of the clutch A, centring the spring (3) previously mounted on the outer edge of the disk (2). -- Complete fitting the disk assembly and clutch springs A on the casing following the above method.
96
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
47
21. Refit the unit (1) composed of: -- forward gear clutch A bottom / reverse gear clutch driving hub B (14, fig. 71) -- bearing (10, fig. 71) of clutch A driven hub (9, fig. 71) -- circlip retaining bearing on the hub (11, fig. 71) -- circlip retaining bearing on part 14 (13, fig. 71).
22. Fit the circlip (1) retaining the unit previously fitted inside the clutch A.
98
99 --
Clutch B 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.
Proceed as follows. 1. Take off the circlip (1) and remove the disk assembly. 2. Carry out operations no. 5. to no. 18. described above for clutch A to correctly disassemble/ assemble the disks and the springs of the clutch B; then refit the clutch B end plate and related circlip.
100
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
48
CALIBRATIONS Fault codes If the Faults Detection Logic reads a fault condition, the code will flash on the information monitor. In this manner, the fault condition can be displayed whilst in HH mode. During calibration, certain faults may be masked.
ATTENTION
2024
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.
101
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 á 50 °C. Unless otherwise specified, the levers: - Shuttle control; - gear control; - range gear control; - creeper lever; are in the NEUTRAL position.
HH MENU ACCESS 1. Turn the starter switch (1, fig. 103) to A (OFF) and connect the tool 380000843 (2) to the diagnostics socket (1).
102
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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 4
49
2. Turn the starter switch (1) to B, the information monitor will show HH MENU plus HO, or HP, or RJ, or JB; two arrows are displayed at the bottom showing the possibility of passing from one option to another. HP = Standard control panel. HO = Advanced control panel. RJ = Transmission, Differential Lock, Four--Wheel Drive and Power Take--Off. JB = Advanced keypad. MDB1669A
103
3. By using the clock adjustment buttons: minutes adjustment (1) and hours adjustment (2) it is possible to pass between the options.
0 x100
1 3
2
104 4. Select the HH menu of the control unit RJ by pressing the push--button (3, fig. 19) and access the sub--system, using the clock adjustment buttons: minutes adjustment (1, fig. 19) or hours adjustment (2, fig. 19) it is possible to access the H1 menu of the control unit RJ of the gearbox, then pressing the push--button (3, fig. 19) to go into calibration.
5. The menu of the selected control unit appears on the information monitor. If the control unit gives a negative response to the ADIC message for menu access the attention sign will appear, in this case you need to turn the switch (1, fig. 18) to A (OFF) and repeat the HH MENU access procedure after checking the supply and connection of the relevant control unit are correct. A. Correct access. B. Module responds incorrectly.
HHMENU RJ
RJ H1
RJ H1
105
RJ HH
HHMENU
A
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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 4
50
CLUTCH CALIBRATION H1 MENU TRANSMISSION Access the HH MENU RJ as described on page 18 and proceed as follows. --
Select the H1 MENU with buttons (1) and (2), press key (3) to access the above--mentioned H1 MENU.
--
To calibrate the clutches the operator must be seated in the driving seat.
--
Press the clutch pedal, start up the engine and take it to a speed of 1250 ÷ 1350 rev/min;
--
0 x100
1 3
2
1st
gear and III range, move the Engage the Power Shuttle control lever onto forward travel and release the clutch pedal.
107
NOTE: The clutches can also be calibrated without the tool 380000843, just keep the buttons (2 and 3) of the HI and LO Dual Command (2 Speed Power Shift) pressed at the same time while starting up the machine. --
If you have selected the H1 MENU you need to do the calibrations or turn the switch (1, fig. 18) to A (OFF).
108
--
The central display will show CAL then the transmission oil temperature 50 °C.
NOTE: Clutch calibration is possible with both high and low oil temperatures, even if the display signals two alarm conditions to the driver: CL -- in the case of cold oil (under 20 °C) CH -- in the case of hot oil (over 100 °C)
RJ
H1
CAL 50C 109
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4 --
--
--
--
--
Using button HI (2, fig. 108) select clutch A then keep the LO button (3, fig. 108) pressed to do the calibration. The display will show in sequence: A = clutch to calibrate; I = vertical bar that, blinking, moves from the left to the right: 280 = progressive calibration value: A/295 = end calibration value that alternates with the clutch. Release the LO button (3, fig. 108)
RJ
51
A
H1
I 280 320
A 110
Using the HI button (2, fig. 108) select the clutches B, C and D and keep the LO button (3, fig. 108) pressed to calibrate the above--mentioned clutches. If a fault is found during calibration, the display will show the relevant error code U (see table on page 52).
b RJ
H1
C d 111
NOTE: After selecting the clutch to calibrate with the button HI (2, fig. 108) it is possible to start automatic calibration by pressing button (2, fig. 108) for a few seconds, then automatically, the other clutches will calibrate and, at the end, the central display will show End.
b RJ
H1
C d End
--
112
After calibrating all the clutches turn the switch (1) to A (OFF) to save the calibrations.
MDB1669A
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 4
52
Calibration error code Code
Meaning
U19
Oil temperature <10 °C, calibration is not possible
U20
Wrong sequence, operate the Power Shuttle control lever and the clutch control pedal
U21
Engine speed too low
U22
Engine speed too high
U23
Power Shuttle control lever on neutral
U24
Wrong range selection (the III range is not engaged)
U25
Gear lever in neutral
U26
Clutch pedal pressed
U31
Tractor moving
U33
Parking brake disengaged
U34
Operator not seated in driving seat
U36
Calibration value too high
U37
Calibration value too low
CL
Low oil temperature <20 °C
CH
High oil temperature > 100 °C
NOTE: For resolution of the error codes, refer to Section 55, Chapter 9.
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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 4
53
TRANSMISSION FAULT CODES The fault codes are shown on the dot--matrix display (1) of the analog--digital control panel (ADIC) and on the lower central display (2).
The disabling errors will be shown on the dot--matrix display of the control panel and will be visible for the driver.
114
115 Hidden and saved fault codes can be displayed by using the fault diagnosis mode of the “H” menus and are not visible for the driver. The “H” menu diagnostic mode can be used to access and clear the fault codes which may be stored in the various controllers. The H--menu diagnostic mode also contains many other useful functions which may be used to assist with diagnostics.
116 NOTE: To access the MENU HH to view the codes and, if necessary, clear them, refer to Section 55, Chapter 10.
87679925A2 - 02 - 2010
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 4
54
TRANSMISSION FAULT CODE LISTING E.C.R. (*)
FAULT CODE
Description of Fault
2011
Clutch pedal potentiometer signal too low
YES
2012
Clutch pedal potentiometer signal too high
YES
2014
Voltage from the gear neutral position switch is high
YES
2015
Voltage from the gear neutral position switch is low
YES
2016
Voltage from the range position switch (R1) is high
YES
2017
Voltage from the range position switch (R1) is low
YES
2018
Voltage from the range position switch (R2) is high
YES
2019
Voltage from the range position switch (R2) is low
YES
2021
Transmission harness disconnected
YES
2024
All the clutches must be calibrated
NO
2025
Engine speed (rpm) high
YES
2026
Clutch D not calibrated
NO
2027
Clutch C not calibrated
NO
2028
Clutch B not calibrated
NO
2029
Clutch A not calibrated
NO
2030
Critical code on transmission
NO
2033
Pressure on clutch A would not decrease
NO
2035
Wheel speed too high
YES
2036
Engine speed (rpm) low
YES
2037
Clutch disconnect switch open circuit
YES
2038
Clutch B solenoid valve short to + 12 volts
NO
2039
Clutch B solenoid valve open circuit or short to ground
NO
2040
Inconsistent gear lever status switches.
YES
2041
Clutch A solenoid valve open circuit or short to ground
NO
2042
Clutch A solenoid valve short to + 12 volts
NO
2043
Pressure on clutch B would not decrease
NO
2047
Clutch disconnect switch set too high
YES
2048
Clutch disconnect switch set too low
NO
2049
Wheel speed sensor too high
YES
2051
Oil temperature sensor open circuit
YES
2052
Oil temperature sensor short circuit
YES
87679925A2 - 02 - 2010
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 4
55
2053
5 volt reference voltage too high
NO
2054
5 volt reference voltage too low
NO
2055
Shuttle lever forward switch voltage high
YES
2056
Shuttle lever forward switch voltage low
YES
2057
Shuttle lever reverse switch voltage high
YES
2058
Shuttle lever reverse switch voltage low
YES
2059
Shuttle Lever sw. disagree
YES
2061
No seat safety switch transition in the last 25 hours of work
NO
2065
Clutch C solenoid valve open circuit or short to ground
NO
2066
Clutch D solenoid valve open circuit or short to ground
NO
2067
Clutch D solenoid valve short to + 12 volts
NO
2068
Clutch C solenoid valve short to + 12 volts
NO
2069
Wheel speed sensor voltage too low
YES
2081
Clutch A safety pressure switch open circuit or short to ground
YES
2082
Clutch A safety pressure switch short circuit
YES
2083
Clutch B safety pressure switch open circuit or short to ground
YES
2084
Clutch B safety pressure switch short circuit
YES
2085
No supply to pressure switches for clutches A and B.
NO
2090
Break in CAN line between PA and ADIC
YES
2092
Signal from the clutch cut--out button shorted to +12 VF
YES
2093
Power supply to HI, LO and clutch cut--out buttons shorted to + 12 VF.
YES
2094
Power supply to HI, LO and clutch cut--out buttons shorted to ground.
YES
2095
Clutch cut--out button jammed closed.
YES
2450
Configuration error
NO
(*) Enter the HH programs of the control panel select the H3 program, enter the ECR, then select the options: E -- show only severe codes, F -- show all codes for 6 minutes of power then pass to â&#x20AC;&#x153;Eâ&#x20AC;?. With option E selected, the word: YES -- means that the code will not be shown on the display but only kept in memory, NO -- means the code will not be shown on the display. NOTE: For resolution of the error codes, refer to Section 55, Chapter 9.
87679925A2 - 02 - 2010
56
SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 4
MDM1553A
2 Longitudinal view of the transmission with Power Shuttle with Dual Command (2 Speed Power Shift) functions
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
1
SECTION 21 -- TRANSMISSIONS Chapter 5 -- Power Shuttle transmission with creeper unit -- 20X20 version CONTENTS Description
Page
Main Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Transmission diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Description and operation of the Power Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sect. 3, page 12 Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sect. 3, page 13 Range and gear lever position sensor adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sect. 3, page 17 Clutch casing with Power Shuttle and creeper unit. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . 14 Disassembly--Assembly -- driving shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sect. 3, page 24 Clutch (A) D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sect. 3, page 25 Clutch (B) D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sect. 3, page 31 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Transmission fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
2
TRANSMISSION DATA Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 speed, constant--mesh, with synchronisers on all gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
helical toothed
Reduction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ordinary gear train with 3 ranges providing a total of 12 gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
spur
Gearbox and reduction unit controls . . . . . . . . . . . . . . . . . . . . . . . . .
independent, by two hand levers located at the operator’s right side
Range and gear position sensor adjustment: available spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
0,5 -- 1,0 -- 1,5
CREEPER UNIT DATA
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordinary gear train with spur gears, located between main clutch and gearbox, in series with the two clutches of the reverser. Providing 20 forward gears and 20 reverse gears
Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
lever located on right--hand side of operator
POWER SHUTTLE UNIT MAIN DATA
Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Shuttle gears and services working pressure . . . . . . . . . . .
mounted on the outer left--hand side of the clutch casing, comprising: -- no. 2 proportional solenoid valves controlling clutches A and B; no. 1 discharge solenoid valve -- one pressure regulating valve; -- no. 2 unions for checking the pressure of the various clutches. bar
15.7 ÷ 16.7 (16 ÷ 17 kg/cm@)
By--pass valve spring (11, fig. 8): --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
20,5
--
spring length under load of 41.2 ÷ 45.2 N (4.2 ÷ 4.6 kg) . . . .
mm
16 (continued)
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
3 (Continued)
Mating clearance between: --
pressure control valve and relative seat on hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
0.025 ÷ 0.035
Pressure control valve spring (9, fig. 8): --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
127
--
spring length under load of 279 ÷ 304 N (28.5 ÷ 31 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
102,5
bar
2.9 ÷ 3.7 (3 ÷ 3.8 kg/cm@)
Power Shuttle transmission lubrication pressure . . . . . . Spring for valve (1, fig.10 sect. 21 Chap. 3) regulating lubricating pressure: --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
38
--
spring length under load of 29 ÷ 31 N (3 ÷ 3.2 kg) . . . . . . . . .
mm
24,5
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
paper cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
fixed to the pump body on suction side
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
the same as used for the hydrostatic steering system (see Section 41)
Power Shuttle unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
to reverse without having to stop the tractor or use the clutch pedal.
Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of hand lever located under the steering wheel, to the left--hand side of the operator.
Number of driven plates in each clutch . . . . . . . . . . . . . . . . . . . . . .
no.
5
Thickness of driven plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
2.65 ÷ 2.75
Driven plate material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
N 401--2
Number of driving plates in each clutch . . . . . . . . . . . . . . . . . . . . . .
no.
5
Driven disc thickness (each) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
2.15 ÷ 2.25 or 2.35 ÷ 2.45
Driving plate material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thickness of clutch assembly under a load of 1600 N (163.1 kg)
steel mm
25.3 ÷ 25.5 (1)
Power Shuttle clutch pistons return spring (13, fig. 6): --
number of springs for each clutch . . . . . . . . . . . . . . . . . . . . . . .
no.
7
--
spring free height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
4,2
--
spring height under a load of 2108 N (215 kg) . . . . . . . . . . . . .
mm
3,3
(1) Value to obtain by varying the thickness of the driving plates.
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SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
4
TRANSMISSION DIAGRAMS 49 39
40
34 16
43 33 27 21
27
17
b
31
d
A
44
42
36 57
24
33 13
d 36
39 46
34
23 50 52
23
b
12 29
34--4wd 37--2wd
c
72
10
c
13 25 65
a 49 39
43 37 30 24
45
34 16
27
17
b
31
B
d 44
42
36 57
24
29
35 4250
13
d 36 12 29
23 50
34
10
23
b c
34--4wd 37--2wd 13 25
72
c
65
a MPM0361A
1 A. Transmission diagram 30 km/h. B. Transmission diagram 40 km/h.
a. Front axle with 4--wheel drive. b. Bevel drive. c. Final reduction gears. d. Differential lock.
87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
C4 87 Nm
5
C3 22 ÷ 25 Nm C2 22 ÷ 25 Nm
C1 22 ÷ 25 Nm
MPM0360A
2
TORQUE WRENCH SETTINGS PARTS TO BE TIGHTENED
Thread
Tightening torque Nm
kgm
For missing data see Chapter 1. Driven shaft manifold cover retaining nut (C1) . . . . . . . . . . . . . . . .
--
22 ÷ 25
2.24 ÷ 2.55
Lubrication manifold retaining screw (C2) . . . . . . . . . . . . . . . . . . . .
--
22 ÷ 25
2.24 ÷ 2.55
Clutch A bell housing retaining nut (C3) . . . . . . . . . . . . . . . . . . . . . .
--
22 ÷ 25
2.24 ÷ 2.55
Flexible coupling retaining nut (C4) (•) . . . . . . . . . . . . . . . . . . . . . . .
--
87
8,84
Control valve cap (C1, fig. 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
70 ÷ 90
7.1 ÷ 9.2
Clutch pressure control union (C2, fig. 3) . . . . . . . . . . . . . . . . . . . . .
--
22 ÷ 29
2.24 ÷ 3
Oil delivery union (C3, fig. 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
70 ÷ 90
7.1 ÷ 9.2
Oil delivery T union (C4, fig. 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
48 ÷ 66
4.9 ÷ 6.7
(•) Apply 1 or 2 drops of LOCTITE 270 before tightening.
87679925A2 - 02 - 2010
6
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
3
87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
7
SPECIAL TOOL 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.
380000227
Clutch casing lift hook.
X 380000290
Tool for fitting internal hub seals on A and B clutches.
380000301
Rotating stand for overhaul operations.
X 380000296
Tool for fitting clutch driving shaft seal (with 380000258).
380000271
Front bracket (with 380000301).
380000278
380000272
Rear bracket (with 380000301).
X 380000289
Limp home device.
X 380000291
Tool for A and B clutch springs.
X 380000843
Connector to access HH diagnostic programs.
Hydraulic pressure testing kit (use with union 295032).
87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
8
27893
Tool to make for clutch casing--engine removal--installation (mark tool with no. 50169 -- Measurements in mm) Make in UNI C40 material
4
MDB1753A
Guide pin to be made for clutch A cover removal--installation (mark tool with no. 50223 -- Measurements in mm) Make in UNI C40 material 87679925A2 - 02 - 2010
5
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
9
LONGITUDINAL CROSS--SECTIONAL VIEW OF POWER SHUTTLE AND CREEPER UNIT GEARBOX
X
X
2
1
18
17
15
16
13 14
MPM0362A
5
3
6
4
12
X
7 8
11
10 9
18 19 20 21 MDB1768A
Longitudinal cross--sectional view of Power Shuttle and creeper unit gearbox. Forward gear shaft. Reverse driving gear / shaft. Reverse driven gear. Creeper unit selector sleeve / driven gear. Shaft / sleeve retaining half--rings (6.). Gearbox input shaft / sleeve. Thrust washer limiting end float between shaft (8.) and (6.). 8. Gearbox main shaft. 9. Gearbox secondary shaft. 10. Creeper unit transmission thrust washer. 11. Creeper unit idler gear. 1. 2. 3. 4. 5. 6. 7.
12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
6
Ball coupling reverse idler gear to the shaft. Fixed sleeve for direct gear engagement. Reverse idler gear. Reverser and creeper unit secondary shaft. Reverse drive clutch. Forward drive clutch. Flexible coupling. Reverse idler gear. Shaft. Bearing. Shaft retaining pin.
NOTE: When fitting apply sealing compound to surfaces X as shown on page 13.
87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
10
CREEPER UNIT SLEEVE ENGAGEMENT DEVICE
a
3
2
1
b
4
A
5 2
6
B
2
10
7 3 8 11
9 13
C
12
14
19
18
17
2
3
13
16 15
MPM0363A
7 87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
11
Creeper unit sleeve engagement device (legend figure 7) A Longitudinal cross--section of clutch casing on creeper unit engagement clevis B Cross--section of clutch casing on creeper unit engagement clevis C Vertical longitudinal view of clutch casing on creeper unit engagement clevis 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Creeper unit status sensor. Creeper unit engagement clevis. Creeper unit engagement rod. Safety pawl operating surface. Power shuttle control valve. Creeper unit selector sleeve. Gearbox input shaft / sleeve. Forward gear shaft. Power take--off shaft. Spring pin. Creeper unit selector external lever.
a b
End of creeper unit engagement clevis in position of reduction unit disengaged. End of creeper unit engagement clevis in position of reduction unit engaged.
Spring pin. Seal. Creeper unit selector internal lever. Rod for range engagement clevis. Safety pawl, prevents engaging the reduction gear with the fast range engaged and it prevents engaging the fast range with the reduction gear engaged. 17. Rod trip unit positioning spring. 18. Poppet ball retaining screw. 19. Poppet ball. 12. 13. 14. 15. 16.
POWER SHUTTLE CONTROL VALVE
8 Power Shuttle transmission control valve. Transmission oil temperature sensor. Unions for diagnostic tests on clutch lines. Reverse solenoid valve (proportional). Forward solenoid valve (proportional). Dump solenoid valve. Power shuttle control valve supply union / oil delivery to the services control valve. 7. Heat exchanger hot oil delivery union. 1. 2. 3. 4. 5. 6.
8. Connections to the forward and reverse gear clutches. 9. Pressure relief valve spring. 10. Pressure relief valve spool. 11. Lubrication by--pass valve. 12. Cold oil lubrication line to the clutch casing. 13. Connection to the discharge.
87679925A2 - 02 - 2010
12
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5 DESCRIPTION AND OPERATION
The Power Shuttle -- creeper unit is a device providing 20 forward gears and 20 reverse gears. The creeper unit only intervenes in slow and medium slow ranges, a mechanical interlock prevents creeper engagement in the fast ranges.
Power Shuttle unit (see fig. 6)
Creeper unit (see fig. 6) The creeper unit is installed inside the clutch casing, after the two clutches of the reverser (Power Shuttle) and it is controlled by a special lever located on the right--hand side of the operator.
The creeper unit is composed of a group of three spur gears: a sliding control gear.
The Power Shuttle unit is composed of two multi--disk clutches in an oil bath located in the front part of the clutch casing, and is controlled by a control valve attached to the left--hand side of the clutch casing.
Speed Transmission
This provides hydraulic control of 4 gears for each range, both forward and in reverse.
4--speed gearbox with constant--mesh helical gears controlled by two synchronizers.
Gear and range selection is carried out by means of the clutch pedal and operating the control levers, located on the right--hand side of the operator.
The range gear has cascade--type constant--mesh spur gears.
The front clutch (A) commands the forward gears and the rear clutch (B) commands the reverse gears. Forward or reverse gear is selected by means of the lever under the steering wheel to the left of the operator; It is not necessary to depress the clutch pedal. The Power Shuttle unit provides 12 forward gears and 12 reverse gears.
The range gear provides 3 gear ranges.
The gearbox and the range gears are controlled by two independent levers located on the right--hand side of the operator.
Lubrication is by means of the oil in the rear transmission/gearbox.
NOTE: As regards the: Description and operation of the Power Shuttle. Hydraulic circuit (general, for lubrication, clutch A at rest and engaged). Range and gear position sensor adjustment. please refer to section 21 chapter 3 from page 12 to page 18.
87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
13
CREEPER UNIT TROUBLESHOOTING
Problems
Possible failures
Remedies
Spontaneous disengagement of 1. External levers and relay rods Adjust correctly. creeper unit. incorrectly adjusted. 2. Partial engagement travel.
Correct reasons for problem and restore full travel.
Difficulty in engaging the creeper 1. External levers and relay rods Adjust correctly. unit. incorrectly adjusted. 2. Stiffness and/or seizure of ex- Check rod pivots and lubricate. ternal levers and rods. 3. Internal controls do not slide Overhaul the controls. easily: rods, forks and sleeves. The reverser--creeper is noisy.
1. Worn or damaged internal Remove the clutch casing and replace the damaged parts. parts.
MDB1772A
Sealing compound application diagram for clutch A cover. The types of sealing compounds to be applied are specified in Section 00.
9
87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
14
CLUTCH CASING WITH POWER SHUTTLE AND CREEPER UNIT 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. In order to work on the reverser--creeper unit first detach the cab or platform as described in Sect. 90 and remove the clutch casing as described in chapter 4. Then proceed as follows:
10 1. Fix the gearbox --transmission casing to the rotating stand 380000301 (1) using front 380000271 and rear 380000272 brackets. 2. For disassembly of the Power Shuttle clutches, please refer to sect. 21 chapter 3 from page 19 operation 1 to 25.
3. Extract the spring pin (1) and retrieve the creeper unit engagement external lever (2).
11 2
3
2 1
4 MPM0364A
12 87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5 4. Unscrew the screw (1), then retrieve the spring (2) and the poppet ball (3).
1
2
3
5. Remove the creeper unit status sensor (1, fig. 7).
15
MPM0365A
13
5 13
14
4
3
2
1
6
12 9 8 MPM0366A
15
7 10
11 14
6. Remove the bearing (1, fig. 14) together with the thrust washer 7 fig. 6, take out the split ring (2, fig. 14) then extract the shaft (3, fig. 14) together with: sliding sleeve (4, fig. 14), clevis (2, fig. 12) and rod (3, fig. 12). 7. Extract the fixed sleeve for direct gear engagement. (5, fig. 14), retrieve the half--rings (6, fig. 14). 8. Retrieve the bearing (7, fig. 14), remove the split ring (8, fig. 14) with the washer. 9. From the front of the casing, use a suitable punch to strike the shaft (9, fig. 14), then from the back retrieve the secondary shaft together with the two idlers (10 and 11, fig. 14) of the reverse and of the creeper unit and thrust washer. 87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
16
10. From the left--hand side of the clutch casing, remove the grub nut (1) retaining the shaft (2) of the reverser idler gear (3), then remove it all.
3 2
1 MPM0367A
11. Remove the creeper unit engagement internal lever (4, fig. 12) and the secondary shaft bearing (15, fig. 14). 12. 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 in fig. 14 page 15 or figs. 6 and 7 page 9 and 10.
--
Before refitting the casings, supports and covers clean and de--grease the mating surfaces and apply sealing compound (approx. 2 mm in diameter) as shown in figure 9.
--
Respect the tightening torques prescribed on page 5 and 6.
--
Fit the secondary shaft bearing and the creeper unit engagement internal lever.
--
Fit the driving shaft unit (forward drive primary, reverse drive and reverser driving gear, with their rings and bearings).
--
Fit the reverse drive idler gear unit, locking it with the screw.
--
From the back, fit the secondary shaft together with the two idlers of the reverser and of the creeper unit and thrust washer and, from the front, secure it with the thrust washer and the split ring.
87679925A2 - 02 - 2010
15
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5 --
Refit the half--rings and refit the fixed sleeve for direct gear engagement.
--
Fit the input sleeve to the gearbox together with: sliding sleeve, clevis and rod, and secure it with the split ring.
--
Mount the transmission shaft lubrication cover and then screw on the retaining nuts.
--
Assemble and secure the lubrication manifold, complete with the transmission shaft lubrication line.
--
Position clutch B on the shaft and secure with the circlip.
--
Assemble and secure the cover and clutch A.
--
Insert the oil drainage union.
--
Re--fit the control valve.
--
Refit the bearings inside the shafts and the thrust washer 7 fig. 6 on the upper shaft.
17
NOTE: As regards the: Driving shaft D A Clutch (A) Disassembly- Assembly Clutch (B) Disassembly- Assembly please refer to section 21 chapter 3 from page 24 to page 32.
87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
18
CALIBRATIONS Fault Codes If the Faults Detection Logic reads a fault condition, the code will flash on the information monitor. In this manner, the fault condition can be displayed whilst in HH mode. During calibration, certain faults may be masked.
ATTENTION
2024
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.
16
Put safety wedges under the front and rear wheels. Check that the transmission oil temperature is between 20 á 50 °C. Unless otherwise specified, the levers: - Shuttle control; - gear control; - range gear control; - creeper lever; are in the NEUTRAL position.
HH MENU ACCESS 1. Turn the starter switch (1, fig. 18) to A (OFF) and connect the tool 380000843 (2) to the diagnostics socket (1).
17
87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
19
2. Turn the starter switch (1) to B, the information monitor will show HH MENU plus HO, or HP, or RJ, or JB; two arrows are displayed at the bottom showing the possibility of passing from one option to another. HP = Standard control panel. HO = Advanced control panel. RJ = Transmission, Differential Lock, Four--Wheel Drive and Power Take--Off. JB = Advanced keypad. MDB1669A
18
3. By using the clock adjustment buttons: minutes adjustment (1) and hours adjustment (2) it is possible to pass between the options.
0 x100
1 3
2
19 4. Select the HH menu of the control unit RJ by pressing the push--button (3, fig. 19) and access the sub--system, using the clock adjustment buttons: minutes adjustment (1, fig. 19) or hours adjustment (2, fig. 19) it is possible to access the H1 menu of the control unit RJ of the gearbox, then pressing the push--button (3, fig. 19) to go into calibration.
5. The menu of the selected control unit appears on the information monitor. If the control unit gives a negative response to the ADIC message for menu access the attention sign will appear, in this case you need to turn the switch (1, fig. 18) to A (OFF) and repeat the HH MENU access procedure after checking the supply and connection of the relevant control unit are correct. A. Correct access. B. Module responds incorrectly.
HHMENU RJ
RJ H1
RJ H1
20
RJ HH
HHMENU
A
B 21 87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
20
CLUTCH CALIBRATION H1 MENU TRANSMISSION Access the HH MENU RJ as described on page 18 and proceed as follows. --
Select the H1 MENU with buttons (1) and (2), press key (3) to access the above--mentioned H1 MENU.
0 x100
--
To calibrate the clutches the operator must be seated in the driving seat.
--
Press the clutch pedal, start up the engine and take it to a speed of 1250 ÷ 1350 rev/min;
--
1 3
2
Engage the 1st gear and III range, move the Power Shuttle control lever onto forward travel and release the clutch pedal.
22
NOTE: The clutches can also be calibrated without the tool 380000843, just keep the buttons (1 and 2, fig. 22) for minutes adjustment or hours adjustment pressed simultaneously while starting the machine. --
If you have selected the H1 MENU you need to do the calibrations or turn the switch (1, fig. 18) to A (OFF).
--
The central display will show CAL then the transmission oil temperature 50 °C.
NOTE: Clutch calibration is possible with both high and low oil temperatures, even if the display signals two alarm conditions to the driver: CL -- in the case of cold oil (under 20 °C) CH -- in the case of hot oil (over 100 °C)
RJ
CAL
H1
50C 23 --
--
--
Using button (2 or 1, fig. 22) select clutch A or B then keep the button (1, fig. 22) pressed to do the calibration. The display will show in sequence: A = clutch to calibrate; I = vertical bar that, blinking, moves from the left to the right: 280 = progressive calibration value: A / 295 = end calibration value that alternates with the clutch. Release the button (1, fig. 22).
A RJ
H1
I 280 320
A 24
87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5 --
--
Using the button (2 or 1, fig. 22) select the clutch B and keep the button (1, fig. 22) pressed to calibrate the clutches. If a fault is found during calibration, the display will show the relevant error code U (see table on page 22).
21
b RJ
H1
I 280 A
320
25
NOTE: After selecting the clutch to calibrate with the button (2 or 1, fig. 22) it is possible to start automatic calibration by pressing button (2, fig. 22) for a few seconds, then automatically, both clutches will calibrate and, at the end, the central display will show End.
RJ
H1
A b End 26
--
After calibrating all the clutches turn the switch (1) to A (OFF) to save the calibrations.
MDB1669A
27
87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
22
Calibration error code Code
Description
U19
Oil temperature <10 °C, calibration is not possible
U20
Wrong sequence, operate the Power Shuttle control lever and the clutch control pedal
U21
Engine speed too low
U22
Engine speed too high
U23
Power Shuttle control lever on neutral
U24
Wrong range selection (the III range is not engaged)
U25
Gear lever in neutral
U26
Clutch pedal pressed
U31
Tractor in motion
U33
Parking brake off
U34
Operator not seated in driving seat
U36
Calibration value too high
U37
Calibration value too low
CL
Low oil temperature <20 °C
CH
High oil temperature > 100 °C
NOTE: For resolution of the error codes, refer to Section 55, Chapter 10.
87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
23
TRANSMISSION FAULT CODES The fault codes are shown on the dot--matrix display (1) of the analog--digital control panel (ADIC) and on the lower central display (2).
The disabling errors will be shown on the dot--matrix display of the control panel and will be visible for the driver.
28
29 Hidden and saved fault codes can be displayed by using the fault diagnosis mode of the “H” menus and are not visible for the driver. The “H” menu diagnostic mode can be used to access and clear the fault codes which may be stored in the various controllers. The H--menu diagnostic mode also contains many other useful functions which may be used to assist with diagnostics.
30 NOTE: To access the MENU HH to view the codes and, if necessary, clear them, refer to Section 55, Chapter 10.
87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
24
TRANSMISSION FAULT CODE LISTING
E.C.R. (*)
Code
Description of Fault
2011
Clutch pedal potentiometer signal too low
YES
2012
Clutch pedal potentiometer signal too high
YES
2014
Voltage from the gear neutral position switch is high
YES
2015
Voltage from the gear neutral position switch is low
YES
2016
Voltage from the range position switch (R1) is high
YES
2017
Voltage from the range position switch (R1) is low
YES
2018
Voltage from the range position switch (R2) is high
YES
2019
Voltage from the range position switch (R2) is low
YES
2021
Transmission harness disconnected
YES
2024
All the clutches must be calibrated
NO
2025
Engine speed (rpm) high
YES
2028
Clutch B not calibrated
NO
2029
Clutch A not calibrated
NO
2030
Critical code on transmission
NO
2035
Wheel speed too high
YES
2036
Engine speed (rpm) low
YES
2037
Clutch disconnect switch open circuit
YES
2038
Clutch B solenoid valve short to + 12 volts
NO
2039
Clutch B solenoid valve open circuit or short to ground
NO
2040
Inconsistent gear lever status switches.
YES
2041
Clutch A solenoid valve open circuit or short to ground
NO
2042
Clutch A solenoid valve short to + 12 volts
NO
2047
Clutch disconnect switch set too high
YES
2048
Clutch disconnect switch set too low
NO
2049
Wheel speed sensor too high
YES
2051
Oil temperature sensor open circuit
YES
2052
Oil temperature sensor short circuit
YES
2053
5 volt reference voltage too high
NO
2054
5 volt reference voltage too low
NO
2055
Shuttle lever forward switch voltage high
YES
2056
Shuttle lever forward switch voltage low
YES
2057
Shuttle lever reverse switch voltage high
YES
87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
25
2058
Shuttle lever reverse switch voltage low
YES
2059
Shuttle Lever sw. disagree
YES
2061
No seat safety switch transition in the last 25 hours of work
NO
2069
Wheel speed sensor voltage too low
YES
2097
Short circuit to +12V to the discharge (dump) solenoid valve.
NO
2098
Short circuit to ground or circuit open to the discharge (dump) solenoid valve.
NO
2430
Creeper unit status switch voltage too low
YES
2431
Creeper unit status switch voltage too high
YES
2450
Configuration error
NO
(*) Enter the HH programs of the control panel select the H3 program, enter the ECR, then select the options: E -- show only severe codes, F -- show all codes for 6 minutes of power then pass to â&#x20AC;&#x153;Eâ&#x20AC;?. With option E selected, the word: YES -- means that the code will not be shown on the display but only kept in memory, NO -- means the code will not be shown on the display. NOTE: For resolution of the error codes, refer to Section 55, Chapter 9.
87679925A2 - 02 - 2010
26
87679925A2 - 02 - 2010
SECTION 21 -- TRANSMISSIONS -- CHAPTER 5
SECTION 23 -- DRIVE LINES -- CHAPTER 1
1
SECTION 23 -- DRIVE LINES Chapter 1 -- Drive lines CONTENT Description
Page
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Description of operation and hydraulic diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Services control valve R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Services control valve D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Drive gear housing R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Drive gear housing D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
87679925A - 12 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
2
MAIN SPECIFICATIONS -- 4WD ELECTROHYDRAULIC ENGAGEMENT Reduction ratio of drive gear device (on all models) . . . . . . . . . . . . . . . . .
34/34 = 1:1
Number of mobile friction sections (14, fig. 3) (one--sided) . . . . . . . . . . .
2
Number of mobile friction sections (14) (two--sided) . . . . . . . . . . . . . . . . .
5
Number of brake disks (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Brake control lever pin diameter (16) . . . . . . . . . . . . . . . . . . . . . . . .
mm
27.979 ÷ 28.000
Brake control lever pin seat diameter on casing (30) . . . . . . . . . .
mm
28.020 ÷ 28.053
Clearance between pin (16) and seat on casing (30) . . . . . . . . . .
mm
0.020 ÷ 0.074
Internal diameter of sliding sleeve (19) . . . . . . . . . . . . . . . . . . . . . .
mm
35.080 ÷ 35.119
Diameter of driving shaft (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
35.002 ÷ 35.027
Internal diameter of sliding sleeve (19) . . . . . . . . . . . . . . . . . . . . . .
mm
50.080 ÷ 50.119
Diameter of driving shaft (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
49.975 ÷ 50.000
Internal diameter of fixed sleeve (8) . . . . . . . . . . . . . . . . . . . . . . . . .
mm
38.050 ÷ 38.089
Diameter of driving shaft (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
37.925 ÷ 37.950
Length of spring (7, with spring free) . . . . . . . . . . . . . . . . . . . . . . . .
mm
82
Spring length (7) under load of 60.5 ÷ 65.5 kg . . . . . . . . . . . . . . . .
mm
40
Mobile friction section (14, one--sided) . . . . . . . . . . . . . . . . . . . . . . .
mm
2.9 ÷ 3.1
Mobile friction section (14, two--sided) . . . . . . . . . . . . . . . . . . . . . . .
mm
4.0 ÷ 4.2
Brake disk (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
3.80 ÷ 3.90
PROPELLER SHAFT DATA Thickness of rings (33, fig 3) that adjust the position of the front sleeve (32) on the 4WD propeller 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
87679925A - 12 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
3
MDF0803A
1
BOLT TORQUES PARTS TO BE TIGHTENED
Thread
Propeller shaft central support retaining bolt (C1) . . . . . . . . . . . . . Parking brake control lever axial retaining bolt (C2) . . . . . . . . . . . . Screw with guide pin for brake disk braking sectors (C3) . . . . . . . Drive gear housing retaining bolt (C4) . . . . . . . . . . . . . . . . . . . . . . . Control cylinder oil delivery union (C5) . . . . . . . . . . . . . . . . . . . . . . .
M12x1.5 M12x1.25 M12x1.25 M12x1.25 M18x1.50
Tightening torque Nm kgm 88 9 44 4.5 25 2.5 98 10 49 5
SPECIAL TOOLS 25
CAUTION 120°
35
∅ 63
∅ 70
The operations described in this section can only be carried out with the 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.
Sm1
r5
10 140
23927
380000279 380000280 380000285
Guard for fitting the seal (28, fig. 3) Guard for fitting the seal (27, fig. 3) Splining tool for fitting the seal (3, fig. 3)
Adapter to make for drive gear spring disassembly--assembly. (Stamp no. 50107) (Measurements in mm)
2
NOTE: Make the tool in F42 material.
87679925A - 12 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
4
MMM1521A
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Sectional view of drive gear with electrohydraulic coupling 18. Driving gear. Driving shaft. 19. Mobile coupling. Dust ring. 20. Plate. Seal. 21. Circlip. Manifold ring. 22. Control cylinder oil delivery union. Circlip. 23. 24. O rings. Ball bearing. 25. Metal seal rings. 4WD engagement spring. 26. Theoretical speed sensor. Fixed engagement. 27. 28. O rings. Intermediate gear journal. 29. Lever axial retaining bolt (16). Idler gear. 30. Casing. Needle bearing. 31. Circlip. Parking brake discs. 32. Front grooved sleeve. Ball bearing. 33. Clearance adjustment ring (L). Braking sectors. 34. Circlip. O--Ring. L.. Axial clearance of sleeve (32). Parking brake control lever. M. Gap = 0.75 mm. between parts (18) and (26). Thrust washer.
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3
SECTION 23 -- DRIVE LINES -- CHAPTER 1
5
4WD gear engaged
Circuit oil under pressure Circuit oil discharging
4WD gear disengaged
4
DESCRIPTION AND OPERATION OF THE ELECTRO--HYDRAULICALLY ENGAGED DRIVE GEAR 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 (19, fig. 3, causing the parts (8 and 19) to engage and the oil to drain from the control circuit (see fig. 4).
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 (19, fig. 3) and the 4WD disengages. Lubrication is guaranteed by the oil in the rear transmission gearbox. 87679925A - 12 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
6
ELECTROHYDRAULIC DRIVE GEAR TROUBLESHOOTING Problems FWD does not engage.
Possible causes
Solutions
1. Drive gear engage/disengage Replace switch. switch faulty. 2. Solenoid valve contactor faulty.
control Check relay. Replace if necessary.
3. Drive gear solenoid valve Check solenoid valve. Replace if control jammed in delivery necessary. position.
4WD remains engaged.
4. Spring (7, fig. 3) deformed.
Overhaul the unit.
1. Transmission oil level low.
Top up oil.
2. Clogged oil filter.
Replace filter.
3. Hydraulic pump faulty.
Overhaul or replace the pump.
4. Drive gear engage/disengage Replace switch. switch faulty. 5. Lack of power supply to the Check electrical connections and solenoid valve: connections replace defective parts. loose or damaged, contactor faulty. 6. Drive gear solenoid valve Overhaul or replace solenoid valve. control jammed in discharge position. 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 disen- 1. Brake pump pressure switch Replace pressure switch. gaged, drive cannot be engaged faulty. by operating the brake pedals.
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SECTION 23 -- DRIVE LINES -- CHAPTER 1
7
SERVICES CONTROL VALVE 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. To remove the Services Control Valve, proceed as follows: 1. Disconnect the battery negative lead (1).
1
25621
2. Remove the plug (1) and drain off the fuel tank into a suitable container (tank capacity is 110 litres).
5
1
3. Lock the front wheels using chocks. 4. Remove the rear left hand wheel.
25518
6 5. Take off the clamp (1) and remove the pipe (2) supplying the injection pump.
1
2
25520
7
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8
SECTION 23 -- DRIVE LINES -- CHAPTER 1
6. Disconnect the electrical connections (1) and the fuel return line (2) located on the fuel gauge unit (4) and detach the breather pipe (3).
2
1
3
4
26138
7. Position a hydraulic jack (1) under the central part of the tank (2) and slightly raise the tank.
8
1
2
25665
9 8. Unscrew the nut (1) securing the clamp (2) and remove from the support bracket (3). Repeat the same operation on the front part.
1
2
3
25666
10
9. Take out the bolts (1) and remove the bracket (2) supporting the fuel tank. Repeat the same operation on the front bracket and remove the tank.
2 1
25770
11 87679925A - 12 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
9
10. Disconnect the piping (4) on the solenoid valve support, unscrew the retaining bolt with the eccentric nut (2) to adjust the control valve rod stroke (1) and lever (3).
NOTE: The control valve rod (1) hydraulically excludes PTO engagement commanded by the flywheel when the PTO is synchronized with the gearbox.
MMM1522A
12
11. Take out the bolts (1) securing the services control valve to the gearbox and remove the control 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. 12. To refit the services control valve, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. ---
--------
Attach the control valve to the gearbox casing with the bolts (1, fig. 13). Connect the lever (2, fig. 14) governing the control valve rod (1) and, using the eccentric nut (2, fig. 12), adjust the control valve rod (1, fig. 14) so as to leave a clearance between the valve (1) and the grub screw (3) at the limit stops: a) PTO synchronized with the gearbox. b) PTO electrohydraulically governed by the engaged flywheel. Reconnect the control valve delivery and return lines. Fit the tank with the clamps and support brackets, as shown in the figures ( 9, 10 and 11). Reconnect the electrical connections (1, fig. 8), the fuel return line (2) located on the fuel gauge unit (4) and refit the breather pipe (3). Refit the injection pump fuel line. Refit the left--hand rear wheel, fill up the fuel tank and reconnect the battery negative lead.
13
1
b a
2
3 MMM1523A
14
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10
SECTION 23 -- DRIVE LINES -- CHAPTER 1
SERVICES CONTROL VALVE (FOR TRACTORS WITHOUT POWER SHUTTLE) D.A.
1
2
4
3
5 6
Proceed as follows: 1. Remove the circlip (6), washer (4) and fulcrum pin (5). 2. Loosen the limit stop screw (1) and take out the valve (3). Remove the O--ring and the dust ring (2). 3. Remove the plug (1) located on the transmission drainage line and check the seal (2).
MMM1524A
15
2
1
3
4
5
NOTE: Also check seals (3 and 5) on the union (4) located on the transmission casing drainage line.
26458
4. Remove the front and rear differential lock delivery union (3).
16
3
2
1
5. Remove the delivery union (1) on the solenoid valve support (2). 6. Remove the union connecting the pressure relief valve to the drainage line (4). 7. Remove the spring (5) and the pressure relief valve (6).
6
5
4
MMM1525A
17 8. Position the Services control valve support in a vice, unscrew the nuts (2) and detach the solenoid valve coils (1). (Mark the detached coils).
MMM1526A
18 87679925A - 12 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
11
9. Remove the three pins (1) on the solenoid valves. Inspect the seals and replace if necessary.
MMM1527A
19 10. To reassemble the Services control valve, proceed as follows: -- Check all the seals and replace if necessary. -- Check and clean all mechanical parts. -- Refit the three pins on the solenoid valves and tighten the nuts (1, fig. 19) to a torque value of (4.8 รท 5.5 kgm). -- Refit the coils (1, fig. 18) on the solenoid valves, tighten the nuts (2) to a torque of (0.55 รท 0.83 kgm). -- Refit the plug (1, fig. 16). -- Reassemble the pressure relief valve parts as shown in fig. 17. -- Refit the seal ring and dust ring (2, fig. 20). -- Reposition the valve (3) and bolt (1). -- Mount the control lever on the fulcrum pin (5), insert the washer (4) and the retaining circlip (6). -- Refit the front and rear differential lock delivery union (7).
1
2
3
4
5 6
MMM1524A
20
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SECTION 23 -- DRIVE LINES -- CHAPTER 1
12
DRIVE GEAR ASSEMBLY R.I.
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 battery negative cable (1).
21
2. Unscrew the front, central and rear drive gear shaft guard retaining bolts.
25038
22 3. Remove the circlip (2) and move the sleeve (1) in the direction indicated by the arrow until it is released from the groove on the drive.
1
2
25040
23
87679925A - 12 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1 4. Take out the plug (1) and drain the tank; recover the fuel in a container positioned under the tank.
13
1
25518
5. Take out the plug (1) and drain the oil from the gearbox/transmission casing.
24
1
25622
25 6. Detach the window washer tank (1) together with the relative electrical connections.
1
25503
7. Disconnect the electrical connections (1) on the floating cap (2).
26
1
2
25539
27 87679925A - 12 - 2007
14
SECTION 23 -- DRIVE LINES -- CHAPTER 1
8. Remove the metal clamp (1) and detach the fuel return lines ((2) on the tank, also detach the fuel priming line.
1
2
25520
28
9. Mark and disconnect the 4WD, PTO engagement, differential lock, rev counter and pressure gauge control connections.
25562
29 10. Take out the bolt (1) and remove the valve lever (2) on the PTO control valve when this is synchronized with the transmission.
MMM1528A
11. Remove the lines (1) on the services control valve.
30
1
25563
31 87679925A - 12 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
15
12. Remove the union (1) and detach the delivery line (2) for drive gear engagement. Detach the 4WD rev counter (3).
MMM1529A
13. Take out the two bolts (1) securing the services control valve to the gearbox/transmission casing. Remove the control valve.
32
1
25565
33 14. Detach the parking brake return spring (1). Remove the pin and detach the tie--rod (2). Remove the unions (3 and 5) and detach the lubrication line (4).
1
2
3 4 5
25724
34
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SECTION 23 -- DRIVE LINES -- CHAPTER 1
16
15. To facilitate disassembly of the drive gear casing, loosen the oil suction lines on the services pump, located under the casing. 16. Position a hydraulic jack under the drive casing (1). Take out the bolts (2) securing the drive casing to the gearbox/transmission casing. Remove the drive gear casing.
1
2
25725
35
17. To refit the 4WD casing to the gearbox/transmission casing proceed as follows.
--
Refit the services control valve.
ATTENTION
--
Tighten the piping and reconnect the three electrical connections on the solenoid valves.
--
Refit the 4WD drive gear piping to the drive gear casing control valve.
--
Reassemble the fuel tank, connect all hoses and the float electrical connection.
--
Refit the window washer tank and the electric motors connections.
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Carefully clean the contact surfaces.
--
Apply a bead of approximately 2 mm of sealing compound on the transmission casing mating surface and, with the aid of a hydraulic jack, fit the drive casing onto this, tightening the retaining bolts to the prescribed torque (see page 3).
--
Reconnect the oil primer line, located under the transmission casing near the drive gear casing.
--
Refit the drive gear shaft sleeve on the drive gear casing grooved shaft, securing in position with a snap ring.
--
Refit the 4WD sensor, securing in position with the two retaining bolts.
--
Refit the guard.
--
Refit the drive gear casing/trailer brake control valve lubrication pipe.
--
Fill up the fuel tank using the pump.
--
Fill the transmission/gearbox casing with oil.
Remount the handbrake tie--rod on the locking rod.
--
Bleed any air from the fuel circuit.
Fit the helical spring on the lever.
--
Connect the battery negative cable.
--
--
87679925A - 12 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
17
DRIVE GEAR HOUSING REMOVED 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. With the drive gear casing on a workbench, proceed as follows: 1. Using a punch, extract the circlip (2), pin (1) and remove the roller bearing, spacer, thrust washers and intermediate gear (3).
1
2
3
25726
36
2. Unscrew the axial retaining screw (1) on the parking brake lever.
1
25727
37 3. Using a wrench, extract the bolt (1) and remove the parking brake lever (2).
38
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18
SECTION 23 -- DRIVE LINES -- CHAPTER 1
4. Using a screwdriver, remove the dust ring (1).
1
25729
39
5. Remove the oil seal (1).
1
25730
40 6. Remove the 4WD drive gear disengagement oil delivery union (1).
1
25731
7. Remove the oil delivery manifold ring (1) with a suitable punch.
41
1
25732
42 87679925A - 12 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1 8. Remove the circlip (1). Extract the shaft (2), complete with parts (6, 7, 19, 20 and 21, page 4); remove the parking brake disks (12 and 14), the driven gear (18), fixed coupling (8) and thrust washer (17).
19
1
2
25733
43
9. Unscrew the two bolts (1) with relative brake sector guide pins and remove the brake sector and rear bearing.
1
25734
44 10. Extract the parking brake shaft (2) and remove the O--ring (1) from the part (2).
1
2
25735
11. Position the driven shaft (1), previously removed in operation (8), in a hydraulic press, securing the bearing (2) in the clamps (3) as indicated in the drawing. Operate the press and extract the bearing (2).
45
1
2
3
25737
46 87679925A - 12 - 2007
SECTION 23 -- DRIVE LINES -- CHAPTER 1
20
12. Rotate the driven shaft through 180_, position on the press as indicated in the drawing and, after having fitted an adapter 50107 (1) on the shaft, operate the press to compress the spring (4). Remove the snap ring (2), plate (3), spring (4) and mobile toothed coupling (5).
1
2
3
4 5
25738
47
13. Assembly Procedure.
1
2
3
To reassemble the drive gear components, follow the disassembly operations described in reverse order.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Check all parts and replace if worn.
--
Check the seals and replace, if necessary.
--
To position the O--rings (27 and 28, fig. 3) in the seats on the driven shaft, use the specific tools: 380000280 (2) for the seal (3) and tool 380000279 for the seal (1).
--
Lubricate all parts.
--
Tighten the retaining bolts to the torque value indicated on page 3.
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25739
48
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
1
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION Chapter 1 -- Front axle mechanical transmission CONTENT Description
Page
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Description of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 *LIM--SLIP self--locking differential operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Description of front differential lock operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Rules for correctly fitting the axle support to the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Front axle R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Front axle D.A. -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Front axle differential -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Front axle differential with LIM--SLIP unit -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Differential lock clutch assembly -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Front epicyclic final drive without brake D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Front epicyclic final drive with brake D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Replacing wheel hub seal with brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Leading wheels. Toe--in check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (see sect. 44)
87679925A - 12 - 2007
2
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
steering, stress--supporting, centrally pivoted
Bevel drive -- differential Pinion--crown gear ratio: -- all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13/36 = 1:2.77
Backlash between bevel drive teeth: -- all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
0.15 ÷ 0.20
Thickness of pinion bearing adjustment spacer rings (84, fig. 8) .
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 bevel crown wheel position adjustment spacer rings (94, fig. 8) (version with differential lock) . . . . . . . . . . . . . . . . . . . . .
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 (87, fig. 8) . . . . . . . . . .
mm
1.470 ÷ 1.530
Thickness of sun pinion thrust washers (89, fig. 8) . . . . . . . . . . . .
mm
1,4 -- 1,5 -- 1,6 -- 1,7 1,8 -- 1,9 -- 2
mm
21.939 ÷ 21.960
-- all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
22.012 ÷ 21.991
Assembly clearance between cross pin and bores . . . . . . . . . . . .
mm
0.031 ÷ 0.073
Side pinion pin diameter (90, fig. 8): -- all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planet pinion pin seat diameter :
Planet pinion grooved profile inside diameter (88, fig. 8): -- all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54 mm
29.790 ÷ 30.000
mm
29.370 ÷ 29.500
mm
29.885 ÷ 30.050
z
10
Axle shaft spline outside diameter: -- all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter of axle shaft bore in differential casing: -- all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of side gear/axle shaft grooved profile teeth: -- all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(overleaf)
87679925A - 12 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
3
(overleaf) Differential lock Spring free length (75. fig. 8): -- all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
≅ 75
-- 1369 ÷ 1566 N (139.7 ÷ 159.7 kg) all models . . . . . . . . . . . . . . .
mm
≅ 41
-- 1666 ÷ 1960 N (169.9 ÷ 199.9 kg) all models . . . . . . . . . . . . . . .
mm
≅ 33
Wire diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
8.95 ÷ 9.05
Spring outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
9.05 ÷ 108.9
Inside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
90.9 ÷ 93.1
-- inside grooved profile, all models . . . . . . . . . . . . . . . . . . . . . . . . .
mm
29.790 ÷ 30.000
-- outside grooved profile, all models . . . . . . . . . . . . . . . . . . . . . . . .
mm
49.240 ÷ 49.400
mm
49.750 ÷ 50.000
-- all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
49.240 ÷ 49.400
Thickness of bronze gear thrust washer
mm
2.750 ÷ 2.850
-- quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
n
2
-- thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
2,8
-- maximum wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
0,10
-- quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
n
8
-- thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
1,6
-- maximum wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
0,15
-- quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
n
10
-- thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
1,5
Spring length under load of:
Diameter of hub keying gear with front teeth on axle shaft:
Inside diameter of gear with front teeth fitted on axle shaft hub and on differential casing: -- all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside diameter of spline on differential right half casing:
LIM--SLIP self--locking differential Friction disc, keyed on side gear (39, fig. 6):
Friction disc, keyed on side gear (40, fig. 6):
Metal disc, keyed on differential casing (41, fig. 6):
(overleaf)
87679925A - 12 - 2007
4
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 (overleaf)
Axle--shafts and swivel assemblies Diameter of outer axle shafts (17, fig. 5) in correspondence with bushes (31, fig. 5): -- all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
46.975 ÷ 47.000
-- all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
47.100 ÷ 47.175(1)
Clearance between axle shafts and bushes . . . . . . . . . . . . . . . . . .
mm
0.100 ÷ 0.200
Diameter of bush seat on spindle . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
51.000 ÷ 51.025
Thickness of steering knuckle bearing adjuster plates (16, fig. 5)
mm
0,10 -- 0,15 -- 0,20 -- 0,25 -- 0,30
Inside diameter of installed bushes (31, fig. 5):
Epicyclic final drives Reduction Ratio: --
all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thickness of driven gear shims (9. fig. 5) . . . . . . . . . . . . . . . . . . . .
12 : (12 + 72) = 1 : 7 mm
0.77 ÷ 0.83
mm
4.45 ÷ 4.55
mm
0.3 ÷ 1.1
Maximum permitted wear clearance . . . . . . . . . . . . . . . . . . . . . . . . .
mm
2
Diameter of axle pivot front pin (63, fig. 7) . . . . . . . . . . . . . . . . . . .
mm
52.652 ÷ 52.671
Installed front bush internal diameter (62, fig. 7) (1) . . . . . . . . . . .
mm
52.720 ÷ 52.790(1)
Assembly clearance between pin (63, fig. 7) and bushing (62, fig. 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
0.049 ÷ 0.138
Outside diameter of rear bush (57, fig. 7) installed in the bevel pinion support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
99.020 ÷ 99.086
Inside diameter of rear bush (58, fig. 7) installed in the axle pivot support (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
99.146 ÷ 99.221(1)
Assembly clearance between the two bushes . . . . . . . . . . . . . . . .
mm
0.060 ÷ 0.201
Thickness of the front (67, fig. 7) and rear (60, fig. 7) front axle thrust washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
4.95 ÷ 5.00
Final drives version with brakes Front axle brake disk thickness (29, fig. 5): --
all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle pivot Axle clearance on pivot between body and support . . . . . . . . . . .
(1) Measurement to be obtained without reaming
87679925A - 12 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
5
BOLT TORQUES
C1 350 รท 450 Nm C2 350 รท 450 Nm
C3 185 รท 206 Nm
C4 267 รท 287 Nm
C5 350 รท 450 Nm
MDM1494A
1
87679925A - 12 - 2007
6
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
FIAT 01619
C7 130 ÷ 144 Nm
50x90x21.75
50x2.65x18 FI AT 01619
30 x 2.75 x10
C6 45 ÷ 50 Nm
Z=13 35x72x18.25
41.275x82.55x26.543
30x2.75x10 FI AT 01619
C8 116 ÷ 144 Nm
50x90x21.75
FIAT 01619
30x2.75x10
Z=36
C9 130 ÷ 144 Nm
C10 75 ÷ 90 Nm
C12 90 ÷ 100 Nm
C11 40 ÷ 55 Nm
C13 55 ÷ 67 Nm Z=29 m=3
95x135x20
95x135x20
C14 393 Nm
35x55x11 30x55x13
Z=12 m=3
B300
Z=72 m=3
C16 55 ÷ 67 Nm
C15 55 ÷ 67 Nm
MDM1495A
2
87679925A - 12 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
7
BOLT TORQUES
PARTS TO BE TIGHTENED
Thread
Front axle support retaining bolt (C1, fig. 1) . . . . . . . . . . . . . . . . . .
Tightening torque Nm
kgm
M18x1.5
350 ÷ 410
35.5 ÷ 41.6
Rear axle support retaining bolt (C2, fig. 1) . . . . . . . . . . . . . . . . . .
M18x1.5
350 ÷ 410
35.5 ÷ 41.6
Steering cylinder head locking ring nut (C3, fig. 1) . . . . . . . . . . . . .
M22x1.5
185 ÷ 206
18.8 ÷ 20.9
Steering knuckle fastener on the piston (C4, fig. 1) . . . . . . . . . . . .
M22x1.5
267 ÷ 287
27.1 ÷ 29.1
Ring nut locking steering cylinder to support (C5, fig. 1) . . . . . . . .
M60x2
630 ÷ 670
64 ÷ 68
Locking piston seat retaining bolt (C6, fig. 2) . . . . . . . . . . . . . . . . . .
M10x1.25
45 ÷ 50
4.6 ÷ 5.1
Differential casing support box retaining bolt (C7, fig. 2) . . . . . . . .
M14x1.5
130 ÷ 144
13.2 ÷ 14.6
Bevel crown wheel bearing cap retaining bolt (C8, fig. 2) . . . . . . .
M12x1.25
116 ÷ 144
11.8 ÷ 14.6
Bevel crown wheel to differential support retaining bolt (C9, fig. 2)
M18x1.5
130 ÷ 144
13.2 ÷ 14.6
Brake pipe bracket retaining bolt (C10, fig. 2) . . . . . . . . . . . . . . . . .
M12x1.25
75 ÷ 90
7.6 ÷ 9.1
Axle shaft bearing bush retaining bolt (C11, fig. 2)* . . . . . . . . . . . .
M12x1.25
40 ÷ 55
4 ÷ 5.6
Final drive bearing retaining washer fixing screws (C12, fig. 2) . .
M12x1.25
90 ÷ 100
9.1 ÷ 10.1
Final drive crown support retaining bolts, axle version with brakes (C13, fig. 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M10x1.25
75 ÷ 82
7.6 ÷ 8.4
Ring nut locking hub on stub axle, axle version without brakes (C14, fig. 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M72x2
394
40
Final drive to hub retaining bolt (C15, fig. 2) . . . . . . . . . . . . . . . . . . .
M10x1.25
55 ÷ 67
5.6 ÷ 6.8
Stub axle pin retaining bolt (C16, fig. 2) . . . . . . . . . . . . . . . . . . . . . .
M10x1.25
55 ÷ 67
5.6 ÷ 6.8
Front axle
*
Apply Loctite 243 on the thread.
87679925A1 - 02 - 2008
8
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 SPECIAL TOOLS
CAUTION The operations described in this section can only be carried out with the 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.
380000251
Front axle overhaul stand.
X 380000234
Front axle swivel pin bearing outer race puller.
380000227
Front differential unit removal--installation hook.
X 380000235
Tool for measurement of rolling drag torque of front axle bearings.
380000255
Front axle differential casing overhaul fixture.
380000240
Universal kit for testing oil pressure for front axle differential lock engagement.
X 380000268
Front axle drive pinion nut spanner.
X 380200017
Sunken seal key on hub (version without brakes).
X 380200018
Sunken seal key on spindle (version with brakes).
X 380200019
Sunken seal key on spindle for axle shafts.
X 380200041
Sunken seal key on pinion.
X 380200042
Dust seal key on pinion.
X 380000257
X 380000252
X 380000269
Front axle drive pinion retaining tool.
Front axle differential casing bearing ring nut spanner.
Wrench for front axle wheel hub bearing retaining nut.
X 380000270
Pair of grips for front axle hub bearing extraction.
X 380000265
Front axle pivot pin removal tool.
87679925A1 - 02 - 2008
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
9
27892
Tool to make for front axle wheel disassembly--assembly (mark tool with no. 50165 -- Measurements in mm) Make in UNI C40 material.
3
25955
Tool to make for removal--installation of the final drive cover (mark tool with no. 50164 -- Measurements in mm) Make in UNI C40 material.
4
87679925A - 12 - 2007
10
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 SECTIONS 1
2
3
4
5
6
7
8
9
10
b
11
a
A 16 17
18
15 19
20
14
21
13 22
12
23
24
25 b 26
27 a
B
34
33
32
31
30
29
28
MDM1496A
NOTE: for the key, refer to page 13.
87679925A - 12 - 2007
5
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
36
50x90x21.75
35
11
Z=13
35x72x18.25
41.275x82.55x26.543
30x2.75x10 FI
AT 01619
50x90x21.75
FI AT 01619
30x2.75x10
Z=36
35
36
C 50x90x21.75
30x2.75x10 FIAT 01619
37 38 39
30x2.75x10 FI
40
41.275x82.55x26.543
AT 01619
35x72x18.25
Z=13 50x90x21.75
41
42
D MDM1497A
NOTE: for the key, refer to page 13.
6
87679925A - 12 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
12
43
44
45
46
47
48
49
50
51
52
E 55
54
53
Asse Motore -- C rankshaft
F
66 Z=13 m=5.025
65
35x72x18.25
41.275x82.55x26.543
56
30x2.75x10 ATFI01619
67 64
63
62
61
53
54
60
59
58
57
MDM1499A
NOTE: for the key, refer to page 13.
87679925A - 12 - 2007
7
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
13
Bevel drive with hydraulic differential lock
69
70
71
72
73
74
75 76 77 78
60
57
80
81
50x90x21.75
50x2.65x18 FI
AT 01619
30 x 2.75 x 10
79
FI AT 01619
68
Z=13
35x72x18.25
41.275x82.55x26.543
30x2.75x10 FI
AT 01619
95 94 93
FI AT 01619
30x2.75x10
Z=36
50x90x21.75
92 91
87
35
36
79
90
89
86
80
85
84
83
82
G
88
MDM1498A
8
ILLUSTRATIONS KEY, PAGE 10, 11, 12 AND 13 A. B. C. D.
Hub without brakes. Hub with brakes. Bevel drive and differential without lock. Bevel drive and self--locking differential.
(Lim--Slip). E. Axle rear view with steering cylinder. F. Axle pivot to support. G. Bevel drive with hydraulic differential lock.
a. 2.5 to 3 mm -- Sunken seal assembly recess.
b. 1 mm -- Seal gap on axle shaft.
1. Steering cylinder unit.
5. 6. 7. 8. 9.
2. Axle shaft bush grub screw. 3. Stub axle pin. 4. Stub axle.
Sunken seal. Final drive ring gear support. Wheel hub. Final drive ring gear. Driven gear shims. 87679925A - 12 - 2007
14 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53.
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 Driven gear support pin. Driven gears. Final drive cover. Wheel hub to spindle mating ring nut. Wheel hub support bearings. Seal. Stub axle adjustment rings. Axle shafts. Bearing retaining circlips. Oil seal. Braking line. Front brake piston bleed compartment plug. Front brake bleed screw. Final drive ring gear / front brake cylinder support. Front brake ring piston. Wheel hub to spindle mating screws. Brake disc hub. Outer brake disc. Outer brake disc thrust ring. Brake disc. Inner brake disc. Antifriction bushing. Double universal joint. O Ring. Front axle shaft bushing. Differential/ring gear bearing support cap. Ring nut for adjusting pre--load of bearings / pinion ring gear teeth clearance. Side gear. Differential casing centring pin. Friction disc keyed onto side gear. Friction disc keyed onto side gear. Metal disc keyed onto casing. Differential casing retaining bolt. Steering head connecting to spindle. Head retaining nut (toe--in adjustment). Steering arm joint. Steering piston rod. Left steering line. Steering cylinder support. Cylinder piston. Steering cylinder chamber. Right steering line. Ring nut fastening steering cylinder to support. Front axle housing.
87679925A - 12 - 2007
54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. 83. 84. 85. 86. 87. 88. 89. 90. 91. 92. 93. 94. 95.
Differential -- bevel drive support. Front axle support. Rear axle support. Bushing mounted on pinion support. Antifriction bushing mounted on rear axle support. Seal. Rear axle support thrust washer. Seal. Front support antifriction bushing. Front axle pivot pin. Front axle support. Front support centring dowel. Front support retaining bolt. Front axle support thrust washer. Differential lock cylinder / casing. Differential lock engagement piston O--ring. Differential lock engagement piston. Front gear thrust washer on the piston. Front gear retaining circlip on the piston. Front gear keyed on right axle shaft. Front gear bronze thrust washer. Differential lock disengagement spring. Lock engagement oil inlet line. Front gear keyed onto differential casing. Differential casing support right bearing retaining circlip. Differential casing support bearing. Pinion support bearings. Pinion retaining ring nut. Dust cover. Oil seal. Pinion bearing pre--load adjustment. Pinion. Crown wheel. Planet pinion shim ring. Side gear. Side gear pinion shim ring. Side pinion pin. Side pinion pin retaining grub screw. Side pinion. Differential cage. Pinion / ring gear teeth clearance adjustment ring. Differential housing support bearing support cap retaining bolt.
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 DESCRIPTION AND OPERATION All the models in the range have their front axle pivoted at the centre with the pivot and drive gear shaft coaxial to the tractorâ&#x20AC;&#x2122;s longitudinal axis; the drive gear shaft has no universal joints. 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. For the hydraulically controlled front gear--type differential lock, see page 16. LIM_SLIP SELF--LOCKING DIFFERENTIAL OPERATION The differential with limited--slip locking (LIM -- SLIP, see figs. 6 and 9) is of the two planet gear--type, provided with two multi--disk clutch assemblies fitted
15
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.
A
A 1
2
3
MDM1500A
9
LIM--SLIP self--locking differential
1. Metal disc keyed onto differential casing. 2. Friction disc keyed onto side gear.
3. Friction disc keyed onto side gear.
87679925A - 12 - 2007
16
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
Front differential lock disengaged
Front differential lock engaged
Discharge oil Pressurised oil
MMM1530A
10
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).
87679925A - 12 - 2007
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
17
FRONT AXLE HYDRAULIC DIFFERENTIAL LOCK TROUBLESHOOTING
Problems
Possible causes
The differential lock fails to en- 1. Transmission oil level low. gage.
Solutions Top up oil.
2. Clogged oil filter.
Replace filter.
3. Hydraulic pump faulty.
Overhaul or replace the pump.
4. Faulty differential lock--unlock Replace switch. switch. 5. Lack of power supply to the sole- Check electrical connections and renoid valve: connections loose or place defective parts. 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 disen- 1. Differential lock solenoid valve Overhaul or replace solenoid valve. gage. jammed in delivery position. 2. Differential lock release spring Replace spring. broken. 3. Lack of power supply to the sole- Check electrical connections and renoid valve: connections loose or place defective parts. damaged, contactor faulty. With differential lock engaged, 1. Differential lock the differential lock does not switch (connected to disengage when brake pedals pump) defective. are pressed.
control Change the switch or repair the elecbrake trical system.
87679925A - 12 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
18
2
1 5 S 4
3
1 9 8
6
7
MDM1579A
11 Approximate cross--sectional view for correctly fitting the axle support to the engine
1. 2. 3. 4. 5.
Front axle support. Crankcase front surface. Engine sump front surface. Shim. Axle support to crankcase retaining bolt.
6. Sump to axle support retaining bolt. 7. Rear axle retaining bracket. 8. Differential support. 9. Steering cylinder.
RULES FOR CORRECTLY FITTING THE AXLE SUPPORT TO THE ENGINE To fit the axle support to the engine on the tractors, proceed as follows. Using a gauge, measure the distance (S, fig. 11) between the sump front (3) and the crankcase front (2). Select the shim (*) to insert on the stem of the screw (5) between the axle support (1) and the crankcase front (2) as illustrated in the figure and in the table alongside. Tighten the screws (1 and 6) to a torque of 550 Nm (56 kgm).
87679925A - 12 - 2007
Distance S
Shim (*) to insert
From 1.30 to 1.50
47136468 (1.6 black)
From 1.51 to 1.70
47128135 (1.8 yellow)
From 1.71 to 1.90
47128136 (2.0 red)
From 1.91 to 2.10
47128137 (2.2 green)
From 2.11 to 2.30
47128138 (2.4 blue)
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
19
FRONT AXLE 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: NOTE: The front axle assembly can be removed from the tractor with either the propshaft removed from or installed in the tractor. 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. Disconnect the battery negative cable (1).
12 2. Unscrew the bolts (1) and remove the front mudguard supports (2).
13
87679925A - 12 - 2007
20
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
3. Remove the split pins, lock pins and front ballast (1).
14
4. Take out the bolts (1) and remove the drive gear shaft guard (2).
15 5. Remove the circlip (2) and move the sleeve (1) in the direction indicated by the arrow until it is released from the groove on the drive. 6. Attach the front axle to a hoist using two nylon slings. 7. Raise the tractor and position a fixed stand under the engine sump.
1
2
25040
8. Remove the unions (1) on the power steering cylinder rigid pipes (2) and disconnect the two hoses (3).
16
17 87679925A - 12 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
21
9. Remove the front differential lock union (1) and the hose (2).
10. Unscrew the retaining bolts and remove the front wheels.
18
19 11. Take out the front axle rear support retaining bolts (1).
12. Take out the front axle front support retaining bolts (1).
20
21 87679925A - 12 - 2007
22
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
13. Using the hoist and the two nylon slings, one on each side, detach the front axle. 14. To assemble the front axle, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
Position the axle, tighten the front and rear supports to the relative support.
--
Fit the front wheels.
--
Reconnect the differential lock pipe and the power steering pipes.
--
Using the hoist, raise the front part of the tractor.
--
Extract the fixed stand.
--
Remove the nylon slings from the axle.
--
Connect the drive shaft and position the guard.
--
Refit the two front mudguards.
--
Attach a nylon sling to the front ballasting, fit and secure in position with the lock rod.
--
Reconnect the battery negative lead.
--
Respect the tightening torques prescribed on page 5.
87679925A - 12 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
23
FRONT AXLE 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.
NOTE: Front axle overhaul operations must be carried out on stand no. 380000251.
22
1. Take out the three bolts (1) retaining the mudguard support (2).
23 2. Remove the plug (1) and drain the oil from the axle casing.
1 25588
3. Remove the plug (1) from the left--hand epicyclic final drive casing; repeat the same operation on the right--hand casing.
24
1
25589
25 87679925A - 12 - 2007
24
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
4. Remove the nuts (1) locking steering heads on stub axles.
5. Using an extractor, extract the steering heads from the seats on the stub axle housings.
26
27 6. Extract the steering heads (1) governing the stub axles, on both sides. On the left--hand side, loosen the locknut (2) for adjusting toe--in, then fully unscrew the head.
7. Take out the power steering pipe bracket retaining bolt (1), remove the related unions and extract them.
28
29 87679925A - 12 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
25
8. Unscrew the ring nut retaining the steering cylinder on the support.
9. Loosen the right--hand steering union (1) then extract it. Then extract the cylinder assembly, taking it out from the left--hand side of the support.
30
31 10. Remove the front axle rear support (1); remove the front support and washer.
11. Take out the bolts (1) securing the left--hand final drive cover. Tighten two pins (2) and, using an extracting tool screwed into the oil drainage plug hole, remove the cover (1).
32
33 87679925A - 12 - 2007
26
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
12. Remove the notching (1) on the ring nut (2) retaining the wheel hub bearings.
13. Remove the lock nut on the wheel hub bearings using wrench 380000269 (1).
34
35 14. Remove the wheel hub (1) together with the epicyclic crown (2) and recover the disassembled parts.
15. Take out the three upper pin retaining bolts (1), take out those of the lower pin and retrieve the shims.
36
37 87679925A - 12 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
27
16. Extract the upper pivot pin (1) as well as the lower one and remove the stub axle. Recover all disassembled parts.
17. Take out the axle shaft bushing retaining bolt.
38
39 18. Using a crowbar, remove the axle shaft (1). 19. To disassemble the right--hand final drive follow the operations carried out for left--hand final drive disassembly, from operation no. 11. to operation no. 18.
20. Take off the bracket (1), unscrew the union (2) and remove the differential lock control rigid pipe.
40
41 87679925A - 12 - 2007
28
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
21. Unscrew the two bevel drive--differential support retaining bolts from the axle casing, screw on the two pins (1). Remove the remaining bolts and the bevel drive-differential support, attach a chain and put the hoist under strain. Remove the bevel drive--differential support (2) from the axle casing.
22. Mount the unit in the vice. From the back of the differential unit, remove the propeller shaft thrust circlip, dust plate and oil seal (1) from the pinion stem. NOTE: To protect the unit, put the lead cheeks between the jaws of the vice and the unit, and when available use tool 380000255.
42
43 23. Remove the rigid coupling for introducing oil into the differential lock (1).
24. Replace two screws of the differential lock actuator unit (select the ones diametrically opposite) with two screws at least 70 mm long; set them at least 5 turns. Unscrew the others by a few turns alternately so as to allow stretching out the differential release spring, then remove both these and the two long ones. Remove the differential lock actuator unit.
44
45 87679925A - 12 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
29
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. 4. Using a screwdriver, remove the circlip (1) and the differential lock sleeve keyed onto the differential casing.
5. Using an Allen wrench remove the right ring nut lock screw (1); using pliers, remove the circlip on the left bearing support.
46
47 6. Take out the bolts (1) retaining the bevel crown wheel--differential support caps and remove them.
7. Remove the crown wheel--differential unit (1) from the casing, retrieve the races of the bearings and the right shim.
48
49 87679925A1 - 02 - 2008
30
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
8. Remove the securing ring on the pinion ring nut. Take off the ring nut with wrench 380000268 (1) keeping the bevel pinion shaft locked with wrench 380000257 (2). Retrieve the pinion together with the front bearing, rear bearing and bearing pre--load shim.
9. To assemble the front axle, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. -----
Study the illustrations in figs. 5, 6, 7 and 8 for the positioning of the various parts. Respect the tightening torques prescribed on page 5. Carry out the adjustments described from page 45 to page 51. Secure the ring nut, fit the seal, dust ring and propeller shaft sleeve thrust ring on the back of the bevel pinion.
NOTE: To mount the sunken oil seal use the tool 380200041, for the dust cup use tool 380200042. ---
---
---
Mount the differential lock sleeve (77, fig. 8) and the stop ring. Mount the differential lock actuator unit together with the spring (75, fig. 8) and secure it with the 2 screws size 70 mm, tighten the other bolts then replace the two long ones with those of normal use. Mount the rigid pipe for delivering oil to the differential lock. Install the bevel drive--differential support to the front axle housing applying sealing compound of diameter approximately 2 mm following the route of fig. 98 mount the differential lock outside pipe. Fit the axle shaft and screw. Fit the stub axle, the adjustment shims, the upper and lower pivot pins.
87679925A1 - 02 - 2008
50
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 --
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 final drive cover.
--
Fit the front and rear supports and the oil drainage plugs.
--
Fit the steering cylinder, secure it with the coupling removed in operation no. 9. secure the cylinder with the ring nut (52, fig. 7).
--
Inset the right steering head then insert both on the stub axles then put on the lower nut and secure it.
--
Mount the rigid pipes of the power steering, fill up with oil then secure the filler caps.
--
Fit the front mudguard supports.
--
Check the toe--in, then tighten the toe--in adjustment locknut.
31
87679925A - 12 - 2007
32
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
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 micrometer.
24597
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 side 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.
51
24598
52
87679925A - 12 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
1
33
2
5 3 2 4
MDD1351A
53 Front axle differential with LIM--SLIP
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 380 000 255 (4), lock in a vice and proceed with disassembly operations as follows. 2. Take out the Allen screws (3) retaining the right (5) and left ring nuts. 3. Check that the right-- and left--hand caps (1) are marked so as not to interchange them during assembly. 4. Remove the right (5) and left--hand bearing adjustment ring nuts from the bevel crown wheel. 5. Take out the bolts (2) and caps (1) and separate the bevel crown wheel from the bevel pinion support. 6. If necessary, take out the retaining bolts (C9, page 5) and the bevel crown wheel.
87679925A - 12 - 2007
34
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
Disassemble the LIM--SLIP self--locking differential lock as follows. 1
7. Remove the retaining bolts (6) from the differential half--casings.
2
8. Remove the differential pin (9), complete with the planet gears (7), the shims (8) and the retaining pin (2) from the half--casing (4). 9. Remove the side gear (5), friction disk (11, fig. 55), metal disks (10) and friction disks (12).
9
10. Remove the side gear (1), friction disk (11), metal disks (10) and the friction disks (12) from the half-casing (3).
8
11. 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.
6
12. 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 (6) and tighten to a torque value of 50 Nm (5.1 kgm).
7
5
4
3
MDD1350A
LIM--SLIP self--locking differential
13. Refit the crown wheel (if previously disassembled) on the half--casing (9), tightening the bolts (C3, page 5) to a torque of 113 Nm (11.5 kgm). 14. Check the rolling torque of the bevel pinion, as indicated on page 48. 15. 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 49.
54
z
27967
55 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
87679925A - 12 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
35
FRONT AXLE DIFFERENTIAL LOCK CLUTCH ASSEMBLY 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. Position the bevel crown wheel--differential assembly on the support 380000255 and proceed as follows: 1. Remove the differential lock control internal pipe. 2. Remove the upper (2) and lower (1) bolts of the external differential lock bell housing 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 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.
56
1
2
25609
4. Using a screwdriver, remove the circlip (2) and the differential lock sleeve.
57
58
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36
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
5. Remove the circlip securing the differential lock piston, recover the sliding sleeve with the two thrust washers.
24093
59
6. Gently tap the piston out of the clutch bell housing.
24094
60 7. Remove the differential lock piston. 8. To refit the differential lock clutch parts follow the disassembly procedure in reverse order, proceeding as follows. 9. Carefully check the condition of the two O--ring seals installed on the piston. 10. Fit the clutch bell unit complete with spring and piston using the two 70 mm bolts used during disassembly operations.
24095
61
87679925A - 12 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
37
FRONT EPICYCLIC FINAL DRIVE WITHOUT BRAKE 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.
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. Position the axle on stand 380000251.
62 2. Remove the plug (1) and drain the oil from the epicyclic final drive.
1
25589
63 3. Unscrew the cover retaining bolts (1) on the final drive, screw in two pins (2) and, using an extracting tool inserted in the oil drainage plug hole, detach the cover (1).
1
2
25594
64
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38
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
4. Remove the notching (1) on the ring nut (2) retaining the wheel hub bearings.
1
2
25597
5. Remove the lock nut on the wheel hub bearings using wrench 380000269 (1).
65
1
25598
66 6. Remove the wheel hub (1) together with the epicyclic final drive fixed gear (2). Recover all disassembled parts. 7. To refit the front epicyclic final drive, proceed as follows.
1
2
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
25599
--
Study the illustrations in figs. 5, 6, 7 and 8 for the positioning of the various parts.
--
Respect the tightening torques prescribed on page 5.
87679925A - 12 - 2007
67
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 --
39
Check the state of the seal (5, fig. 5), if it should be changed then remove it and turn the hub over on a bench, clean the seat of the seal thoroughly. Set it inside the circumference of the hub and with tool 380200017 (1) drive it in until the edge of the tool meets the top surface of the hub so as to ensure the assembly stand--in (a, fig. 5) of the oil seal.
68 --
Also check the state of the seal on the wheel hub between it and the axle shaft (15, fig. 5), if it should be changed then take it out and using tool 380200019 insert it until the tool makes contact with the spindle so as to leave the gap (b fig. 5).
--
Assemble the wheel hub and the epicyclic final drive fixed gear.
--
Progressively tighten the ring nut, using the torque wrench and wrench 380000269 (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.
24072
69 --
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):
87679925A - 12 - 2007
40
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
--
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 = 4.28 รท 10.71 kg
--
If the measurement is less than 5.9 Nm (0.6 kgm) or with the torque meter on 4.28 kg it is necessary to replace the affected parts and repeat the check. Progressively tighten the ring nut, using the torque wrench and wrench 380000269 (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 in fig. 98.
--
Assemble the epicyclic final drive casing, complete with gears.
--
Fill up the front epicyclic final drive (for recommended products and quantities see Section 00).
--
Mount the steering heads.
87679925A - 12 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
41
FRONT EPICYCLIC FINAL DRIVE WITH BRAKE 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. 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. Position the axle on stand 380000251. 2. Remove the plug (1) and drain the oil from the epicyclic final drive.
1
25559
70 3. Unscrew all of the epicyclic final drive casing retaining bolts (1).
1
25560
4. Using an extractor (1), fitted on the oil drainage plug, detach the epicyclic final drive casing (2).
71
1
2
25561
72
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42
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
5. Remove the circlip (1) and extract the external brake disk (2).
6. Remove the hub (1) and associated brake friction disk.
73
1
25563
74 7. Take out the retaining bolts and remove the final drive fixed gear (1) using two screws as an extractor.
1
8. To refit the front epicyclic final drive, proceed as follows.
ATTENTION
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
25562
--
Study the illustrations in figs. 5, 6, 7 and 8 for the positioning of the various parts.
--
Respect the tightening torques prescribed on page 5.
--
Refit the drive fixed gear.
--
Refit the brake disk hub.
--
Fit the outer brake disk and secure in position.
87679925A - 12 - 2007
75
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 --
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 fig. 98.
--
Assemble the epicyclic final drive casing, complete with gears.
--
Fill up the front epicyclic final drive (for recommended products and quantities see Section 00.
43
87679925A - 12 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
44
WHEEL HUB SEAL WITH BRAKE Renew
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. Disassemble the front epicyclic final drive with brake (see page 41) and remove the hub casing (1). 2. Remove the seal and fit the pins (1) of tool 380200018.
76
77 3. 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. 4. Fit the seal (2, Fig. 79) fully tightening the screws on tool 380200018 (1).
5. To refit the wheel hub parts, proceed as follows.
78
ATTENTION
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. ---
Remove tool 380200018 from the hub. Mount the front epicyclic final drive with brake (see page 42).
79 87679925A - 12 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
45
STUB AXLE ADJUSTMENTS
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. Position the front axle on stand 380000251 and proceed as follows:
1. Smear AMBRA GR9 GREASE on the outer races of the bearings and fit the upper cover, without the plates, but with tool 380000235 (1). Tighten the retaining screws (C16, fig. 2) to a torque of 64 Nm (6.5 kgm). NOTE: At some points on the upper pin the lubricator is no longer positioned vertically, but is horizontal, for access with the front mudguard support. Put a few washers under the tool as shims, temporarily inserting longer screws.
80
2. Fit the lower cover without adjustment plates, lubricate the three retaining bolts with engine oil. 3. Gradually tighten the lower cover bolts in sequence, while simultaneously rotating the casing to allow the excess grease to escape.
81 4. Using a torque wrench and tool 380000235 (1), check that the torque required to rotate the casing is: 3.9 รท 5.8 Nm (0.4 รท 0.6 kgm) without considering the peak starting value. If not, adjust by way of the lower cover bolts. 5. Measure the gap (H) created between the lower cover and the casing adjacent to each of the three bolts.
1
MDD029A
82
87679925A - 12 - 2007
46
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
6. Calculate the average of the three values measured. The total thickness of the adjustment plates (16, fig. 5) to be fitted under the lower cover will be given by: S=H If necessary, round the value down to the next 0.05 mm.
24079
7. Partially unscrew the lower cover bolts, insert the shims (16, fig. 5) and tighten the bolts (C16, fig. 2) to a torque of: 64 Nm (6.5 kgm).
8. Check that the torque necessary to rotate the casing is 3.9 รท 9.8 Nm (0.4 รท 1 kgm), without considering the initial peak torque.
9. 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.
10. Fit the grease nipples in the upper and lower covers and grease the assembly.
87679925A - 12 - 2007
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SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
47
PINION AND CROWN WHEEL ADJUSTMENTS Adjusting the bevel pinion shaft bearing preload with shims (84, fig. 8).
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. After removing the pinion (1), use a gauge or a 1/20 depth gauge to measure the distance L of the end of the pinion to the diameter, of the pinion, of the thrust element of the bearing pre--load adjustment shim (2).
2
1
L MDM1501A
84 2. Refit the pinion on the support complete with the bearings (80, fig. 8), omit assembling the adjustment shim (84, fig. 8), keeping it still with the tool 380000257, then tighten the ring nut with the tool 380000268.
85 3. Tighten the ring nut to a torque of 382.5 Nm (39 kgm) ensuring the bearings bed in. Then check again that the rolling torque is: A1 0.49 รท 0.98 Nm (0.05 รท 0.1 kgm) without considering the initial peak torque. Select a thinner shim if the torque is greater otherwise select one with a greater thickness it is less. NOTE: During these operations be sure the bearings are bedded in, perhaps do not tighten the ring nut to torque immediately, but tighten it to a markedly lower torque, then turn the pinion so that the bearings are bedded in.
86
87679925A1 - 02 - 2008
48
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
4. Measure the distance L1 from the back end of the pinion (1) and the back end of the ring nut (2).
2
1
L1 MDM1502A
87
5. Remove the pinion. The bearing pre--load adjustment shim S (2) will be: S = L -- (L1 + C + G + 0.05) mm where: C = thickness of the bearing. G = height of the ring nut.
2
1
S C
MDM1503A
L1 G L 88
6. Refit the pinion on the support complete with the bearings (80, fig. 8) and the adjustment shim (84, fig. 8), keeping it still with the tool 380000257 (1), then tighten the ring nut with the tool 380000268 (2).
7. Tighten the ring nut to a torque of 382.5 Nm (39 kgm) ensuring the bearings bed in. Then check again that the rolling torque is:
89
A1 0.49 รท 0.98 Nm (0.05 รท 0.1 kgm) without considering the initial peak torque. Select a thinner shim if the torque is greater otherwise select one with a greater thickness it is less.
90 87679925A1 - 02 - 2008
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
49
PINION AND CROWN WHEEL ADJUSTMENTS Adjusting the bevel crown wheel bearings and checking the clearance between the sides of the bevel drive teeth Proceed as follows: 1. Fit the differential unit on the differential bevel drive support together with the bevel drive complete with bearings (79, fig. 8) and, on the right side bearing adjustment ring (94, fig. 8) Sp after measuring it.
91 2. Install the differential casing 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). Fit the related circlip on the right--hand side.
92 3. With the bearings perfectly lubricated, rotate the bevel crown wheel and, at the same time, tighten the ring nut using wrench 380000252 (1) to a torque value of 39 รท 59 Nm (4 รท 6 kgm) to take up the axial play between the components.
93
87679925A - 12 - 2007
50
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
4. 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). 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 á 0.20 mm average value 0.18 mm. If the measured backlash exceeds the prescribed value, fit a thinner adjustment shim (94, fig. 8).
94
NOTE: On standard models (version 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 value (94, fig. 8) to fit on the bevel drive--differential support will be given by: or: -- 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 (94, fig. 8), the value being given by: -- S = Sp + {(0.18 -- Gm ) x 1.35} 5. Fit a shim (94, fig. 8) of the calculated thickness and with a 1/100 scale dial gauge (1) 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 0.15 to 0.20 mm.
95
87679925A - 12 - 2007
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
51
6. Using wrench 380000257 adjust the ring nut and check, using torque wrench (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. 96 7. Tighten the cap retaining screws (C10, fig. 1) to a torque of 113 Nm (11.5 kgm). 8. Fit the safety plate, screwing the adjustment ring nut in or out, to reach the nearest notch. 9. 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.
97 Sealing compound application diagram for assembly of bevel drive unit and epicyclic final drive unit The types of sealing compounds to be applied are specified in Section 00.
24595
98
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SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
1
SECTION 27 -- REAR MECHANICAL TRANSMISSION Chapter 1 -- Rear axle mechanical transmission CONTENT Description
Page
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Gearbox--transmission casing R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Gearbox/transmission casing D.A. and adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Adjustments -- differential lock control pedal travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Final drive casing R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Adjustments -- bevel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Epicyclic final drive D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Drive wheel shaft D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Platform R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (See sect. 90)
87679925A - 12 - 2007
2
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 TRANSMISSION AND RANGE GEAR DATA
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --
gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reduction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --
gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox and reduction unit controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox driving shaft end float:
4 speed, constant--mesh, with synchronisers on all gears helical cascade--type with 3 ranges. spur independent, by means of two hand levers located on the right-hand side of the operator See adjustment on page 43
all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
0.00 ÷ 0.25
Thickness of gearbox driving shaft adjustment ring . . . . . . . . . . .
mm
3.00--3.25--3.50--3.75--4.00
Inside diameter of gearbox driven gears . . . . . . . . . . . . . . . . . . . . .
mm
50.050 ÷ 50.075
External diameter of relative bushings (15, fig. 10) . . . . . . . . . . . .
mm
49.925 ÷ 49.950
Clearance between gears and bushings . . . . . . . . . . . . . . . . . . . . .
mm
0.100 ÷ 0.150
Diameter of gearbox driven shaft (16, fig. 10) . . . . . . . . . . . . . . . .
mm
39.175 ÷ 39.191
Internal diameter of bushings (15, fig. 10) . . . . . . . . . . . . . . . . . . . .
mm
39.200 ÷ 39.239
Clearance between shaft and bushings . . . . . . . . . . . . . . . . . . . . . .
mm
0.009 ÷ 0.064
PTO clutch shaft diameter (4, fig. 10) . . . . . . . . . . . . . . . . . . . . . . .
mm
24.975 ÷ 24.955
Installed bush internal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
25.040 ÷ 25.092 (1)
Clearance between PTO clutch shaft and relative bushing . . . . .
mm
0.040 ÷ 0.113
Bush instalment interference on transmission drive shaft . . . . . . .
mm
0.037 ÷ 0.091
--
Springs (5, fig. 11) for main gear and creeper rod poppet balls: --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
30
--
spring length under load of 50 ÷ 56 N (5.13 ÷ 5.67 kg) . . . . .
mm
25,5
Gear and range gear lever retaining springs: --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
75
--
spring length under load of 94 ÷ 104 N (9.6 ÷ 10.6 kg) . . . . .
mm
42
(1) Value to be obtained without grinding operations.
87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
3
BEVEL DRIVE AND DIFFERENTIAL DATA Bevel drive gear ratio: -All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearance between sides of bevel drive gear teeth: (1) -All models (first series of casings) . . . . . . . . . . . . . . . . . . . . -All models (next series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type of differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanically controlled differential lock . . . . . . . . . . . . . . . . . . . Differential release control for mechanical command . . . . . . .
mm mm
Electrohydraulically controlled differential lock . . . . . . . . . . . . .
10/44 = 1:4.4 See adjustments pages 48 e 51 0.18 ÷ 0.23 0.15 ÷ 0.50 with two side pinions pedal operated hydraulic, pedal--controlled, service brakes controlled by switch located on control panel
Side pinion internal seat diameter (7, figs. 12, 13 and 14): --
Mod. 56/76, 63/86 and 71/97 KW/HP . . . . . . . . . . . . . . . . .
mm
25.040 ÷ 25.061
--
Mod. 78/106 and 83/113 KW/HP . . . . . . . . . . . . . . . . . . . . .
mm
30.040 ÷ 30.061
Side pinion pin diameter (36, figs. 12, 13 and 14): --
Mod. 56/76, 63/86 and 71/97 KW/HP . . . . . . . . . . . . . . . . .
mm
24.939 ÷ 24.960
--
Mod. 78/106 and 83/113 KW/HP . . . . . . . . . . . . . . . . . . . . .
mm
29.939 ÷ 29.960
Clearance between side pinions and pin . . . . . . . . . . . . . . . . . . Diameter of crown wheel pinion hub seats on differential housing (1, figs. 12, 13 and 14):
mm
0.080 ÷ 0.122
--
Mod. 56/76, 63/86 and 71/97 KW/HP . . . . . . . . . . . . . . . . .
mm
51.100 ÷ 51.146
--
Mod. 78/106 and 83/113 KW/HP . . . . . . . . . . . . . . . . . . . . .
mm
60.100 ÷ 60.146
Crown wheel hub diameter (27, figs. 12, 13 and 14): --
Mod. 56/76, 63/86 and 71/97 KW/HP . . . . . . . . . . . . . . . . .
mm
50.954 ÷ 51.000
--
Mod. 78/106 and 83/113 KW/HP . . . . . . . . . . . . . . . . . . . . .
mm
59.954 ÷ 60.000
Clearance between sun pinion hubs and seats . . . . . . . . . . . . Bevel pinion position adjustment: (1)
mm
Bevel pinion position adjustment shims (1) . . . . . . . . . . . . . . . . .
mm
Distance between pinion base and crown centre . . . . . . . . . . . . Clearance between sides of sun and planet pinion teeth:
mm
0.100 ÷ 0.192 See adjustment on page 45 1.85 -- 1.90 -- 1.95 -- 2.00 -- 2.05 -2.10 -- 2.15 -- 2.20 -- 2.25 -- 2.30 -2.35 -- 2.40 -- 2.45 -- 2.50 -- 2.55 -2.60 -- 2.65 -- 2.70 145.5 See adjustment on page 53
--
Mod. 56/76, 63/86 and 71/97 KW/HP . . . . . . . . . . . . . . . . .
mm
0.226 ÷ 0.302
--
Mod. 78/106 and 83/113 KW/HP . . . . . . . . . . . . . . . . . . . . .
mm
0.303 ÷ 0.307
Thickness of differential crown wheel shim adjustment rings: --
Mod. 56/76, 63/86 and 71/97 KW/HP . . . . . . . . . . . . . . . . .
mm 1.4 -- 1.5 -- 1.6 -- 1.7 -- 1.8 -- 1.9 -- 2.0
--
Mod. 78/106 and 83/113 KW/HP . . . . . . . . . . . . . . . . . . . . .
mm
1.4 -- 1.5 -- 1.6 -- 1.7 -- 1.8 -- 1.9 -2.0 -- 2.1 -- 2.2
(1) This adjustment is only to be done on the first series of machines, for further information see page 45.
(overleaf)
87679925A2 - 02 - 2010
4
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 (overleaf)
Thickness of side gears thrust washers: . . . . . . . . . . . . . . . . . . Differential lock sliding sleeve travel adjustments (b, figs. 12, 13 and 14): -All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thickness of differential lock control fork adjuster . . . . . . . . . . Differential lock control fork spring (Mechanical control): -spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -spring length under load of 177 ÷ 195 N (1.81 ÷ 19.9 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential lock control fork spring (Electrohydraulic control): -spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -spring length under a load of 304 ÷ 335 N (31.0 ÷ 34.2 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
1.470 ÷ 1.530
mm mm
See adjustment on page 44 8.1 ÷ 8.2 0.5
mm
220
mm
157.5
mm
237
mm
159.5
FINAL DRIVE DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
epicyclic with three side pinions with straight toothing
Reduction Ratio: --
all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thickness of side gears thrust washers . . . . . . . . . . . . . . . . . .
13 : (13+65) = 1 : 6 mm
Adjusting end float of side pinion casing (b, figs. 12, 13 and 14): --
axle shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thickness of end float adjuster rings for side pinion casing .
87679925A2 - 02 - 2010
1 see adjustment on page 60
mm
0.2 ÷ 0.4
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
5
BOLT TORQUES PARTS TO BE TIGHTENED
Thread
Gearbox--transmission casing upper cover retaining bolts (C1) .
Tightening torque Nm
kgm
M 10x1.25
59
6
Bolts securing lift to rear transmission casing (C2) . . . . . . . . . . . .
M 12x1.25
98
10
Retaining bolts securing power take--off casing to gearbox--transmission casing (C3) . . . . . . . . . . . . . . . . . . . . . . . . . .
M 16x1.5
221
22.5
Bolts securing flex bar to the gearbox--transmission casing (C4)
M 16x1.5
221
22.5
Nuts for stud bolts securing final drive casing to gearbox--transmission casing (C5) . . . . . . . . . . . . . . . . . . . . . . . . . .
M 14x1.5
176
18
Nuts for drive wheel ballast ring retaining bolts (C6) . . . . . . . . . . .
M 14x1.5
98
10
Locknuts for drive wheel hub plate disk (C7) . . . . . . . . . . . . . . . . . .
M 18x1.5
255
26
Nuts for bolts securing steel plate disc to drive wheel rim (C8) . .
M 16x1.5
245
25
Drive wheel axle retaining bolt (C9) . . . . . . . . . . . . . . . . . . . . . . . . .
M 16x1.5
250
25.5
Bevel drive retaining bolts (C10) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 12x1.25
123
12.5
Bevel drive support retaining bolts (C11) . . . . . . . . . . . . . . . . . . . . .
M 10x1.25
61
6.2
Retaining bolts securing clutch casing to gearbox--transmission casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 12x1.25
98
10
Retaining bolts securing drive casing to gearbox--transmission casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 12x1.25
98
10
Nuts for drive wheel rim -- RAIL disk retaining bolts . . . . . . . . . . .
M 20x1.5
245
25
Nuts for drive wheel hub -- fixed disk retaining bolts . . . . . . . . . . .
M 18x1.5
314
32
Pinion bearing pre--load ring nut (C12) . . . . . . . . . . . . . . . . . . . . . . .
M 45x1.5
38 ÷ 42
3.87 ÷ 4.28
Gear driven shaft ring nut (C13) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 32x1.5
280 ÷ 309
28.5 ÷ 31.5
Gear driven shaft front bearing retaining bolt (C14) . . . . . . . . . . . .
M 8x1.25
26 ÷ 30
2.65 ÷ 3.06
87679925A - 12 - 2007
6
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 BOLT TORQUES
1
87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
7
SPECIAL TOOLS
CAUTION The operations described in this section can only be carried out with the 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.
380000301 Rotating stand for overhaul operations.
380000271 Front bracket (with 380000301).
380000272 Rear bracket (with 380000301).
380000249 Bevel pinion positioning gauge. List of specific tools required for the various operations described in this Section.
380000236 Tractor disassembly trolley.
380000227 Clutch casing lift hook.
380000250 Tool for differential lock spring.
380000294 Cab lift adapter.
380000240 Universal hydraulic pressure control kit.
26260
2 Tool to be constructed for adjusting differential lock sleeve travel (Mark part with No. 50041 -- Measurements in mm) Make using C40 material
87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
8
25955
3 Tool to make for removal--installation of the final drive cover (mark tool with no. 50164 -- Measurements in mm) Make in UNI C40 material
26259
Tool to make for adjusting the assembly position of the bevel pinion shaft (Stamp no. 50004 -- Measurements in mm) Make using Aq 45 material
87679925A - 12 - 2007
4
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
9
Punch to make for gearbox driving shaft disassembly (mark part with no. 50006 -Measurements in mm). Make in UNI C40 material.
26215
5
Tool to make for adjusting the gearbox driving shaft bearings (mark part with No. 50007 -Measurements in mm). Make using Aq 45 material.
26216
6 87679925A - 12 - 2007
10
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
27893
Tool to make for front axle reduction unit cover disassembly--assembly (mark tool with no. 50169 -- Measurements in mm) Make in UNI C40 material
Tool to make for bevel pinion extraction (mark tool with no. 50144 -- Measurements in mm) Construct in UNI C40 material. Retaining pin 3 x 20 mm. 87679925A - 12 - 2007
7
8
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
11
9 Tool to make for adjusting the bevel drive (mark tool with no. 50027 -- Measurements in mm) Make in Fe 42 C material
87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
12
Longitudinal section of gearbox--transmission (mechanical 12X12 version)
1
2
3
4
5
6
7
8
9
10
11
12
X
X
X
Z=40 Z=33
Z=27 Z=21
45x85x19
40x90x23 40x80x18 D
A
60x110x22
Z 14
42x47x27
m 3.5 m=2.75
D1
m=2.75 m=2.75 m=2.75 45x100x20.75
40x90x23
35x80x21
45x100x38.25
10/44
27.5x52x21
540
Z=33 Z=39 4ٛ 3ٛ
Z=46
2ٛ 1ٛ 10.5
Z=52 10.5
Z 57
X X
13
X
14
15
16
17
18
19
20
21
X
22
MDM1504A
10
A. Maximum gearbox driving shaft end float 0.25 mm. 1. Gearbox driving shaft. 2. Bushings. 3. Gearbox fork drive nib. 4. Power Take Off driveshaft. 5. Spring for poppet ball of rod driving 1st and 2nd gear fork. 6. Poppet ball of rod driving 1st and 2nd gear fork. 7. Range driving shaft. 8. Low range gear drive. 9. Medium range engagement sleeve. 10. Medium range driving gear.
11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
PTO shaft joint fixed sleeve. Differential lock engagement fork. Gear driving shaft ring nut. 3rd and 4th gear synchroniser. Bushes. Gear driving shaft. Low and high gear engagement sleeve. Pinion bearing pre--load ring nut. Pinion. Crown wheel. Differential side pinion. Differential side pin.
NOTE: When fitting apply sealing compound to surfaces X as shown on page 34.
87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
1
2
1
2
13
3
14
16
12
10 9
17
85
15
4
34
11
11
12
13
14
8
7 5
6
5 6
11 11
10
9
8
7
4
3
MDM1505A
11 Transmission--gearbox cross--sectional views 1. 2. 3. 4. 5. 6. 7. 8.
Gear and range lever control rod. Fork and fork transmission drive nib. Medium range control fork. High and low range control fork. Springs for balls (8). Rod poppet balls. Safety pawls. Pawl insertion plug (screw in with Loctite 242 adhesive).
9. 10. 11. 12. 13. 14. 15. 16. 17.
Medium range fork control transmission. High and low range fork control transmission. Rods. 3rd and 4th gear fork. 1st and 2nd gear fork control transmission. 1st and 2nd gear fork control fork. 3rd and 4th gear synchroniser. Medium range engagement sleeve. Low and high range engagement sleeve.
87679925A - 12 - 2007
14
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
75x130x25
Transmission--gearbox cross--sectional views mods. 56/76 and 63/86 KW/HP
16
15 17
13
18
60x110x22
14
19 a
:- 0.4 Clearance 0.2-
12 X
21
35.7x49.7x21
X
22
9
X
B
10
20
I=78
11
X
23
8 65x100x23
25 26
7
27 b
0
6
55x100x22.75
*
5
29
28 30
4
31
3
32
2 1
36
35
34
33
MDM1506A
For the key, refer to page 17.
87679925A - 12 - 2007
12
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
15
75x130x25
Transmission--gearbox cross--sectional views mod. 71/97 KW/HP
16
15 17
13
18 65x120x23
14
19
12
10
: 0.2-- 0.4
X
a
20 21
X
11
22
X
I=78
9
X
23
8
25
7
26 27 b
6 5
30
4
31
3
32
2 1
36
35
34
33
MDM1507A
For the key, refer to page 17.
13
87679925A2 - 02 - 2010
16
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
75x130x25
Transmission--gearbox cross--sectional views mod. 78/106 and 83/113 KW/HP*
16
15 17
13
18 65x120x23
14
19
12 a
20
: 0.2-- 0.4
X
11
X
10
21 22 I=78
23
X
9
X 24
26,5 @0.03
25
75X115X25
+0,05 0
8 7
26
A**76.730* ***76.520*
27
6 b
28
*
5
65X100X23
29
4
30
3
31
2 1
36
35
34
33
32
MDM1508A
14 * This reinforced transmission, as a variant, can be fitted also on mod. 71/97 kW/HP For the key, refer to page 17. 87679925A2 - 02 - 2010
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
17
Key to rear transmission cross--sectional views mod. 56/76, 63/86, 71/97, 78/106 and 83/113 KW/HP
a
Rear reduction gear axle shaft assembly end float 0.2 รท 0.4 mm.
b
Differential lock engagement sliding sleeve travel 8.1 รท 8.2 mm.
1. Differential cage.
20. Rear brakes cylinder.
2. Differential lock control fork rod.
21. Rear brakes piston.
3. Differential lock fork.
22. Rear brake disc.
4. Differential lock disengagement spring.
23. Rear brake friction disc.
5. Pinion.
24. Plate retaining right--hand bearing supporting the differential in the transmission casing (mod. 105 and 113 Hp).
6. Crown wheel. 7. Side pinions. 8. Differential/rear reduction gear axle shaft.
25. Differential right--hand bearing support in the transmission casing (mod. 75, 85 and 95 Hp).
9. Oil infeed pipe to the braking system.
26. Differential support right--hand bearing.
10. Reduction gear side pinion carrier pins.
27. Crown wheels.
11. Reduction gear side pinion bearings.
28. Oil plug/oil anti--emulsion(*) casing fastener.
12. Reduction gear side pinions.
29. Oil anti--emulsion casing.
13. Circlip retaining pins (10) to the side pinion carrier.
30. Differential lock sliding sleeve.
14. Rear axle shaft support bearings.
31. Left--hand bearing support supporting the differential in the transmission casing.
15. Rear axle shaft.
32. Differential bearing pre--load ring nut.
16. Rear axle shaft oil seal.
33. Pre--load ring nut safety plate.
17. Bolt retaining side pinion carrier to the rear axle shaft.
34. Differential support left--hand bearing.
18. Side pinion carrier.
35. Pins locking the left--hand side gear to the differential casing.
19. Reduction ring gear.
36. Side pinion pin.
NOTE: When fitting apply sealing compound to surfaces X as shown on page 34. (*)
To prevent this plug from accidentally getting unscrewed and therefore the internal casing, losing its only point of anchorage, from getting between the metal parts and preventing them from rolling, the recessed hexagon at its bottom end has been covered with a sheet metal plug. Should this plug accidentally come out of its seat, on unscrewing the plug by a few turns it would become oddly stiff and the operation would be prevented by the split pin inserted on the upper end of the plug. All the plugs with a magnet for the oil coming out of the transmission are hexagonal plugs and not recessed hexagonal ones. To unscrew them you need a wrench and not an Allen wrench.
87679925A2 - 02 - 2010
18
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
1
2
3
4
5
26269
Rear differential lock disengaged
1
2
3
4
5
26270
Rear differential lock engaged Pressurised oil Discharge oil
DESCRIPTION AND OPERATION The rear transmission transmits drive from the gearbox to the final drives by means of the bevel drive, the teeth on the bevel drive are helical supported on tapered roller bearings. The differential has two planet gears and is fitted with a mechanically or hydraulically operated differential
15
lock. Operation of this device is described below. The final drives are of the epicyclical type and are operated by the bevel drive output half shafts, the same shafts that control the service brakes.
HYDRAULICALLY CONTROLLED REAR DIFFERENTIAL LOCK When the differential lock is not being used, it is held in the disengaged position by the pressure of the spring (4) on the fork (3). By operating the relative switch on the control panel, the solenoid valve opens to allow the oil sent from the pump to enter the chamber (1). After acting on the piston (2)
87679925A2 - 02 - 2010
and spring (4), it 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.
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
19
BEVEL DRIVE AND DIFFERENTIAL TROUBLESHOOTING Problems Transmission is noisy while the tractor is moving, even when the gears are in neutral (not due to Final drives).
Possible causes
Solutions
1. Incorrect adjustment of bevel Remove the rear transmission pinion and / or bevel crown gearbox and correctly adjust the wheel bearings. pinion support bearings (page 47) and bevel crown wheel (page 48 and 51). 2. Incorrect adjustment or wear Remove the rear transmission of sun and side pinions. casing, replace the worn parts and correctly adjust the differential gears (page 53). 3. Excessive clearance between Remove the rear transmission half--shaft keyed groove and casing and replace the damaged sun gears. parts.
Transmission is noisy when tractor is under or released from load.
Transmission noisy and assembly overheats.
1. Excessive coupling clearance between the teeth of the pinion and of the bevel crown wheel.
Remove the rear transmission casing and correctly adjust the bevel crown wheel and pinion support bearings (page 48 and 51).
2. Internal part faulty.
Remove the rear transmission casing, replace the worn parts and correctly adjust the differential gear clearance (page 53).
1. Pinion and / or bevel crown Remove the rear transmission wheel support bearing clear- casing and correctly adjust the bevel ance insufficient. crown wheel and pinion support bearings (page 47, 48 and 51). 2. Insufficient coupling clearance between the teeth of the pinion and of the bevel crown wheel.
Remove the rear transmission casing and correctly adjust the bevel crown wheel support bearings (page 48 and 51).
FINAL DRIVE FAULT DIAGNOSIS Problems Final drives are noisy while the tractor is moving, even when the gears are in neutral. neutral
Possible causes
Solutions
1. Incorrect adjustment of wheel Remove the final drive casing and axle shaft support bearings. adjust the bearings (page 61). 2. Internal part faulty.
Remove the final drive housing and replace the damaged parts.
3. Excessive clearance between Remove the final drive housing and wheel axle shaft spline and replace the damaged parts. epicyclic final drives.
87679925A - 12 - 2007
20
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 HYDRAULICALLY CONTROLLED DIFFERENTIAL LOCK TROUBLESHOOTING Problems
The differential lock fails to engage engage.
Possible causes
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 lock--unlock Replace switch. 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 sole- Overhaul or replace solenoid valve. noid 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 Overhaul or replace solenoid valve. valve jammed in delivery position. 3. Disengage spring faulty.
With the differential lock engaged, it cannot be disengaged by operating the brake pedals.
87679925A - 12 - 2007
Remove the hydraulic lift and replace the spring.
1. Differential lock control Replace switch. switch (connected to brake pump) defective.
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
21
REAR GEARBOX--TRANSMISSION CASING R.I.
ATTENTION
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 remove the rear transmission--gearbox casing proceed as follows: 1. Detach the cab (1) as directed in operation 9015010 and put it down on a wooden base.
16 2. Remove the plug (1) and drain off the fuel tank into a suitable container (tank capacity is 127 litres).
1
25518
17
87679925A - 12 - 2007
22
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
3. Take out the plug (1) and drain oil from the gearbox--transmission casing.
1
25622
18
4. Remove the 4WD transmission shaft guard by unscrewing the front, central and rear retaining bolts. Take off the circlip (2) and extract the sleeve (1) from the front axle pinion.
2
1
25039
19 5. Take off the circlip (2) and extract the sleeve (1) from the drive.
1
2
25040
6. Remove the propeller shaft central support (1) retaining bolts and extract the shaft together with the support.
20
1
25041
21 87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
23
7. Detach the pump oil suction pipe (3) from the gearbox--transmission casing, loosen the union and detach the delivery pipe (2) from the pump to the trailer brake control valve (1).
8. Disconnect: the trailer brake control piping (1) from the supporting plate (2).
22
2
1
25537
23 9. Disconnect the electrical connection (1) of the seven--pin socket, remove the two--pin socket (3) from its mounting, and unscrew the bolts (2 and 4) to disconnect the ground cables.
1
2 3
4 25536
10. Disconnect the electrical connection (1) on the PTO rev counter.
24
1
25545
25 87679925A - 12 - 2007
24
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
11. Unscrew the two top link third point support retaining bolts (1) and remove together with the support plate (2).
1
2
25544
12. Loosen the unions (1), (2), (3) and (4) and, on the side of the control valves (5), move away the rigid pipes (6), (7) and (8) connected to the trailer brake valve (9).
26
27 13. Remove the control valve oil drain piping (1).
14. Remove the piping (1), delivering oil to the control valve of the lift.
28
29 87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
25
15. Remove the oil drain pipes (1) and (2) from the rear quick connectors.
16. Take out the four bolts (1) securing the control valve support (2).
30
31 17. Loosen the nut (2) securing the union of the transmission oil inlet pipe (1), turn the pipe (1) at the front so as to move it away from the rear route of the control valve pipes.
18. Remove the control valve assembly (1), together with the respective pipes and quick--fit couplers (2).
32
33 87679925A - 12 - 2007
26
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
19. Unscrew the bolts, raise and remove the cover (1) and transmission--gearbox casing assembly.
1
25764
20. Remove the union (1) and disconnect the power take--off brake control pipe (2).
34
1
2
25766
35 21. Take out the retaining bolts and, using hook 380000227 (1), remove the hydraulic lift.
1
25768
22. Remove the union (2) and disconnect the brake control pipe (1); perform this operation on the right--hand side too.
36
1
2
25769
37 87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
27
23. Take off the clamps and remove the injection pump fuel pipe (2) and the fuel breather pipes (1).
24. Position a hydraulic jack (1) under the central part of the tank (2), slightly raising the latter.
38
1
2
25665
39 25. Take out the bolts fastening it to the support (1) and remove the left--hand steps (2).
26. Remove the retaining nuts (1), the front clamp retaining the tank (2) and the bracket supporting the tank (3).
40
1
2
3
25666
41 87679925A - 12 - 2007
28
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
27. Remove the retaining nuts (1), the rear clamp retaining the tank and the bracket supporting the tank (2).
2 1
25770
28. Lower the hydraulic lift (1) and remove the tank (2).
42
1
2
MDF1820A
43 29. Remove the union (2) and disconnect the p.t.o. coupling control pipe (1). Remove the union (3) and disconnect the power take--off lubrication pipe (4).
2
1
3
4 25771
30. Mark and disconnect all the electrical connections: of the controlling solenoid valves (1 and 3): four--wheel drive, PTO and differential lock and of the speed sensor (2).
44
1 2 3
25562
45 87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 31. Disconnect all the lines from the solenoid valve support, unscrew the retaining bolt (1) and detach the solenoid valve exclusion lever (2) with PTO synchronised with engaged gearbox.
1
29
2
25772
46
32. Position one mobile stand (1) of tool 380000569 under the front part of the transmission--gearbox casing and the other mobile stand under the rear part of the casing.
47 33. Position the fixed carriage (1) of tool 380000569 under the clutch casing and insert a wooden block (3) in between. Unscrew the retaining bolts and remove the rear wheels; if necessary, position two fixed stands under the final drives.
1
2 3 25670
34. Take out the bolts (1) securing the services solenoid valve support to the gearbox--transmission casing and remove it.
48
1
25565
49 87679925A - 12 - 2007
30
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
35. Using a chain, hitch the towbar to the hoist, unscrew the six retaining bolts (1) and detach the towbar (2).
1
2
25512
36. Unscrew the nut (1), extract the bolt, remove the lower arms (3) and relative spacers (2).
50
2
1
3
25773
51 37. Unscrew the bolt (1) and remove the tank (2).
1
2
25774
38. Using a chain, connect the PTO unit (1) to the hoist, unscrew the retaining bolts and detach the unit from the transmission--gearbox casing (2).
52
1
2
25775
53 87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 39. Using a chain, connect the right--hand final drive unit (1), unscrew the nuts and detach the unit from the transmission--gearbox casing, removing the crown (2) with the brake unit (3) and the friction disk (4).
1
2
3
31
4
25776
54
40. Detach the left--hand final drive following the description in operation 39. To remove the friction disc (2) it is necessary to turn the differential lock control union (1).
25777
55 41. Remove the plug (2) and drain the oil from the flex bar support. Using a nylon sling, connect the end of the flex bar (1), to the hoist, unscrew the retaining bolts and remove the unit together with the internal drive rod.
1 2
3 25778
42. Hitch the chain (1) to the transmission--gearbox casing (2), connect to a hoist and take up the slack. Unscrew the retaining bolts and detach the transmission--gearbox casing from the clutch casing using stand 380000569.
56
1
2
25779
57 87679925A - 12 - 2007
32
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
43. To refit the rear transmission--gearbox casing, proceed as follows.
--
Assemble the lower arms and relative spacers.
ATTENTION
--
Assemble the towbar.
--
Assemble the solenoid valves support, connect all the piping between the valves and the various services.
--
Fit the rear 380000569.
--
Connect the solenoid valve exclusion lever with PTO synchronised with engaged gearbox, adjusting as described in Section 31.
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
--
For the correct orientation of the various parts, refer to the illustrations in figs. 10 รท 14.
Before refitting the casings, supports and covers clean and de--grease the mating surfaces and apply sealing compound (approx. 2 mm in diameter) as shown in figure 58.
wheels
and
remove
stand
--
Respect the tightening torques prescribed on page 5.
--
Connect the electrical connections to the relative solenoid valves and gauges.
--
Using stand 380000569, refit the rear transmission--gearbox casing to the clutch casing.
--
Connect the PTO control and lubrication lines and relative brake.
--
Fit the flex bar and internal drive rod.
--
Assemble the fuel tank together with the relative retaining brackets.
--
Position the left--hand brake friction disk and secure with the differential lock control union. Assemble the brake unit, crown and final drive unit.
--
Fit the left--hand steps with the retaining bolts to the base support.
--
Fit the injection pump fuel pipes and the fuel breather pipes with their clamps.
--
Connect the service brakes control piping.
--
Refit the hydraulic lift and control valve.
--
Refit the power take--off brake control pipe with its union.
--
--
--
Assemble the left--hand brake friction disk, the brake unit, crown and final drive unit.
Refit the PTO to the rear transmission--gearbox casing.
Assemble the internal tank with relative oil drainage pipe.
87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 --
Insert the springs, poppet balls and assemble the gear control rod support cover and final drive on the rear transmission--gearbox casing.
--
Refit the control valve assembly, together with the respective pipes and quick--fit couplers.
--
Turn the transmission oil inlet pipe at the rear to bring it back to its original position near the rear route of the control valve pipes, locking the union retaining nut.
--
Fit the four retaining bolts on the control valve support.
--
Fit the oil drain pipes to the rear quick--fit couplers.
33
--
Connect the PTO revs counter connection.
--
Refit/connect the electrical connection of the seven--pin socket, bipolar socket and earth cables to the relevant support plate, tightening the retaining bolts.
--
Refit the trailer brake control piping to the support plate.
--
Refit the oil suction pipe connecting the gearbox--transmission casing to the pumps and the pipe connecting the pump delivery to the trailer brake control valve, tightening their respective unions.
--
Assemble the transmission shaft, securing with the central support and the front and rear sleeves.
--
Fit the pipe delivering oil to the lift control valve.
--
Fit the control valve oil drain piping.
--
Position and secure the drive shaft guard.
--
Refit the rigid pipes connected to the trailer brake valve and their unions.
--
Tighten the rear transmission--gearbox casing oil drainage plugs and the fuel tank drainage plug.
--
Assemble the 3--point linkage device support together with the quick--fit coupler and power socket support plate.
--
Refit the cab, positioning it on the transmission as directed in operation 9015010.
87679925A - 12 - 2007
26249
Sealing compound application diagram for transmission--gear box casing The types of sealing compounds to be applied are specified in Section 00
58
34 SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
35
GEARBOX--TRANSMISSION CASING D.A. and adjustments
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. Fix the gearbox--transmission casing to the rotating stand 380000301 using front bracket 380000272 and rear bracket 380000271. 2. Rotate the casing through 180° unscrew the bolts (1) and remove the drive casing (2).
25781
59
1
2
25782
60 3. Rotate the casing through 180° using a punch, extract the pins (1) and remove the rods, teeth and control forks on the gear and range unit.
1
25783
4. Extract the oil inlet union (1), tighten one bolt and extract the differential lock control piston.
61
1
2
25784
62 87679925A - 12 - 2007
36
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
5. Unscrew the bolts (1), detach the stop plate (2) and remove the adjusting shims.
1
2
25785
6. Using a punch, remove the pin (2) securing the differential lock engagement fork (1), extract the rod (4) and remove the spring (3) and fork.
63
1
2
3
4
25786
64 7. Unscrew the bolts (1) securing the differential support (carry out on both sides.
1
25787
65
8. Remove the differential bearing supports (1) from the seat (on both sides) and remove the bevel crown wheel, complete with differential, from the transmission casing.
25788
66 87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 9. Extract the pin (2) and detach the external lever (1) for the PTO synchronized with gearbox.
37
1
2 25790
10. Extract the internal lever (2), spring (1) and block (3).
67
1
2
3
25791
68 11. Release and unscrew the nut (1) securing the driven shaft.
1
25792
12. Remove the circlip (1) retaining the final drive driving shaft bearing from the rear.
69
1
25793
70 87679925A - 12 - 2007
38
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
13. Using a hammer and a brass punch (1) extract the mid gear unit (2) together with the relative bearing and engagement sleeve (3).
1
2
3
25794
71
14. Extract the final drive driving shaft (1).
1
25795
72 15. Remove the circlip (1) retaining the bearing (2) on the gearbox driving shaft.
1
2
25796
16. Fit the tool 50006 (2, fig. 5) on the driving shaft and, using the extractor (1), remove the driving shaft, retrieving the bearings, gears and bushings.
73
1
2
25797
74 87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 17. Release the washer on the nut (1) and loosen the nut.
39
1
25799
18. Tighten the adapter 50144 (2, Fig. 8) on the pinion (3) and, using the extractor (1), move the bevel pinion, in the direction indicated, by a few millimeters.
75
1
3
2
25901
76 19. Move the engagement sleeve (1) until pliers (2) can be inserted to remove the circlip.
1
2
25800
20. Move the gear unit (1) in the direction indicated by the arrow and remove the two split rings (2), unscrew the nut (3) and extract the bevel pinion and all parts.
77
1
2
3
25902
78 87679925A - 12 - 2007
40
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
21. Unscrew the bolts (3), disassemble the support plate (1) and remove the bearing (2).
1
2 3
25903
22. Using a brass punch (2) and hammer, extract the driven shaft (1) and remove all parts. 23. To assemble the rear transmission--gearbox casing, proceed as follows. 24. For the correct orientation of the various parts, refer to the illustrations in figs. 10 รท 14. 25. Respect the tightening torques prescribed on page 5.
79
1
2
25904
80
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
1
2
26. Position the casing vertically, insert the gearbox driven shaft gear assembly (2) and fit the shaft (1).
25907
81
87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 27. Rotate the casing through 90°, assemble the front bearing (1) and nut (2), tightening to the prescribed torque value.
41
2
1
25908
28. Fit the bearing (2) in its seat on the casing (front side) and lock it with the plate (1).
82
1
2
25903
83 29. Insert the gear forks (1 and 3) on the synchroniser sliding rings (2 and 4). 30. Assemble the bevel pinion with all parts and carry out the adjustments described on page 45.
1
2
3 4
25912
31. Assemble the gearbox driving shaft, with all parts, and the adjusting shim (see adjustment on page 43), then position the bearing (2) and secure with the circlip (1).
84
1
2
25796
85 87679925A - 12 - 2007
42
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
32. Insert the final drive driving shaft, from the rear, fit the bearing (2) in the seat and secure with the circlip (1).
1
2
25913
33. Fit the lever (1) governing the p.t.o. synchronized with the gearbox comprehensive of spring, pawl and external lever.
86
1
34. Fit the bevel crown wheel assembly (see adjustments on page 48). 35. Assemble the differential lock engagement fork and spring rod, external plate and relative adjusting shims (see page 44). 36. Assemble the piston and differential lock control union. 37. Assemble all the gearbox and range control rods, forks and teeth. 38. Assemble the drive unit.
87679925A - 12 - 2007
25791
87
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
43
GEARBOX TRANSMISSION CASING Gearbox driving shaft end float adjustment
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. NOTE: When fitted, the driving shaft gears must have an end float of 0 รท 0.25 mm. The bearings must be adjusted to avoid assembling the unit with axial preload. In order to carry out this adjustment, construct tool 5007 in a workshop, as shown in fig. 6. 1. Assemble all driving shaft components on the workbench, replacing the two rear bearings and the adjusting ring with tool 50007 (1). 2. Insert a screwdriver between the gear and the relative bushing and measure the clearance (H) with a feeler gauge.
1
2 H
3 25910
3. Measure the height (C) of the tool 50007 and the thickness of the internal rings of the two rear bearings (1 and 2). 4. The required adjusting thickness will be given by: S = H + C -- A -- B where: H = measured clearance A and B = bearings measured thickness C = height of the tool. Example: -- measured clearance H = 1.3 mm -- height of tool = 43.5 mm -- thickness of ball bearing (1) = 22.9 mm -- thickness of roller bearing (2) = 18 mm -- adjusting shim thickness: S = 1.3 + 43.5 -- 22.9 -- 18 = 3.9 mm
88
1
B
2
C
A
H 25911
89
NOTE: As the gears must be assembled with an axial clearance of 0 รท 0.25 mm, a 3.75 mm shim (S) must be assembled, providing axial clearance of: 3.9 -- 3.75 = 0.15 mm.
87679925A - 12 - 2007
44
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
GEARBOX TRANSMISSION CASING 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. Assemble the differential lock release device (mechanically operated model) or the plate (version with hydraulic control) without the adjusting shim. 2. Insert gauge 50041 (2, fig. 2) 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.
1
2 25914
90
4. Using a feeler gauge (1), measure the clearance between the control pin (2) and the seat on the rod (3) (mechanically operated model).
26250
91 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 release control device (mechanically operated model) or under the plate (2) (hydraulically operated model) and secure in position using the bolts.
26251
92
87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
45
PINION AND CROWN WHEEL ADJUSTMENTS Determining the bevel pinion positioning adjustment ring NOTE: Adjustment Necessary only on the first series of machines. When disassembling these transmissions, if there are the bearing pre--load ring nuts on the bevel drive supports on both sides, this adjustment is Necessary on this machine.
2
1
Proceed as follows: 1. Assemble the bearing external ring (1) on the gearbox--transmission casing with the test shim (2) and the bearing external ring.
25915 26251
93 2. Position the bearing (2) on tool 50004 (1, see fig. 4), insert the bearing (3) and lock the tool (1).
1 2
3
25916
94 3. Position tool 380000249 (2) with the conical parts in the bevel crown wheel supports and insert the micrometer (1) with the depth rod in the seat, securing in position with the bolt.
1
2
25917
95
87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
46
4. Screw the two cones (1 and 2) in or out in order to position the micrometer in correspondence with the bearing, adjust the cones (1 and 2) by hand to lock the tool on the support and eliminate any end float. 5. Move the rod so that it makes contact with the bearing and note the reading (H1).
1 H1
2
25918
96 6. Determine the correct distance (H2), between the bevel gear axis and the large diameter base of the pinion: H2 = 145.5 mm 7. The thickness of the adjustment shim (S) will be given by: S = H1 + Sp -- H2 where: H1 = micrometer reading. H2 = corrected nominal distance between the crown wheel axis and the greater diameter base of the pinion. Sp =Test ring. 8. Disassemble tools 380000249 and 50004; take out the test shim and two differential supports.
1 H1
2
25918
97
87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
47
ADJUSTING THE BEVEL GEAR PAIR Tapered roller bearings adjustment for pinion shaft
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. Assemble the bearing external race with the previously determined shim ring (1).
1
2. Assemble the bevel pinion and relative parts. 3. Tighten the adjusting nut (1), while simultaneously rotating the pinion shaft to ensure that the bearings are seated correctly, to a rolling torque of 0.75 รท 1.5 Nm (0.075 รท 0.150 kgm). Take the reading with a torque wrench and cable wound round the low gear unit located on the pinion, making sure that the gear shaft is not dragged. 4. The rolling torque corresponds to the force read with the torque wrench (1) of 8.6 รท 17.2 N (0.88 รท 1.75 kg).
25799
98
1
NOTE: The pinion rolling torque can be read directly on the bevel crown wheel (not pre--loaded) using the values shown on page 49.
25919
99
87679925A - 12 - 2007
48
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
ADJUSTING THE BEVEL GEAR PAIR Adjusting the bevel crown wheel bearings and checking the clearance between the bevel drive teeth. NOTE: Adjustment Necessary only on the first series of machines. When disassembling these transmissions, if there are the bearing pre--load ring nuts on the bevel drive supports on both sides, this adjustment is Necessary on this machine, otherwise see page 51.
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. With the bevel pinion fitted, insert the differential assembly complete with the bevel crown wheel. Fit the right--hand support (1) on the gearbox--transmission casing and position the ring nut (2) flush to the support.
100
2. Assemble the left--hand support and tighten, using wrench 50027 (see fig. 9), the ring nut to a torque of 49 Nm (5 kgm) to bed the bearings. 3. Unscrew the left--hand ring nut, always keeping it in contact with the bearing. 4. Bring the left--hand ring nut into contact with the relative bearing and tighten to a torque of 9.8 Nm (1 kgm) to adjust the clearance. 5. Using a 1/100 dial gauge (1), measure the radial clearance on the sides of the bevel drive teeth (three measurements at 120° and arithmetic mean of the three readings) and compare the average of the three values with the normal clearance: G = 0.18 á 0.23 mm, on average 0.21 mm (the difference between the three measurements must not exceed 0.05 mm).
87679925A - 12 - 2007
1
25929
101
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
49
6. Loosen the left--hand ring nut and tighten the right--hand one by the same amount to obtain the minimum clearance: G = 0.18 mm 7. Using wrench 50027 (2), tighten the left--hand ring nut (1) to preload the bevel drive bearings. 8. Check the rolling torque on the bevel crown wheel according to the values shown on the table below, and make sure that the gear shafts are not dragged during this operation.
10/44 bevel drive Pinion rolling torque
Pinion rolling torque on crown wheel
Total pinion and crown wheel rolling torque on crown wheel
kgm
kgm
kgm
0.075 ÷ 0.150
0.360 ÷ 0.720
pinion torque + (0.100 ÷ 0.200)
9. The rolling torque can be checked using torque wrench (1), according to the values shown on the table below.
1
25926
102 Differential casing ∅ 159.5 mm (models 56/76, 63/86 and 71/97 KW/HP) 10/44 bevel drive Pinion rolling torque
Torque wrench force, of pinion, on crown wheel
Torque wrench force, of pinion and crown wheel, on crown wheel
kgm
kg
kg
0.075 ÷ 0.150
4.51 ÷ 9.02
Force on pinion + (1.25 ÷ 2.51)
Differential casing ∅ 184 mm (78/106 and 83/113 KW/HP) 10/44 bevel drive Pinion rolling torque
Torque wrench force, of pinion, on crown wheel
Torque wrench force, of pinion and crown wheel, on crown wheel
kgm
kg
kg
0.075 ÷ 0.150
3.91 ÷ 7.82
Force on pinion + (1.09 ÷ 2.17)
87679925A2 - 02 - 2010
50
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
10. Check the clearance between the teeth again, make three measurements 120° apart, calculate the mean and the result should be:
1
G = 0.18 ÷ 0.23 mm,
25929
11. Lock the right and left--hand ring nuts in position with the lock ring (1).
103
104
87679925A2 - 02 - 2010
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
51
BEVEL DRIVE ADJUSTMENTS Adjusting the preloading on the bevel drive bearings NOTE: When disassembling the transmission, if there is the bearing pre--load ring nut on the left--hand side only, use the ring nut on the left--hand side to pre--load the bearings only.
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. With the bevel pinion fitted, insert the differential assembly complete with the bevel crown wheel. On the gearbox--transmission casing, secure the right--hand bearing support (25, fig. 12 and 13 for mods. 56/76, 63/86, 71/97 and 83/113 KW/HP) or mount the bearing straight onto the transmission casing (for mod. 78/106 KW/HP) keeping it in position with the plate (24, fig. 14). 2. Assemble the left--hand support and tighten, using wrench 50027 (see fig. 9), the ring nut to the torque progressively, turning the differential unit a few times, to bed the bearings. 3. Check the rolling torque on the bevel crown wheel according to the values shown on the table below, and make sure that the gear shafts are not dragged during this operation.
10/44 bevel drive Pinion rolling torque
Pinion rolling torque on crown wheel
Total pinion and crown wheel rolling torque on crown wheel
kgm
kgm
kgm
0.075 รท 0.150
0.360 รท 0.720
pinion torque + (0.100 รท 0.200)
87679925A2 - 02 - 2010
52
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
4. The rolling torque can be checked using torque wrench (1), according to the values shown on the table below.
1
25926
105
Differential casing ∅ 159.5 mm (models 56/76, 63/86 and 71/97 KW/HP) 10/44 bevel drive Pinion rolling torque
Torque wrench force, of pinion, on crown wheel
Torque wrench force, of pinion and crown wheel, on crown wheel
kgm
kg
kg
0.075 ÷ 0.150
4.51 ÷ 9.02
Force on pinion + (1.25 ÷ 2.51)
Differential casing ∅ 184 mm (model 78/106 and 83/113 KW/HP) 10/44 bevel drive Pinion rolling torque
Torque wrench force, of pinion, on crown wheel
Torque wrench force, of pinion and crown wheel, on crown wheel
kgm
kg
kg
0.075 ÷ 0.150
3.91 ÷ 7.82
Force on pinion + (1.09 ÷ 2.17)
5. Check the clearance between the teeth, make three measurements 120° apart, calculate the mean and the result should be between:
1
G = 0.15 ÷ 0.50 mm.
25929
106 6. Lock the left--hand ring nuts in position with the lock ring (1).
87679925A2 - 02 - 2010
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
53
BEVEL DRIVE ADJUSTMENTS Adjustment of the clearance between the sun and planet pinion teeth With the differential disassembled on the bench, proceed as follows. 1. Fit the two sun gears (2 and 5) without rings (1 and 6) on the differential casing. Insert the planet gears (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.
1
2
3
4
5 6
7 8 25920
107
2. Manipulate the LH sun gear so that it comes into contact with the planet gear 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
108 3. Push the sun gear so that it touches the differential casing and measure the distance (H2).
4. Repeat the same operations for the RH side gear.
25922
H2 109
87679925A2 - 02 - 2010
54
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
5. The axial movement of the sun gears (2 and 5) without adjustment shims 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 sun gear;
7
H1 and H2 = are the LH or RH sun gear measurements. The normal clearance envisaged between the sides of the side gear and differential pinion teeth is: 0.226 รท 0.302 mm on average 0.264 mm for mod. 56/76, 63/86 and 71/97 KW/HP 0.303 รท 0.307 mm on average 0.610 mm for mod. 78/106 and 83/113 KW/HP. 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: 0.264 x 1.7 = 0.45 mm for mod. 56/76, 63/86 and 71/97 KW/HP. 0.610 x 1.7 = 1.04 mm for mod. 78/106 and 83/113 KW/HP. Therefore the adjustment rings (1 and 6) to insert on the differential housing will be given by: Ss = Gs -- 0.45 mm (for LH crown wheel models 56/76, 63/86 and 71/97 KW/HP) Sd = Gd -- 0.25 mm (for RH crown wheel mod. 56/76, 63/86 and 71/97 KW/HP) Ss = Gs -- 1.04 mm (for LH crown wheel 78/106 and 83/113 KW/HP). Sd = Gd -- 1.04 mm (for RH crown wheel 78/106 and 83/113 KW/HP). Insert the adjustment rings closest to the value obtained (the available values are listed on page 2).
87679925A2 - 02 - 2010
8 25920
110
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
55
Adjustment of the DIFFERENTIAL LOCK CONTROL PEDAL STROKE For models fitted with the platform and safety bar, the distance (H1) between the base of the control pedal and the top of the trim must be 40 mm to ensure coupling of the differential lock sleeve. For models fitted with cabs the distance (H) between the base of the pedal and the top of the trim must be 20 mm. 26152
If not, proceed as follows.
111
1. Remove the relative split pin and extract the pivot pin (6) on the fork (5). 2. Loosen: the locknut (4), nut (2) and the relative locknut inside the fork (1). 3. Screw or unscrew the tie--rod (3) and the fork (5) until the required height of the differential lock pedal from the top of the trim is obtained. 4. Lock: the nut (2), the relative locknut inside the fork (1) and the locknut (4). 5. Attach the pivot pin (6) with the relative split pin.
87679925A - 12 - 2007
56
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
Final drive casing 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. To remove the final drive casing proceed as follows. 1. Disconnect the battery negative lead (1). 2. Lock the front wheels using chocks.
112 3. Detach the vertical tie--rod (1) and the LH anti--swing rod (2).
2 1 26253
113
4. Raise the rear part of the tractor and position a fixed stand under the flex bar support.
25647
114 5. Unscrew the retaining bolts and remove the rear LH wheel.
87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
57
6. Detach the window washer reservoir from the support bracket and disconnect the electrical connections and delivery lines.
25646
7. Take out the bolt securing the cab to the bracket (1).
115
1
8. Slightly raise the cab and position a suitable piece of wood between the hydraulic lift and the cab, making sure that there is no contact with the piping.
25502
116 9. Take out the plug (1) and drain the oil from the gearbox--rear transmission casing.
1
25622
10. Take out the cab supporting bracket (1) retaining bolts.
117
1
25504
118 87679925A - 12 - 2007
58
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
11. Position a stand (1) under the rear part of the fuel tank.
1
25505
12. Connect the final drive casing to suitable equipment for lifting and retaining. Take out the retaining bolts and remove the final drive casing from the transmission casing.
119
1
13. 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 casings, supports and covers clean and de--grease the mating surfaces and apply sealing compound (approx. 2 mm in diameter) as shown in figure 58.
--
Fit the final drive assembly using suitable equipment for lifting and retaining.
--
Attach the cab support bracket.
--
Remove the wooden block and secure the cab to the relative bracket.
--
Fit the window washer reservoir.
--
Assemble the rear LH wheel.
--
Fit the stabiliser strut and the vertical rod.
--
Tighten the oil drainage plug to the drive gear casing and fill up with oil: the prescribed product and quantity are given in section 00.
--
Connect the battery negative lead.
87679925A - 12 - 2007
25507
120
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
59
26254
121 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
Epicyclic final drive 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. With the assembly detached from the housing, proceed as follows. 1. Remove the retaining ring (1). 2. Extract the pins and remove the gears, complete with the roller bearings. 3. Refit all epicyclic final drive parts by inverting operations 1 and 2.
24620
122
87679925A - 12 - 2007
60
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
Drive wheel shaft 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.
1
With the final drive casing removed from the rear transmission, proceed as follows. 1. Position the final drive casing (1) on a rotating stand. 2. Take out the bolt (1) securing the driven gear support on the drive wheel shaft and remove the safety plate.
24608
123
1 24610
124 3. Extract the support (1) from the driven gears and remove the end float adjuster shim from the support.
24611
1 125
4. Using an extractor, extract the drive wheel shaft (1).
24613
126 87679925A - 12 - 2007
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
61
5. Remove the seal (1). 6. To refit the final drive casing, proceed as follows. -- For the correct orientation of the various parts, refer to the illustrations in figs. 10 รท 14. -- Respect the tightening torques prescribed on page 5. -- Fit the seal using a suitable drift. -- Assemble the drive wheel shaft.
1
24614
127
--
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 end float of the support (2) is 0.2 รท 0.4 mm; if not, adjust the shim.
1
NOTE: The adjustment shims are listed on page 4.
2 26255
128
87679925A - 12 - 2007
62
SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
1
SECTION 31 -- POWER TAKE--OFF Chapter 1 -- Mechanical power take--off CONTENT Description
Page
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Description of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Fitting cooler with mechanical transmission and mechanical power take--off . . . . . . . . . . . . . . . . . . . . . . . . 12 Power take--off housing R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Power take--off driving shaft D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Driven shaft and other parts D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
2
MECHANICAL POWER TAKE--OFF DATA 540 rev/min power take--off
Standard equipment on models: 56/76 and 63/86 KW/HP (ISO and NAR)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
independent in relation to tractor speed
Engagement and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mechanical, by means of hand lever located on the LH and RH side of the driving position (see page 10)
Direction of rotation (from tractor rear) . . . . . . . . . . . . . . . . . . . . . . . . .
clockwise
Engine speed with PTO at 540 rpm . . . . . . . . . . . . . . . . . . . .
rpm
2199
PTO revolution speed with engine at max. power of (2300 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rpm
565
Diameter of driven shaft at bearings . . . . . . . . . . . . . . . . . . .
mm
49.938 ÷ 50.000
Diameter of driven shaft at grooved terminal . . . . . . . . . . . . . . . . . . .
13/8” (6 grooves) Standard equipment on models: 71/97 and 78/106 KW/HP
PTO 540/750 rpm (on request on 56/76 and 63/86 KW/HP)
Type (two functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. independent with respect to tractor speed or on request on all models: 2. synchronized to gearbox
Engagement and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mechanical, by means of hand lever located on RH and LH side of driver’s position (see page 10)
Direction of rotation (from tractor rear) . . . . . . . . . . . . . . . . . . . . . . . . .
clockwise
Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of hand lever located on the rear RH side of the driver’s seat
Engine speed with PTO at 540 rpm . . . . . . . . . . . . . . . . . . . .
rpm
2196
Engine speed with PTO at 750 rpm . . . . . . . . . . . . . . . . . . . .
rpm
2132
PTO revolution speed with engine at max. power of 2300 rpm: -for PTO 540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -for 750 rpm PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rpm rpm
565 809
Synchronized PTO revolution speed: -for PTO 540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --
for 750 rpm PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
revs/ wheel rev revs/ wheel rev
Diameter of driven shaft at grooved terminal . . . . . . . . . . . . . . . . . . .
87679925A - 12 - 2007
8,2 11,7 13/8” (6 grooves)
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
3
MECHANICAL POWER TAKE--OFF NORTH AMERICA version 71/97 and 78/106 KW/HP
PTO 540/1000 rpm Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engagement and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Independent in relation to tractor speed mechanical, by means of hand lever located on the LH and RH side of the driving position (see page 10)
Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direction of rotation (from tractor rear) . . . . . . . . . . . . . . . .
Activated, by means of an internal mechanical device, replacing the splined output shaft (see page clockwise
Engine speed with PTO at 540 rpm . . . . . . . . . . . . . . . . . . . .
rpm
Engine speed with PTO at 1000 rpm . . . . . . . . . . . . . . . . . . .
rpm
PTO revolution speed with engine at max. power of 2300 rpm: -for PTO 540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -for PTO 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rpm rpm
565 1017
Diameter of driven shaft at grooved terminal: -540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rpm rpm
13/8” (6 grooves) 13/8” (21 grooves)
2196 2261
SPECIAL TOOLS
CAUTION The operations described in this section can only be carried out with the 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.
380000227
Hook for lifting the power take--off.
380000233
Striker for PTO driving shaft bearings.
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
4
C4 -- 20 รท 25 Nm
Z 19
Z 15 40x90x23
40x90x23
C3 -- 25 Nm m3
m 3.25
540
750 40x90x23
35x80x21
40x2.65x14 FI
C1 -- 294 Nm
AT 01619
Z 54
C2 -- 221 Nm
Z 61
MDM1509A
1
BOLT TORQUES PARTS TO BE TIGHTENED
Thread
Bearing support retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torque Nm
kgm
M12x1.25
98
10
Driven gear shaft locknut (C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M32x1.5
294
30
PTO casing retaining bolts (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M16x1.5
221
22,5
PTO guard retaining bolts (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M8x1.25
25
2,6
PTO shaft braking device retaining bolts (C4)* . . . . . . . . . . . . . . . .
M8x1.25
20 รท 25
2.0 รท 2.5
*
Before tightening the bolt apply a few drops of Loctite 243.
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
5
SECTIONS 2
X
3
4
5 6
1
7 8 9
12
11
10
13 14 16
15
15
X MDM1510A
2 Longitudinal sectional diagram of 540 rpm PTO PTO output shaft with 6 grooves.
1.
Power take--off driving shaft.
9.
2.
Driving gear 540 rpm (z 14).
10. Oil seal.
3.
Support bearing retaining circlip.
11. Bearing retaining circlip.
4.
Drive shaft bearings.
12. Rear bearing supporting the output shaft.
5.
PTO shaft braking disc.
13. Spacer.
6.
Braking pre--load spring.
14. Front bearing supporting the output shaft.
7.
Braking device retaining bolt.
15. Driven gear 540 rpm (z 57).
8.
Bearing retaining circlip on PTO shaft.
16. Driven shaft retaining ring nut.
NOTE: On assembly, apply the type of sealing compound noted on page 1, Sect. 00 on surface X following the diagram in fig. 23 page 17. 87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
6
1
2
16
X
17
3
Z 19
40x90x23
540
4
Z 15 40x90x23
AT 01619 35x80x21 40x2.65x14 FI
750
40x90x23
18 19 20
15
m3
5
m 3.25
6 15
540
750
21
40x90x23
35x80x21
40x2.65x14 FI AT 01619
4
4
20 22 19 14
7
Z 54
18
16
8
Z 61
9
23
24
X 13
12
11
10
17
16
25
MDM1511A
3 Sectional views of 540 -- 750 rpm PTO
(key, see page 7)
NOTE: On assembly, apply the type of sealing compound noted on page 1, Sect. 00 on surface X following the diagram in fig. 23 page 17. 87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
7
Sectional views of 540 -- 750 rpm PTO (see page 6) 1.
Driving gear 540 rpm (z 15).
14. Ring nut tightening PTO driven shaft parts.
2.
Driving gear 750 rpm (z 19).
15. Bearings internal support.
3.
PTO shaft braking device (see section 2, page 5).
16. Gear lever shaft.
4.
Thrust washer.
17. Gear lever.
5.
Speed selector fork.
6.
6 spline PTO output/driven shaft.
7.
PTO speed sensor.
8.
Bushings.
9.
750 rpm driven gear (z 54).
18. Gearbox fork guide plate. 19. Fork guide plate status cap 18. 20. Fork sliding rod 5. 21. Rod stop cap 20 (1).
10. Sliding speed selection sleeve.
22. Fork guide cap 20 on plate 18.
11. Fixed portion, keyed onto the sleeve shaft 10.
23. PTO gearbox flexible cable.
12. Driven gear 540 rpm (z 61).
24. Cable reaction support 23.
13. Thrust spacer.
25. Power take--off shaft cover.
(1) Before screwing the cap onto the support, apply a few drops of Loctite 242 on its thread, then screw on fully
but without tightening it.
Cross--sectional views of 540 -- 1000 rpm PTO NORTH AMERICA (see page 8) 1.
Driving gear 540 rpm (z 15).
13. Fixed portion, keyed onto the sleeve shaft 5.
2.
Driving gear 1000 rpm (z 23).
14. Driven gear 540 rpm (z 61).
3.
PTO shaft braking device (see section 2, page 5).
15. Bushing.
4.
Speed selector fork.
16. Ring nut retaining PTO driven shaft parts.
5.
Sliding speed selection sleeve.
6.
PTO driven shaft.
7.
Splined output shaft retaining circlip (1).
8.
Cap inserted in the bottom of the 1000 rpm output shaft, 21 grooves, moving the rod enables engaging the corresponding speed (not available on the 540 rpm shaft).
9.
Output shaft for 1000 rpm PTO.
17. Speed selection plate. 18. Driven shaft support bearing. 19. Bearings internal support. 20. Fork sliding rod 4. 21. Fork guide pin 4. 22. Speed selection driven rod.
10. O rings.
23. Plate adjustment cap 17 (2).
11. Speed selection driving rod.
24. Plate pivot pin 17.
12. 1000 rpm driven gear (z 52).
25. Plate support 17.
(1) After installing the circlip in its seat, turn it half way round until it is opposite the flat surface of the PTO output shaft in order to lock it. (2) ----
To adjust cap 23 proceed as follows: Mount the 1000 rpm PTO output shaft. Screw the cap on flush with the sliding sleeve on the 1000 rpm driven gear. Unscrew the cap by half a turn and lock it with the nut.
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
8
1
2
3
4 5
6
19
7
18
8 9
17
10
16 11
20
12 4 15
14
13
21
22 23 17
25
24
MDM1573A
4 Sectional views of 540 -- 1000 rpm PTO NORTH AMERICA (key, see page 7)
NOTE: On assembly, apply the type of sealing compound noted on page 1, Sect. 00 on surface X following the diagram in fig. 23.
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
2
5 3
1
9
4
2
9
3
8 8 6
7
10
13 5 3
11
12 MDM1512A
5 Cross--sectional views of synchronized PTO 1.
PTO shaft joint sleeve.
8.
Shaft from PTO clutch.
2.
Sleeve retaining circlip 1.
9.
Range driving shaft.
3.
PTO driven shaft.
4.
Synchronized PTO and mid--range driving gear.
5.
Synchronized power take--off sliding sleeve.
6.
Roller bearing.
12. Speed selection runner.
7.
Mid--range driven gear.
13. Synchronized PTO internal engagement lever.
10. Synchronized PTO external engagement lever. 11. Lever position stop cap 10.
87679925A - 12 - 2007
10
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
DESCRIPTION AND MECHANICAL PTO
OPERATION
OF
2
1
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) twin speed, 540/750 rpm. -- (on request)* two--speed 540/1000 rpm. * NORTH AMERICAN version 26280
6
PTO controlled directly from the engine clutch Proceed as follows: -- disengage the PTO clutch by moving the lever (1, fig. 7) to position A; -- move the operation selection lever (1, fig. 8) to position (B), thereby engaging the PTO sleeve (3, fig. 9) on the shaft gear coupling (2) which is moved by the main clutch; -- slowly engage the main clutch by moving the lever (1, fig. 7) to position D.
1
A D 26355
7
When engaged, the PTO grooved terminal rotates and the relevant lamp on the dashboard illuminates. 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). -- To disengage the PTO move selection lever (1, fig. 8) to position E. 26356
8
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
11
PTO synchronised with gears Proceed as follows: --
hold clutch lever (1, fig. 7) in position A;
--
fully press the main gear clutch pedal;
--
wait briefly, then move the lever (1, fig. 8) to position C and release the main gear clutch pedal. In these conditions the PTO coupling sleeve (3, fig. 9) is directly driven by the main gear toothed coupling (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. NOTE: When the PTO is not in use, move lever (1, fig. 8) to position (E), in relation to the neutral position of the PTO coupling sleeve (3, fig. 9).
26281
9 Selecting the speed with the lever (2, fig. 10) To select power take--off speeds, proceed as described below: -- pull the stop knob (1) upwards; -- position lever (2) in the required speed sector (3). This activates the external control lever (13, fig. 3) by means of a tie--rod. The external control lever rotates the internal cam device (14) and selects the required PTO speed by means of coupling sleeves (10 and 15). 26325
10
MECHANICAL PTO TROUBLESHOOTING Problems
Possible causes
Solutions
Slipping with speed loss on PTO grooved terminal.
Wear of clutch disk or of engine flywheel pressure plate. PTO clutch lever adjustment.
Check the data on the appropriate pages in Sect. 18, replace the worn parts and adjust the clutch lever.
Difficulty in selecting PTO speed by means of lever 2, fig. 10.
External control stiff or incorrectly adjusted.
Lubricate the control cable sheath. Adjust the control.
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
12
FITTING COOLER WITH MECHANICAL TRANSMISSION AND MECHANICAL POWER TAKE--OFF
Pressurised oil Intake oil Excess oil to the pressure regulating valve Oil at static rest
1
2
3
4
5
6
10
9
8
7
16
15
14
13
12
11
MMM0497A
11 General hydraulic system
1.
Steering cylinders.
9.
2.
Gearbox oil pressure switch on services control valve supply line (oil discharge from the power steering).
10. Return line from cooler.
3.
Power steering control valve (orbitrol).
4.
Differential lock solenoid valve.
5.
4WD disengagement solenoid valve.
13. Front differential lock.
6.
Services pressure regulating valve.
14. Delivery line to cooler.
7.
4WD pressure switch warning light.
15. Heat exchanger.
8.
Rear differential lock.
16. Low pressure pump.
87679925A - 12 - 2007
By--pass valve protecting the cooler.
11. Restrictor. 12. Suction filter.
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
13
12 1.
Pipe from the outlet of the services control valve (3) to the cooler, travelled by oil at high temperature.
2.
Services control valve supply line.
3.
Excess oil discharge to the pressure regulating valve; discharge to the services control valve.
4.
Line from the services control valve outlet (3) to the inlet hole into the transmission housing; travelled by oil at low temperature.
5.
Pressure regulating valve compartment plug with oil drain line overhead the valve.
6.
By--pass valve.
7.
Restrictor union.
8.
Return line from the cooler, connected to the Tee coupling (9) introducing oil into the transmission housing, travelled by oil cooled by the cooler.
9.
Tee coupling draining oil into the transmission housing.
87679925A - 12 - 2007
14
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 COOLING SYSTEM DESCRIPTION AND OPERATION
To prevent the transmission oil from reaching too high a temperature it is possible to fit a cooler on the mechanical transmissions with either a hydraulic PTO (see chap. 2 section 31) or a mechanical PTO. The oil coming from the control valve of the power steering via line (2, fig. 12) reaches the services control valve. It enters from the side of the pressure regulating valve that regulates the four--wheel drive disengagement and front/rear lock engagement oil to a pressure of 15.7 รท 16.7 bar (16 รท 17 Kg/cm2), the excess oil is sent straight to the transmission housing, where the cooler is not fitted. On machines with a cooler, the oil leaves the Tee coupling (3, fig. 12), some of it is discharged directly through a hole in the control valve and, depending on the temperature, it takes two routes: A) With cold oil: its density produces an increase in pressure as it passes into the cooler; this increase causes the by--pass valve (6, fig. 12) to open and allows the oil to flow straight to the Tee coupling (9, fig. 12) for introducing oil into the clutch casing; therefore, in practice, when the oil is cold it discharges into the transmission casing via the line (4, fig. 12). B) With hot oil: with the increase in temperature and associated decrease in density, there is a decrease in the pressure on the line (1, fig. 12) and on the cooler so that the by--pass valve (6, fig. 12) closes and the oil passes into the cooler through the feed pipe (1, fig. 12) to then pass via the return pipe from the cooler (8, fig. 12), and enter the Tee coupling (9, fig. 12) on the transmission casing, thereby reaching the outlet.
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
15
POWER TAKE--OFF HOUSING 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. 1. Disconnect the battery negative cable. 2. Detach the three--point linkage (1).
1
24952
13
3. Detach the tow bar hook (1).
1
24953
14
4. Remove the tow bar (1).
1
24954
15
87679925A - 12 - 2007
16
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
5. Remove the six retaining bolts (1) securing the towbar hook.
1
24955
16
6. Drain the oil from the transmission/gearbox into a suitable container.
24956
17 7. Remove the two upper bolts (1) securing the PTO unit to the transmission.
1
24957
18
8. Insert the two guide pins (1) and unscrew the two lower bolts (2) securing the PTO unit to the transmission.
1
24958
2 19
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 9. Remove the pin spring (1) and detach the PTO speed selection cable.
17
1
24959
10. Unscrew the PTO speed selection cable sheath bracket (1) retaining bolts. 11. Move lever (1, fig. 8) to position (C), PTO synchronized with gears, so that the sleeve (3, fig. 9) remains on the shaft (2) during the removal operation. Extract the PTO unit by a few centimeters and remove using a hook and lifting chain 380000227 (1).
20
1
24960
21 To assemble, proceed as follows: -- Clean the contact surface between the transmission casing and the PTO casing and apply sealing compound as indicated in fig. 23. -- Clean the mating surface on the PTO unit. -- Raise and position the PTO unit in front of the transmission casing and insert on the previously installed guide pins. -- Detach the hook and chain (1, fig. 22) and secure the PTO unit with the four bolts. -- Remove the two guide pins.
1
24961
------
22
Refit the PTO speed selection cable sheath bracket (1, fig. 21), connect the cable to the lever and insert the pin and spring (1, fig. 20). Reassemble the towbar hook assemble support. Refit the towbar hook and three--point bar. Tighten the drainage plug and then fill up the transmission/gearbox casing. Connect the battery negative lead.
26282
23 87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
18
MECHANICAL POWER TAKE--OFF SHAFTS 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.
1. Position the PTO unit in a vice on a workbench (1).
1
24962
24 2. Using a punch, release the securing ring (1) on the driven shaft ring nut.
1
24963
3. Remove the driven shaft ringnut (1).
25
1
24964
26
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 4. Remove the four retaining bolts (1) securing the PTO unit internal support.
19
1
24965
27
5. Remove the fork rod Allen screw (1).
1
24966
28 6. Extract the rod (1) from the rear casing.
1
24967
7. Partially extract the end of the shaft (1), remove the internal support (3) together with the driving shaft (2), the driven gears (4), the engaged/disengaged/neutral fork and sleeve, the 540/750 PTO; also remove the bearing thrust washer on the gearing side. Remove also the PTO driving shaft braking device from the rear external cover.
29
1
2
4 3 24968
30 87679925A - 12 - 2007
20
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
8. Remove the rear bearing thrust washer (1) and the secondary shaft (2), together with the PTO terminal.
1
2
24969
9. Remove the retaining circlip, bearing (1) and seal (if it is to be changed) from the rear cover.
31
1
24970
32 To assemble (for the positioning of the parts see figure 3) proceed as follows: -- Fit the seal (if it needs to be replaced), the rear bearing and the snap ring on the rear cover. -- Refit also the PTO driving shaft braking device on the external cover. -- Refit the driven shaft with the thrust washer. -- Refit the driven shaft gear, the fixed gear, the sleeve, the fork and fork support rod. -- Insert the gear on the driven shaft, assemble the internal support together with the driving shaft. Secure the support with the four bolts, tightening to the torque value noted on page 4. -- Fit the thrust washer on the gear, install the bearing on the internal support of the driven shaft. -- Secure the rod that supports the PTO speed selection fork with the Allen screw. -- Tighten the driven shaft ring nut to the torque value noted on page 4, secure the ringnut to prevent it from loosening.
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
1
Chapter 2 -- Electro--hydraulic PTO CONTENTS Description
Page
Main Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Description and operation of the electrohydraulic PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Additional PTO controls for cab--version tractors with Power Shuttle transmissions . . . . . . . . . . . . . . . . . . 25 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Power take--off clutch brake Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Electro--hydraulic power take--off housing R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Fitting cooler with mechanical transmission and power take--off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Services control valve R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (See Sect. 23) Services control valve for tractors without Power shuttle D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . (See Sect. 23)
87679925A2 - 02 - 2010
2
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2 ELECTRO--HYDRAULIC PTO DATA
Power take--off 540 rpm (standard equipment on all models with Power Shuttle)
56/76, 63/86, 71/97 and 78/106 KW/HP (ISO and NAR)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Independent with respect to tractor speed (see page 19)
Engagement and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
electrohydraulic/mechanical by means of knob and hand lever (see page 13)
Direction of rotation (from tractor rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
clockwise
Engine speed with PTO at 540 rpm . . . . . . . . . . . . . . . . . . . .
rpm
2199
PTO revolution speed with engine at max. power (2300 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rpm
565
Splined output shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . .
mm
13/8” (6 grooves)
540/750/1000 rev/min power take--off Standard equipment on model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On request for the other models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type (two functions, see page 21) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engagement and control (see page 15) . . . . . . . . . . . . . . . . . . . . . .
83/113 KW/HP 56/76, 63/86, 71/97 and 78/106 kW/ hp 1. independent with respect to tractor speed or: 2. synchronized to gearbox 1. electrohydraulic/mechanical by means of knob and hand lever 2. mechanical, by means of hand lever located to the RH side of the driving position
Direction of rotation (from tractor rear) . . . . . . . . . . . . . . . . . . . . . . . . .
clockwise
Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of hand lever located on the rear RH side of the driver’s seat
Engine speed with PTO at 540 rpm . . . . . . . . . . . . . . . . . . . .
rpm
2196
Engine speed with PTO at 750 rpm . . . . . . . . . . . . . . . . . . . .
rpm
2132
Engine speed with PTO at 1000 rpm . . . . . . . . . . . . . . . . . . .
rpm
2261
PTO revolution speed with engine at max. power of 2300: -for 540 rpm PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -for 750 rpm PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -for 1000 rpm PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rpm rpm rpm
565 809 1017
87679925A2 - 02 - 2010
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
Synchronized PTO revolution speed: revs/ wheel rev -for 540 rpm PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . revs/ -for 750 rpm PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . wheel rev revs/ -for 1000 rpm PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . wheel rev Diameter of driven shaft at grooved terminal: -540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -750 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rpm rpm rpm
3
8,2 11,7 14,7 13/8” (6 grooves) 13/8” (6 grooves) 13/8” (21 grooves)
MECHANICAL POWER TAKE--OFF NORTH AMERICA version PTO 540/1000 rpm
63/86, 71/97 and 78/106 KW/HP
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
independent with respect to tractor speed
Engagement and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
electrohydraulic by means of knob
Direction of rotation (from tractor rear) . . . . . . . . . . . . . . . . . . . . . . . . .
clockwise
Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Activated, by means of an internal mechanical device, replacing the grooved shaft (see page 21)
Engine speed with PTO at 540 rpm . . . . . . . . . . . . . . . . . . . .
rpm
2196
Engine speed with PTO at 1000 rpm . . . . . . . . . . . . . . . . . . .
rpm
2261
PTO revolution speed with engine at max. power of 2300: -for PTO 540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -for PTO 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rpm rpm
565 1017
Diameter of driven shaft at grooved terminal: -540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rpm rpm
13/8” (6 grooves) 13/8” (21 grooves)
87679925A2 - 02 - 2010
4
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2 ELECTRO--HYDRAULIC PTO CLUTCH UNIT DATA
Clutch driving disk (11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch driven disk (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reaction plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch driving disk thickness (11): -- supplier Welmann . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- supplier Hoerbiger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch driven disk thickness (12) . . . . . . . . . . . . . . . . . . . . . . Reaction plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston return spring (10) (length with spring free) . . . . . . . . Piston return spring (10) (spring length under load of 102.3 ± 5 kg) . . . . . . . . . . . . . . . Pressure relief valve lubrication spring (12, fig. 6) (length with spring free) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure relief valve lubrication spring (12) (length under load of 8.1 ± 0.4 kg) . . . . . . . . . . . . . . . . . . . . . Pressure relief valve lubrication calibration . . . . . . . . . . . . . . Spring free length (5), for valve (4) locking disks (11 and 12, fig. 4) and rear bearing lubrication (13) . . . . . . . Spring length (5, fig. 6) under load of 2.48 ± 0.1 kg . . . . . . Valve diameter (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat diameter (4) on relative support . . . . . . . . . . . . . . Clearance between valve (4) and relative seat on support . Accumulator spring (14) (spring free) . . . . . . . . . . . . . . . . . . . Accumulator spring (14) (spring under load of 34.9 ± 1.7 kg) . . . . . . . . . . . . . . . . . . .
Qty Qty Qty
56/76, 63/86, 71/97, 78/106 and 83/113 KW/HP 5 5 1
mm mm mm mm mm
2 ± 0,05 2,00 ÷ 2,08 2,3 ± 0,05 9 61
mm
34
mm
29
mm bar
22 4.4 ÷ 5.9 (4.5 ÷ 6 kg/cm2)
mm mm mm mm mm mm
57 36 11.988 ÷ 11.996 12.016 ÷ 12.030 0.020 ÷ 0.042 122
mm
100
DATA ON CONTROL VALVE WITH SOLENOID VALVES 56/76, 63/86, 71/97, 78/106 and 83/113 KW/HP Coupling clearance between control valve rod (11, fig. 7) and seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coupling clearance between pressure relief valve (20) and seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure relief valve spring (18) (with spring free) . . . . . . . . Pressure relief valve spring (18) (spring length under load of 29.7 ± 1.30 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure relief valve (20) setting . . . . . . . . . . . . . . . . . . . . . .
87679925A2 - 02 - 2010
mm
0.025 ÷ 0.035
mm mm
0,025 127
mm bar
102,5 15.7 ÷ 16.7 (16 ÷ 17 kg/cm2)
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
5
SPECIAL TOOLS
CAUTION The operations described in this section can only be carried out with the 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. 380000227
Hook for lifting the power take--off.
380000243
Press for clutch spring.
380000258
Handgrip (with 50135).
sm 2
Material Q.ty
Drift (to use with 380000258)
UNI C 40 1
Models
Series T5000
N. tool
50135
1 26328
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
6
C1 -- 294 Nm
C2 -- 25 Nm
C3 -- 25 Nm C4 -- 221 Nm
C6 -- 98 Nm
C5 -- 55 Nm
MDE0041A
2
BOLT TORQUES PARTS TO BE TIGHTENED
Thread
Driven gear shaft locknut (C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torque Nm
kgm
M28x1.5
294
30
Clutch cover retaining bolts (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M8
25
2.6
PTO guard retaining bolts (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M8
25
2.6
PTO housing retaining bolts (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . .
M16x1.5
221
22.5
Retaining bolts for speed selection cable sheath bracket (C5) . . .
M10x1.25
55
5.6
Rear bearing support retaining bolts (C6) . . . . . . . . . . . . . . . . . . . .
M12x1.25
98
10
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
1
2
3
4 x
7
5
6 x
7 8
MDE0045A
3 Longitudinal sectional diagram of 540 rpm PTO 1.
Flywheel PTO shaft.
5.
Drive engagement clutch commanded by shaft (1).
2.
Retaining snap ring.
6.
Splined output shaft / driven shaft of the PTO.
3.
Bearing thrust ring.
7.
Spacer.
4.
Driving gear 540 rpm (z 14).
8.
540 rpm driven gear (z 54).
NOTE: On assembly, apply the type of sealing compound noted on page 1, Sect. 00 on surface X following the diagram in fig. 43 and 45.
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
8
1
2
3
4
5
6
7
8
9
10
11 12
13
14
x 18 22
21
16 17
19
x 20
MDE0042A
25 24 23 31
15
28
32 26
25 26
24 29
30 29
31 27
28
1
MDM1513A
4 Sectional views of 540 -- 750 -- 1000 rpm PTO (key, see page 9) NOTE: On assembly, apply the type of sealing compound noted on page 1, Sect. 00 on surface X following the diagram in fig. 43 and 45.
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
9
Sectional views of 540 -- 750 -- 1000 rpm PTO (see page 8) 1.
Driven shaft locking ring nut.
16. PTO output shaft retaining circlip (1).
2.
750 rpm PTO coupling sleeve.
17. Seal.
3.
750 rpm rear driven gear (z 54).
18. Driven gear front and central bushings (19).
4.
Flywheel drive shaft.
5.
Gearbox mid gear drive shaft (synchronized PTO, see sect. 31 Chap. 1, page 9); front driving gear 540 rpm (z 15), rear driving gear 1000 rpm (z 23).
19. 1000 rpm front driven gear (z52) and 540 rpm central driven gear (z 61). 20. PTO unit retaining bolt. 21. Driven gear rear bushing (3).
6.
750 rpm driving gears (z 19).
22. Driven shaft.
7.
Rear bearing support.
23. Rod stop cap 25 (2).
8.
Oil delivery manifold on hydraulic cylinder (9).
24. 540/1000 rpm engagement fork.
9.
Clutch engagement hydraulic cylinder (drive from flywheel).
25. Fork sliding rod. 26. Speed selection lever pin.
10. Clutch disk disengagement spring (11 and 12).
27. Fork guide pin (24).
11. Clutch driving disk.
28. Speed selection internal plate.
12. Clutch driven disk.
29. Plate status cap (28).
13. Clutch rear bearing.
30. Fork guide pin (31).
14. Shaft guards (15).
31. 750 rpm engagement fork.
15. PTO grooved terminal.
32. speed selection external lever.
(1) After installing the circlip in its seat, turn it half way round until it is opposite the flat surface of the PTO output shaft in order to lock it. (2) Before screwing the cap onto the support, apply a few drops of Loctite 242 on its thread, then screw on fully but without tightening it.
Sectional views of PTO clutch unit (see page 12) A. Version with Power Shuttle.
8.
Lubrication pressure control valve (version without power shuttle). Spring for valve (8).
B. Version without Power Shuttle. 1.
Clutch.
9.
2.
Restrictor.
10. Plug (version with power shuttle).
3.
Oil drain valve.
11. Restrictor.
4.
Lubrication control valve.
12. Spring and accumulator bottom).
5.
Spring for valve (4).
6.
Lubrication pressure control valve (version without power shuttle).
7.
Lubrication oil inlet union.
13. Accumulator. 14. Power take--off clutch brake. 15. Pressurized oil inlet union.
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
10
Cross--sectional views of 540 -- 1000 rpm PTO NORTH AMERICA (see page11) Speed selection pin.
1.
Flywheel drive shaft.
9.
2.
Retaining snap ring (3).
10. Speed selection sleeve control fork.
3.
Bearing thrust ring.
11. Return spring.
4.
PTO driving shaft, 540 rpm front gear (z 15), 1000 rpm rear gear (z 23).
12. Speed selection fork control pin.
5.
Drive engagement clutch, governs the shaft (4).
6.
Grooved terminal 1 3/8” (6 grooves) for 540 rpm PTO or 1 3/8” (21 grooves) for 1000 rpm PTO.
15. Speed selection sleeve.
7.
Driven shaft.
16. 1000 rpm driven gear (z 52).
8.
Splined output shaft retaining circlip
(1).
13. Speed selection support lever. 14. Speed selection lever, with adjustment cap (2).
17. Driven gear 540 rpm (z 61).
(1) After installing the circlip in its seat, turn it half way round until it is opposite the flat surface of the PTO output shaft in order to lock it. (2) To adjust the cap (14) proceed as follows: --
Mount the 1000 rpm PTO output shaft.
--
Screw the cap on flush with the sliding sleeve on the 1000 rpm driven gear.
--
Unscrew the cap by half a turn and lock it with the nut.
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
11
4 1
2
x
3
540
x
5
1000
6 x 7 x
16 8
17 15
14 9 13 MDE0044A
12 Cross--sectional views of 540 -- 1000 rpm PTO NORTH AMERICA (key, see page 10)
10 11 5
NOTE: On assembly, apply the type of sealing compound noted on page 1, Sect. 00 on surface X following the diagram in fig. 43 and 45.
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
12
2 1
3
4
5
6 13
12
11
A
B 9
10
8
7
16
MDE0043A
15
7
14
MDE0042B
6 Sectional views of PTO clutch unit
(key, see page 10)
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
1
2
3
4
5
13
6
A B
20 19 18
7
17 16 15
8
14
13
12
11
10
9
MMM1531A
7 Sectional views of the services with solenoid valves (tractor without Power shuttle) A. Lever position with PTO synchronized with gearbox 8. PTO clutch rear bearing lubrication delivery union. engaged. 9. Pressure relief valve--outlet connecting union. B. Lever position with hydraulic PTO commanded by 10. External plug on outlet line. flywheel engaged. 11. Oil delivery to solenoid valve (14) control valve rod. 1. 4WD disengagement solenoid valve. 12. Bolt retaining valve (11). 2. Front or rear differential lock engagement solenoid 13. Valve seal and dust seal (11). valve. 14. Oil delivery solenoid valve to PTO clutch or clutch 3. Front or rear differential lock delivery union. brake. 15. Clutch brake delivery union. 4. 4WD engagement delivery union. 16. PTO clutch engagement cylinder delivery union. 5. Oil flow cut--off lever to solenoid valve (14), flywheel PTO clutch engagement, when engaged the PTO is 17. Outlet line to transmission casing. synchronized with gearbox. 18. Pressure relief valve spring. 6. Cam to adjust valve stroke (11). 19. Solenoid valve support delivery union. 7. 4WD engagement delivery union. 20. Pressure relief valve.
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
14
1
2
3
4
5
6
A B
19
7
17 16 15
14
13
12
11
10
MMM1532A
8
Sectional views of the services with solenoid valves (tractor without Power shuttle) A. Lever position with PTO synchronized with gearbox 7. 4WD engagement delivery union. engaged. 10 External plug on outlet line. B. Lever position with electrohydraulic PTO 11 Oil delivery to solenoid valve (14) control valve rod. commanded by flywheel engaged. 12 Bolt retaining valve (11). 1. 4WD disengagement solenoid valve. 13 Valve seal and dust seal (11). 2. Front or rear differential lock engagement solenoid valve. 14 Solenoid valve for oil flow to PTO clutch or clutch brake. 3. Front or rear differential lock delivery union. 15 Clutch brake delivery union. 4. 4WD engagement delivery union. 16 PTO clutch engagement cylinder delivery union. 5. Oil flow cut--off lever to solenoid valve (14), flywheel 17 Outlet line to transmission casing. PTO clutch engagement, when engaged the PTO is 19 Solenoid valve support delivery union. synchronized with gearbox. 6.
Cam to adjust valve stroke (11).
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
15
DESCRIPTION AND OPERATION OF ELECTROHYDRAULIC PTO
The PTO installed on the tractor transfers motion to the transported or towed implements. It can be controlled: a) directly by the flywheel; b) synchronized with the gearbox. The electrohydraulically engaged/disengaged PTO is available in three versions. The description and operation is of the most complete PTO, i.e.: the 540 -- 750 -- 1000, for the other two versions see page 21. The controls are located inside the cab on the right--hand side to the rear of the driving position. a) PTO Independent electro--hydraulically controlled power take--off (directly by flywheel)
9
To engage, proceed as follows: 1. Check that the knob (1, fig. 9) is in the STOP position (A), equivalent to oil delivery solenoid valve (1, fig. 12) de--energized.
26337
10 2. Move the PTO operation selection lever (1, fig. 10) into position (E). In this position the sleeve (2, fig. 11) is freed from the toothed coupling of the gearbox gear (1), so only the PTO connected to the flywheel via the shaft (3) can work.
1
2
3
26338
11
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
16
Moving the lever (1, fig. 10) onto (E) acts, via the control levers, also on the rod of the control valve (4, fig. 12), which takes on the above--mentioned position. With the rod (4) in this position and the solenoid valve (1) deactivated, the control valve hydraulic diagram is as shown in fig. 12. The line (11) receives pressurized oil from the pump and the control valve (4) directs the pressurized oil to the solenoid control valve (1). With the solenoid valve (1) deactivated, the delivery line to the PTO clutch engagement cylinder (2) discharges and is connected to line (10), whereas the delivery line to the clutch brake (3) remains pressurized. Under these conditions the PTO clutch is disengaged and the clutch brake is engaged.
1
2
3
The hydraulic diagram shown in fig. 21 illustrates this phase. In this phase the delivery line (7, fig. 21) discharges, whilst the lubrication valve (8), assumes the position shown in fig. 21 thereby only lubricating the clutch rear bearing (3). The oil under pressure from line (11, fig. 12) can moreover be used for the services of lines (8) and (9). The figure shows solenoid valves (5) and (6) deactivated. With solenoid valve (5) deactivated, the delivery line (9) discharges and the 4WD engages. With solenoid valve (6) deactivated the delivery line (8) discharges, with the relative disengagement of the front and rear differential lock.
4
5
6
7
8
Pressurised oil Discharge oil
11
10
9
MDE0046A
12 Service control valve hydraulic diagram (points 1--2 page 15) 1. 2. 3. 4. 5.
Oil delivery solenoid valve to PTO clutch or clutch brake (deactivated). Delivery line (discharging) to the PTO clutch engagement cylinder. Delivery line (pressurized) to the clutch brake. Control valve rod position (4) when the lever (1, fig. 10) is in position E. 4WD disengagement solenoid valve.
87679925A - 12 - 2007
Front or rear differential engagement solenoid valve. Control valve support. Delivery lines discharging (front and rear differential disengaged). 9. Delivery line discharging (4WD engaged). 10. Outlet line to transmission casing. 11. Delivery line from the pump to the services control valve (7). 6. 7. 8.
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
17
3. After having carried out operation (2, page 15), turn the knob (1, fig. 13), onto (B), equivalent to solenoid valve (1, fig. 15) energized. This transfers movement from the flywheel, via shaft (12, fig. 22) and clutch (3), to the PTO grooved terminal.
For the hydraulic operation derived from operations 2 and 3, see the description on page18.
13
With operations 2 and 3 (previously described) the independent PTO is electrohydraulically engaged and directly controlled from the flywheel. Selecting the speed with the lever Proceed as follows. 1. Turn the knob (1, fig. 13) onto the STOP position (A) in order to disengage the clutch (3, fig. 22) of the PTO.
2. Pull the stop knob (1, fig. 14) upwards and move the lever (2) onto sector (3) on the selected speed; this operation acts on parts (33 and 24, fig. 4) and on the speed engagement sleeve forks (24 or 31, fig. 4).
3. Turn the knob (1, fig. 13) onto (B) to re--engage the PTO clutch.
26325
14
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
18
DESCRIPTION AND OPERATION With lever (1, fig. 10) on E and solenoid valve (1, fig. 15) energized, the hydraulic diagram of the control valve is the one shown in the figure 15. The line (11) receives pressurized oil from the pump and the control valve (4) directs the pressurized oil to the solenoid control valve (1). With the solenoid valve (1) activated, the delivery line to the PTO clutch engagement cylinder (2) is pressurized, whilst the delivery line to clutch brake (3) discharges and is connected to line (10). The PTO clutch is therefore engaged and the clutch brake is disengaged. The hydraulic diagram shown in fig. 22, illustrates this phase. In this phase the delivery line (7, fig. 22)
1
2
3
is pressurized, so the lubrication control valve (8), takes on the position shown in the figure, permitting lubrication of the clutch front/rear bearings and the clutch. The oil under pressure from line (11, fig. 15) can moreover be used for the services of lines (8) and (9). The figure activated.
shows
solenoid
valve (5)
and (6)
With the solenoid valve (5) activated, the delivery line (9) is pressurized and 4WD is disengaged. With the solenoid valve (6) activated, the delivery line (8) is pressurized and the front and rear differential lock is engaged.
4
5
6
7
8
Pressurised oil Discharge oil
11
10
9
MDE0047A
15 Services control valve hydraulic diagram (points 2 and 3 pages 15 and 17) 1.
Oil delivery solenoid valve to PTO clutch or clutch brake (energized).
6.
Front or rear differential engagement solenoid valve.
2.
Delivery line (pressurized) to the PTO clutch engagement cylinder.
7.
Control valve support.
8.
Pressurized delivery lines (front and rear differential engaged).
3.
Delivery line (discharging) to the clutch brake.
9.
Delivery line pressurized (4WD disengaged).
4.
Control valve rod position (4, fig. 15) when the lever (1, fig. 10) is in position E.
10. Outlet line to transmission casing.
5.
4WD disengagement solenoid valve.
87679925A - 12 - 2007
11. Delivery line from the pump to the services control valve (7).
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
19
b) PTO synchronized to gearbox To engage, proceed as follows:
1. Check that the knob (1, fig. 16) is in the STOP position (A), equivalent to solenoid valve (1, fig. 12) de--energized.
16
2. Press the gearbox engine clutch control pedal fully down, after a few moments move the lever (1, fig. 17) onto (B) and release the pedal. This activates levers on the control valve rod (4), as indicated in fig. 19 positioning it in relation to the PTO synchronized with gearbox.
26337
17 NOTE: At the same time, move the PTO operation selection lever (1, fig. 17) onto (B) engaging sleeve (2, fig. 18) on the gearbox gearing teeth (1) (PTO synchronized with gearbox). The hydraulic diagram in fig. 19 and the relative description show the operation of the services control valve when the control valve rod (4) is in position in relation to the PTO synchronized with gearbox.
1
2
3
26338
18
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
20
DESCRIPTION AND OPERATION WITH ROD (4) IN THE PTO SYNCHRONIZED WITH GEARBOX POSITION When the PTO is synchronized with the gearbox (as indicated in points 1--2, page 19), the rod of the control valve (4) is in the position shown in figure 19.
The oil under pressure from line (11) can moreover be used for the services of lines (8) and (9).
The line (11) receives pressurized oil from the pump, but the control valve (4) closes the oil flow to the PTO clutch (2) engagement cylinder delivery lines and to the PTO clutch brake (3), connecting to the discharge line (10) to the transmission casing, as shown in the drawing.
With the solenoid valve (5) activated, the delivery line (9) is pressurized and 4WD is disengaged.
1
2
3
The figure activated.
shows
solenoid
valve (5)
and (6)
With the solenoid valve (6) activated, the delivery line (8) is pressurized and the front and rear differential lock is engaged.
4
5
6
7
8
Pressurised oil Discharge oil
11
10
9
MDE0048A
19 Services control valve with rod (4) in PTO synchronized with gearbox position hydraulic diagram 1.
Oil delivery solenoid valve to PTO clutch or clutch brake (deactivated).
6.
Front or rear differential engagement command solenoid valve activated.
2.
Delivery line (discharging) to the PTO clutch engagement cylinder.
7.
Control valve support.
8.
3.
Delivery line (discharging) to the clutch brake.
Pressurized delivery lines (front and rear differential engaged).
4.
Control valve rod oil delivery to solenoid valve (1) in PTO synchronized with gearbox position.
9.
Delivery line pressurized (4WD disengaged).
5.
4WD disengagement command solenoid valve activated.
87679925A - 12 - 2007
10. Outlet line to transmission casing. 11. Delivery line from the pump to the services control valve (7).
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2 DESCRIPTION AND OPERATION OF 540--1000 RPM ELECTROHYDRAULIC PTO ”NASO” VERSION
21
DESCRIPTION AND OPERATION OF 540 RPM PTO WITH ELECTROHYDRAULIC ENGAGEMENT
(Optional for all models, see page 11) As opposed to the PTO previously described, the 540--1000 rpm PTO cannot be synchronized with the gearbox.
(Standard equipment for all ISO and NASO version models, see page 7).
This version can only be driven by the flywheel via shaft (4) and clutch (5).
This version is driven by the flywheel via the shaft (4) and clutch (5).
With regard to the description, operation and hydraulic diagrams, see 540--750--1000 PTO with electrohydraulic engagement (directly controlled by the flywheel) described in point (a, pages 15 ÷ 18), bearing in mind that in this case the speed is selected when the grooved terminal is changed. On changing the grooved terminal (6, fig. 5) 1 3/8” with 6 grooves (for 540 rpm PTO) with the hole on the bottom open, or 1 3/8” with 21 grooves (for 1000 rpm PTO) with the hole on the bottom closed, the pin (9) acts on an internal lever mechanism which engages the PTO speed selection engagement sleeve (15) by means of the fork (10).
With regard to the description, operation and hydraulic diagrams, see 540--750--1000 PTO with electrohydraulic engagement described in points (a, pages 15 ÷ 18) bearing in mind that, with this version, the speed cannot be selected by means of the lever described on page 17.
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
22
Pressurised oil Intake and discharge oil Lubricating oil Oil at static rest
3
4
6
7
8
9
10
2 11 1
5
17
16
15
14
13
12
MDM0341A
Tractor hydraulic diagram
1. Heat exchanger. 2. 3. 4. 5. 6. 7. 8.
Steering pump. Steering cylinders. Low pressure switch. Front differential lock. Power steering control valve. Power take--off solenoid valve. Differential lock solenoid valve.
9. 10. 11. 12. 13. 14. 15. 16. 17.
20
4WD circuit. PTO brake. Electrohydraulic PTO unit. Rear differential lock. User control valve. Four wheel drive release solenoid valve. Gearbox hydraulic control valve. Oil filter on delivery. Oil filter on suction.
Description of operation -- Hydraulic system The hydraulic system (see fig. 20) functions as The services control valve (13) (operation described follows; on pages 16, 18), 20 enables: The pump (2) sucks oil from the rear transmission -- controlling the clutch brake cylinder (10); through the line, the oil is filtered through filter (17) -- controlling the PTO clutch engagement cylinder and directed through the line to the power steering (11); (6). After having served the power steering, the oil is -- lubricating the clutch bearings and the PTO directed through the filter (16), to control valve (15) of engagement clutch; the transmission unit, and from here to the services -- controlling the front and rear differential lock control valve (13) and heat exchanger (1) in order to engagement (5 and 12); lower the temperature, afterwards the oil goes to -- disengaging four--wheel drive. provide lubrication.
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
23
Hydraulic diagram with solenoid valve 1, fig. 12 (de--energized) 1. 2. 3. 4.
1
2
3
4
Clutch brake cylinder with line (4) pressurized. PTO clutch engagement cylinder (3) with line (7) discharging. PTO clutch. Delivery line to pressurized clutch brake cylinder.
5
5. 6. 7.
Lubrication line with valve (8) for lubrication of clutch rear bearing only. Position of accumulator cylinder for gradual PTO engagement with line (7) discharging. Discharging pump delivery line.
Position of lubrication valve (8) with line (7) discharging (only lubricates rear bearing. 9. Lubrication line (5) external union. 10. Lubrication line pressure relief valve. 8.
6
7 8 9 10
Pressurised oil Discharge oil Lubrication oil
21
MDE0049A
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
24
Hydraulic diagram with solenoid valve 1, fig. 15 (energized) 1. 2. 3. 4. 5.
1
2
3
4
Clutch brake cylinder with line (4) discharging. PTO clutch engagement cylinder (3) with line (7) pressurized. PTO clutch. Clutch brake cylinder delivery line discharging. Lubrication line with valve (8) for lubrication of front/rear bearings and clutch disks.
5
6. 7. 8.
Position of accumulator cylinder for gradual PTO engagement with line (7) pressurized. Pressurized pump delivery line. Position of lubrication valve (8) with line (7) pressurized (lubrication of front/rear bearings and clutch disks.
9. 10. 11. 12.
Lubrication line (5) external union. Lubrication line pressure relief valve. Threaded plug. Flywheel drive shaft.
6
7 8 9 10
12
11
Pressurised oil Discharge oil Lubrication oil
22
MDE0050A
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
25
ADDITIONAL PTO CONTROLS FOR CAB-VERSION TRACTORS WITH POWER SHUTTLE TRANSMISSIONS External controls on mudguards (if installed) On request, on both rear mudguards, it is possible to fit a PTO button (1, fig. 23), which helps align the grooves of the PTO shaft with the implement and facilitates static applications of the PTO. With the engine running, touch the button momentarily (for less than 5 sec) to cause the PTO shaft to index round to align the shaft splines. If the button is pressed for less than 12 sec and longer than 5 sec, the shaft turns normally, press the switch again to stop the rotation. If the time exceeds 12 sec the control unit will block rotation of the PTO and cause the warning light to blink; under these conditions, if the switch is pressed again for 10 sec the control unit will generate fault code 5043 and disable the PTO, until the engine is next switched off. 23 NOTE: Simultaneous operation, within two seconds, of in cab and external PTO controls will have no effect. A 10 second delay will occur before PTO control operation will recommence. NOTE: The external buttons on the mudguards (1, fig. 23) can be deactivated by going into the HH MENU programs of the Power Shuttle control unit (RJ) in mode H3; refer to Section 55, Chapter 10.
ATTENTION Before leaving the tractor to operate the external Power Take--Off buttons (1): •
Place all gear shift levers in neutral.
•
Disengage the P.T.O.
•
Apply the parking brake.
With the engine running, move the hand throttle lever to the low idle position (fully rearwards). The operator must use the external PTO buttons (1) solely from the side of the tractor (outside the rear tyres).
87679925A2 - 02 - 2010
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
26
Modulating function selection (if installed) Before engaging the PTO: pushing the button (2) and pulling the knob (1) upwards, if special tools are connected it is possible to activate modulated engagement for them.
24
Gradual engagement is activated by means of a rocker switch next to the steering wheel on the left--hand side. Gradual engagement modulates the PTO clutch for a few seconds so that drive transmission takes place slowly and progressively. To activate the modulating function, use the button (1, fig. 25) as follows: -- Position A = modulating function on. -- Position B = modulating function off. All this is controlled by the gearbox control unit (RJ) and there is no need for enabling.
25 NOTE: When there are certain problems the gearbox control unit displays a series of fault codes. For reading the codes and, if necessary, clearing them, see chapter 10 section 55, for resolving the codes see chapter 9 section 55.
REAR PTO FAULT CODE LISTING FAULT CODE 5007
Description of Fault PTO clutch solenoid valve short to + 12 volts
E.C.R. (*) NO
5008
PTO clutch solenoid valve open circuit or short to ground
NO
5033
Rear PTO cab normally closed switch open circuit
NO
5034
Open circuit or short to ground to the PTO switches on the mudguards
NO
5035
Short to + 12V from the PTO switches on the mudguards
NO
5037
Cab rear PTO switch jammed on (normally off)
NO
5043
Switch on mudguards jammed on
NO
(*) Enter the HH programs of the control panel select the H3 program, enter the ECR, then select the options: E -- show only severe codes, F -- show all codes for 6 minutes of power then pass to â&#x20AC;&#x153;Eâ&#x20AC;?. With option E selected, the word: YES -- means that the code will not be shown on the display but only kept in memory, NO -- means the code will not be shown on the display.
87679925A2 - 02 - 2010
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
27
PTO TROUBLESHOOTING Problems
Possible causes
Solutions
The independent PTO (governed 1. Transmission oil level low. by the flywheel) fails to work. work 2. Clogged oil filter. 3. Hydraulic pump faulty. 4. PTO engagement faulty.
Top up oil. Replace filter. Overhaul or replace the pump.
switch Replace switch.
5. Lack of power supply to the Check electrical connections and resolenoid valve: connections place defective parts. loose or damaged, contactor faulty. 6. Solenoid valve (1, page 16) Overhaul or replace solenoid valve. governing the PTO clutch locked on delivery to brake. 7. Oil leakage through the seals Replace damaged seals. with consequent pressure drop: seal of the manifold, control plunger, etc. (see figs. 6 -- 22). The independent PTO (governed 1. PTO engagement faulty. by the flywheel) stays on.
switch Replace switch.
2. Solenoid valve (1, page16) Overhaul or replace solenoid valve. governing the PTO clutch locked on delivery to clutch. The PTO clutch drags.
1. Solenoid valve (1, page16) Overhaul or replace solenoid valve. governing the brake locked on delivery to clutch. 2. Brake (24, fig. 4) of the PTO Replace the brake. worn. 3. Clutch plates damaged or Replace discs. deformed.
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
28
POWER TAKE--OFF CLUTCH BRAKE Renew
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. Disconnect the battery negative cable (1).
Detach the tow bar and the top link on the three--point linkage device (1).
26
1
25534
27 Fit a sling on the support with pick--up hitch hook (2), remove the six PTO casing retaining bolts (1) and detach the support with pick--up hitch hook.
1
2
25512
Remove the right--hand vertical tie--rod (1) from the lift arm, to have more room for subsequent disassembly.
28
1
25571
29 87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
29
Remove the brake cover retaining snap ring (1).
1
25572
30
Remove the cover (1) with a screwdriver.
1
25573
31 Screw bolt (1) on the brake piston threaded hole (2) and extract the piston using pliers.
1
2
Assembly Procedure.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. ---
Refit the brake, the cover and insert the brake cover retaining snap ring. Reconnect the right--hand vertical tie--rod to the lift arm.
--
Refit the pick--up hitch hook.
--
Refit the tow bar and the three--point linkage device top link.
--
Re--connect the battery negative lead and fit the guard on the battery.
25574
32
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
30
ELECTRO--HYDRAULIC POWER TAKE--OFF HOUSING R.I.
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. Disconnect the battery negative cable (1).
Remove the tow bar and the top link on the three--point linkage device (1).
33
1
25534
34 Take out the plug (1) and drain the oil from the gearbox/transmission casing.
1
25622
35
Remove the PTO speed sensor (1).
1
25648
36 87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2 Fit a sling on the support with pick--up hitch hook (2), remove the six PTO casing retaining bolts (1) and detach the support with pick--up hitch hook.
31
2
1
25512
37
Take out the four retaining bolts (1), remove the guard (2) on the PTO terminal.
2
1 25513
38 Unscrew the unions and remove the three pipes (1) from the PTO.
1
25514
39
Remove the PTO cover (4), take off the front circlip (3) and the support (2) of the clutch driving disks.
1 2 3 4 MDE0052A
40 87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
32
Remove the rear securing snap ring (1).
1
25516
Hitch the PTO unit (1) to the lifting hook with chain 380000227, and allow the hoist to take the strain, unscrew the four bolts retaining the PTO unit to the transmission/gearbox casing and remove the PTO unit.
41
1
NOTE: Before removing the PTO unit, insert the PTO synchronized with gearbox lever, from inside the cab.
25517
42
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. To reassemble the PTO unit, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Clean the rear contact surface between the transmission/gearbox casing and the PTO casing.
--
Re--tighten the two guide pins (used for disassembly) on the PTO unit.
--
Clean the surface of the PTO casing and apply a 2 mm diameter bead of the sealing compound indicated on page 1, Sect. 00, following the indications in fig 43.
--
Hitch the PTO unit to hook 380000227 with the chain.
--
Place the PTO unit in front of the transmission casing, use a hoist to move the parts into position and insert on the centering pins.
87679925A - 12 - 2007
26372
43
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2 --
Remove the chain and secure the PTO with the four screws.
--
Remove the centering pins.
--
Place the stop ring (1) on the grooved shaft.
--
Refit the grooved support (2) on the PTO clutch and insert the retaining snap ring (3).
--
--
Carefully clean the contact surface the PTO cover (4) and apply the sealing compound indicated on page 1, Sect. 00 of the diameter of 2 mm along the marked line shown in fig. 45. Refit the cover (4) and the PTO terminal guard.
--
Refit the PTO speed sensor and secure with two bolts.
--
Secure the PTO speed sensor electric cable bracket.
--
Refit the PTO lines (lubrication, clutch engagement and brake) on the PTO casing unions.
--
Refit the tie--rod on the PTO speed selection external lever. Refit the sheath on the support bracket. Raise the support with pick--up hitch hook using a chain and secure to the PTO with the six retaining bolts. Refit the tow bar and the three--point linkage device tie--rod. Fill the transmission/gearbox casing with oil. Reconnect the battery negative lead. Respect the tightening torques prescribed on page 6.
-------
33
1 2 3 4 MDE0052A
44
26451
45
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
34
ELECTROHYDRAULIC POWER TAKE--OFF HOUSING D.A. NOTE: PTO unit overhaul operations must be carried out on a workbench.
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. Secure the PTO (1) in the vice on the workbench and detach lifting hook 380000227 with chain. Remove the securing ring and unscrew the driven shaft lock nut (2).
1
2
25740
Unscrew the fork (1) rod retaining Allen screw (3) on the (2).
46
1
2
3
25741
47 Extract the rod (1) with a punch.
1
25742
48
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2 Remove the fork (2) and the engagement sleeve (1).
1
35
2
25743
Remove the 750 rpm driven gear (1) and the bearing thrust ring.
49
1
25744
50 Remove the retaining ring (2) and retrieve the support of the clutch driving discs with the related bearing (1).
1
2
25745
Remove the external support with the hydraulic clutch disks (1).
51
1
25746
52 87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
36
Using a mallet and punch, extract the speed selection (2) external lever securing pin (1) and remove the relevant parts.
1 2 25747
Remove the snap rings (1) and (2) and extract the driving shaft (3) tapping on the end with a plastic mallet; remove gear unit (4).
53
1
4
3
2
25748
54 Take out the four bolts (1) securing the gear support (2). With the pliers compress the terminal parts of the PTO terminal shaft, remove the snap ring and extract the shaft (3) from the rear part. Remove all parts, including the thrust washers.
2
1
3 25749
Remove the retaining circlip (1) and extract the bearing (2) from the PTO cover.
55
1 2
25750
56 87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2 Using a screwdriver extract the oil seal (1) from the PTO cover.
37
1
25751
With pliers, remove the snap ring (1) and the cover (2).
57
1
2
25752
58 Tighten the screw (3) in the threaded hole on the piston (1), extract the piston and check the condition of the O--ring seal (2).
1
2
3 25753
Unscrew the pressure relief valve (1) on the lubrication line of the internal gear support (2).
59
1
2
25754
60 87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
38
Remove the accumulator cap (1).
1
25755
Remove the accumulator components, i.e.: the piston (1), the spring (2), the cover (3).
61
1
2
3
25756
62 Remove the snap ring (1) the clutch disks reaction ring (2), and the driving and driven clutch disks.
1
2
25757
Fit spring press tool 380000243 (1) on the disks support (2) as shown in the figure, tighten the tool to compress the internal spring.
63
1
2
25758
64 87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2 When possible, remove the snap ring (1) using a screwdriver. Loosen nut (2) and disassemble tool 380000243 (3).
1
39
2
3
25759
Using a compressed air gun, expel the piston (1) from the disk support (2).
65
1
2
25760
66 Remove and check the condition of all parts, replacing O--ring seals (1) and (2), if necessary.
1
2
25761
Fit the extractor with separator (4) on the driving shaft (2) and secure in the vice. Fit the extractor (1) and connect it to the extractor (4). Position a plate on the end of the shaft (2) and tighten the extractor until the bearing (3) is extracted.
67
1 2 3 4
25762
68 87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
40
--
Position the PTO cover in the vice, fit the rear bearing (2, fig. 56) and the retaining snap ring (1).
--
Assemble the speed selection lever (2, fig. 53) on the cover and secure with the spring pin.
--
Fit the spacer between the rear bearing and the 1000 rpm driven gear on the driven shaft (22, fig. 4).
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
Assemble the 1000 rpm driven gear, complete with sleeve, fork and bushing.
--
For the correct orientation of the various parts, refer to figs. 4 and 6.
--
Partially insert the speed selection lever rod (1, fig. 48) so that the 540 and 1000 rpm gear engagement sleeve is held in position.
--
Insert the cylinder (9, fig. 4) in the sliding seat, fit the spring (10) and the spring rear retaining plate.
--
Insert the 540 rpm gear and front bearing thrust washer on the shaft (22, fig. 4).
--
Apply tool 380000243 (3, fig. 65) as shown in the figure, tighten nut (2) to load the spring (10) and when possible, insert the retaining ring (1) on the spring rear plate (10), then remove tool 380000243.
--
Fit the gear support (2, fig. 55) and bearings.
--
Refit the driving shaft (3, fig. 54) with the clutch disk locking cylinder (previously assembled), then gear unit (4) and the retaining snap rings (1) and (2).
--
Position the spacer between the gear (3, fig. 4) and the front bearing on the driven shaft.
--
Fit the driven gear 750 rpm (1, fig. 50), then the coupling sleeve (1, fig. 49) and the fork (2).
--
Fit the nut (2, fig. 46) and tighten to the torque value indicated on page 6 securing the edge on the driven shaft thread to prevent the nut from loosening.
--
Lock the fork support rod (3, fig. 47) with the retaining Allen bolt (1) on the support (2).
Assembly Procedure Check the condition of all components, especially the clutches and seals, and replace any worn parts. To reassemble the PTO unit parts, proceed as follows:
ATTENTION
--
--
Heat the intermediate bearing and fit on the shaft (5, fig. 4), then assemble the clutch control cylinder on the shaft (5). Alternately mount the driven (12) and driving (11) disks on the clutch casing, fitting the external reaction ring (2, fig. 63) with the retaining snap ring (1).
--
Refit the piston, the spring and the accumulator cover (as shown in fig. 62).
--
Refit the pressure relief valve (as shown in fig. 60).
--
Reassemble the brake and secure the cover with the snap ring (as shown in fig. 58).
--
Refit the oil seal (1, fig. 57), using a punch to correctly position the seal.
NOTE: For the assembly of the remaining parts see the description of the installation operations (see figs. 43-- 44-- 45).
NOTE: ( 1) -- Before screwing the cap onto the support, apply a few drops of Loctite 242 on its thread, then screw on fully but without tightening it.
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
41
FITTING COOLER WITH MECHANICAL TRANSMISSION AND HYDRAULIC POWER TAKE--OFF Pressurised oil Intake oil Excess oil to the pressure regulating valve (PTO lubrication) Oil at static rest
1
2
3
5
4
6
7
8
21 9 20 10 19
11
18
17
16
15
14
13
12
MMM0495A MMM0495A
69 General hydraulic system 1.
Steering cylinders.
12. Rear differential lock.
2.
Gearbox oil pressure switch on services control valve supply line (oil discharge from the power steering).
13. Services pressure regulating valve.
3.
Power steering control valve (orbitrol).
4.
Differential lock solenoid valve.
5.
PTO engagement solenoid valve.
6.
Pressure line to the PTO clutch.
7.
4WD disengagement line.
8.
Pressure line to the PTO brake.
9.
Hydraulic PTO unit.
14. 4WD disengagement solenoid valve. 15. Restrictor union. 16. Return line from the cooler, discharge into the transmission. 17. Suction filter. 18. Front differential lock. 19. Delivery line to cooler.
10. Lubricating pressure regulating valve.
20. Heat exchanger.
11. PTO lubrication line.
21. Low pressure pump. 87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
42
70 1.
Pipe from the outlet of the services control valve (3) to the cooler, travelled by oil at high temperature.
6.
PTO lubrication line.
2.
Services control valve supply line.
7.
L--coupling draining oil into the transmission housing.
3.
Excess oil discharge to the pressure regulating valve; oil destined partly for lubrication and partly for discharge.
8.
Restrictor union.
4.
PTO clutch engagement solenoid valve unit.
9.
5.
Pressure regulating valve compartment plug with oil drain line overhead the valve.
Return line from the cooler, connected to the L--coupling (7) introducing oil into the transmission housing, travelled by the excess oil for PTO clutch lubrication cooled by the cooler.
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
43
COOLING SYSTEM DESCRIPTION AND OPERATION To prevent the transmission oil from reaching too high a temperature it is possible to fit a cooler on the mechanical transmissions with either a mechanical PTO (see chap. 1 section 31) or a hydraulic PTO. The oil coming from the control valve of the power steering via line (2, fig. 70) reaches the services control valve. It enters from the side of the pressure regulating valve that regulates the four--wheel drive disengagement and front/rear lock engagement oil to a pressure of 15.7 รท 16.7 bar (16 รท 17 kg/cm2), the excess oil is sent partly to PTO lubrication, it reaches the PTO clutch unit and acts on the lubricating pressure regulating valve that regulates the pressure to 4.4 รท 5.9 bar (4.5 รท 6 kg/cm2), and partly to the discharge. On machines with a cooler, the oil leaves the Tee coupling (3, fig. 70), some of it goes to lubrication via line (6, fig. 70) and some, depending on the temperature, takes two routes: A) With cold oil: the density of the cold oil enables an increase in pressure when it passes through the restrictor union (8, fig. 70) and into the cooler, then it goes straight to the outlet in the transmission casing, partly via a passage inside the control valve and partly via the opening of the lubricating pressure regulating valve on the PTO unit. B) With hot oil: with the increase in temperature and associated decrease in density, there is a decrease in the pressure on the line (1, fig. 70) and on the restrictor union (8, fig. 70) then on the cooler, the oil passes into the cooler through the feed pipe (1, fig. 70) to then pass via the return pipe from the cooler (9, fig. 70), and enter the L--union (7, fig. 70) on the transmission casing, thereby reaching the outlet.
87679925A - 12 - 2007
44
87679925A - 12 - 2007
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
1
SECTION 33 -- BRAKES Chapter 1 -- Braking system CONTENT Description
Page
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Handbrake control. Travel adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Parking brake casing. R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Parking brake casing. D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Brake hydraulic system. Air bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Service brake pump. R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Service brake cylinder. R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
87679925A - 12 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
2
SPECIFICATIONS Type: -service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --
with oil bath disk, acting on differential drive shafts with oil bath disks, engaging a gear on the bevel pinion shaft
parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driving: -service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --
hydrostatic, with independent pedals (connected by means of a pin) mechanical, by means of a hand lever sintered steel sintered or organic agglomerate
parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service brake disk material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking brake disk material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking brake mobile sectors material . . . . . . . . . . . . . . . . . . . . . . .
Quantity of disks: 2--wheel drive -service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--wheel drive -service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disk thickness: -service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking brake mobile sectors thickness: -lateral sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -intermediate sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic control Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake on front axle Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantity of disks Disk thickness Bleeding air from brake circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control pedal adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87679925A - 12 - 2007
n n
1 on each side 4
n n
1 on each side 5
mm mm
9.52 รท 9.68 3.95 รท 4.05
mm mm
2.95 รท 3.10 4.05 รท 4.20
bar
with 2 master cylinders independently operated by brake pedals 17.6 (18 kg/cm2) with oil bath disk, acting on differential drive shafts hydrostatic, with paired pedals (by means of a pilot valve) 1 on each side 4.45 รท 4.55 see page 14 see page 17
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
3
32 MDF1436A
1
BOLT TORQUES
Tightening torque PARTS TO BE TIGHTENED
Th d Thread Nm
kgm
Nut securing final drive to transmission casing (C1) . . . . . . . . . . .
M 14 x 1.5
176
18
Bolts retaining shaft for parking brake driven gear (C2) . . . . . . . .
M 10 x 1.25
64
6,5
Guide bolts for parking brake mobile sector (C3) . . . . . . . . . . . . . .
M 12 x 1.25
32
3,2
Bolt retaining parking brake support to transmission casing (C4)
M 12 x 1.25
98
10
Brake piston /stub axle retaining bolt (C5) . . . . . . . . . . . . . . . . . . . .
M 10 x 1.25
75 รท 82
7.6 รท 8.4
87679925A2 - 02 - 2010
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
4
1
2
3
4
5
6
MDM1534A
1
2
3
4
5
6
X
X
X
A
X
B
C 2 Service brake and parking brake sectional drawings A. Mod. 56/76 and 63/86 KW/HP. B. Mod. 71/97, 78/106 and 83/113 KW/HP. C. For 2WD models. For 4WD models, see sect. 23 chap. 1 fig. 3. 1. Brake wear disk. 2. Hydraulic braking system pipe. 3. Service brake disc. 4. Seal. 5. Brake piston. 6. Axle shaft. 7. Driven gear.
8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Parking brake discs. Driven gear pin (7). Two--sided friction sections. One--sided friction sections. Parking brake internal control lever. Parking brake support. Circlip. Thrust washer. Parking brake external lever. Bolt locking lever (16). Parking brake shaft.
NOTE: During assembly apply sealing compound on surfaces marked with an X as shown on pages 13 and 22. 87679925A2 - 02 - 2010
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
5
Sectional view of service brakes on front axle.
1. Oil inlet union. 2. Bleed screw. 3. Plug on the hub to access bleed screw on brake cylinder. 4. Brake cylinder/final drive ring gear support. 5. Wear disk. 6. Reaction plate. 7. Disk unit retaining circlip. 8. Brake disc. 9. Seal. 10. Brake piston.
1
2
MDM1535A
3
10
4
9
5
8
6
7 3
Service brake sectional drawing
24664
4 Service brake sectional drawing 1. 2. 3.
Spring. Pump body. Control piston.
4. 5. 6.
Rear seal. Central seal. Front seals.
87679925A - 12 - 2007
6
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 DESCRIPTION AND OPERATION
SERVICE BRAKES (see fig. 5)
The service brakes are the hydraulically operated wet disk type.
The two control pumps (one for each pedal) are located in the front part of the cab and are connected to their pedals (3) by means of tie--rods.
The pumps can be operated on their own by each pedal, or as a pair with both pedals (connected by a pin).
The connecting pipe (6) between the two pumps ensures balanced braking, even when the brake disks are not equally worn.
The control pumps are fed from a single reservoir installed on 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 mounted on the differential drive shafts.
87679925A - 12 - 2007
SERVICE BRAKE ON FRONT AXLE (see fig. 5)
The service brakes on the front axle (four--wheel drive only), when fitted, are operated with the two rear brake pedals when they are pressed simultaneously (brakes locked).
Pressing just one pedal (with the pedals free) produces no braking action on the front brake thanks to a pilot valve (7); the valve operation is described on page 8.
PARKING BRAKE (see fig. 2)
The parking brake is operated by a control lever on the left--hand side of the operator.
When acting on the control lever, a flexible tie--rod operates the lever (12) inside the parking brake support (13), bearing the brake sector assembly (10 and 11) and the brake disks (8) keyed onto the driven gear (7) and locking it.
Locking the rear bevel pinion shaft intermediate gear (7), locks the rear bevel pinion shaft too and therefore the tractor cannot move.
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
Right--hand rear brake line Left--hand rear brake line Front brake line Pump pressure oil
7
To the trailer brake To the additional control valves lift Exhaust
2
3
4
1
B 5
7
6
A
MDE0783A
Hydraulic diagram -- brakes A. B. 1. 2. 3.
To the left--hand rear brake. To the right--hand front brake. Left--hand front brake. Pressure switches. Hydraulic brakes.
4. 5. 6. 7.
5
Right--hand rear brake. Trailer brake valve. Pressure balancing pipe. Pilot valve.
NOTE: The pressure switches (2) are normally closed, they only open on braking. If you operate just one pedal, the differential lock is disengaged and, when pressing the left pedal, the brake lights switch off (on machines with a cab). If you operate both pedals, four--wheel drive is engaged, the brake lights come on (on machines without a cab) and the differential lock is disengaged. Operating both pedals, moreover, applies front braking.
87679925A - 12 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
8 Pilot valve operation
Brakes at rest When the tractorâ&#x20AC;&#x2122;s brakes are at rest, there is no pressure on the pipes (A -- B -- C).
1
A
6 C 2 5 4 MDE0784A
1
Oil from the left--hand brake cylinder. Oil from the right--hand brake cylinder. Oil delivered to the front brakes. Left--hand piston. Bleeding devices. Right--hand piston. Ball. Pin. Ball.
87679925A - 12 - 2007
A
6 C 2 5 4 MDE0785A
3
B 7
1
A
6 C 2 5 4 MDE0786A
A. B. C. 1. 2. 3. 4. 5. 6.
B 6
Braking applied on just one pedal When pressing just one brake pedal (for instance, the one operating the right--hand rear brake), the pressure reaches the pilot valve through the pipe (B), shifts the ball (4) in contact with the tapered seat of the piston (3) bringing this into contact with the piston (1). No pressurized oil comes from the pipe (A), accordingly the ball (4) shifts the pin (5) and the ball (6) towards the piping (A). The oil pressure keeps the ball (4) in contact with the tapered seat of the piston (3) obstructing the flow of oil being delivered to the front brakes through the piping (C) and accordingly the front brakes are not subjected to braking. Braking applied on both brake pedals When both brake pedals are pressed, the pressurized oil reaches the pilot valve via both pipes (A and B). The pressurized oil shifts the pistons (1 and 3) towards the centre of the valve while the pin (5) keeps the balls (4 and 6) detached from the tapered seats on the pistons (1 and 3). In this position, the oil can arrive under pressure through the piping (C) with an according braking action of the front brakes.
3
3
B
Tractor brake circuit oil (brakes off) Tractor brake oil circuit (under pressure)
8
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
9
BRAKE TROUBLESHOOTING Problems Brake pedals hard to operate.
Possible causes
Solutions
1. Corresponding master cylin- Replace the brake control pump. der seized. 2. Brake control pipes obstruc- Clean or replace the control pipes. ted or pinched.
The brakes stick when the pedals 1. Brake control pump pistons Release the piston and, if necessary, are released. locked. replace the brake control pumps. 2. Master cylinders seized.
Replace the brake control pumps.
Noisy brakes.
1. Friction material on brake Replace the brake disks. disks worn (3., fig. 2).
Pedal stroke too long. g
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. g
3. Pump connection pipes ob- Clean or replace the pipes. structed or pinched. 4. Brake control pipes obstruc- Clean or replace the control pipes. ted or pinched. 5. Pump control piston seals Replace the brake control pumps. worn or damaged. 6. Friction material on brake Replace disk. disks worn (3., fig. 2). Inefficient braking.
1. Friction material on brake Replace the brake disks. disks worn (3., fig. 2). 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 incorrectly adju- Adjust correctly. sted. 2. Braking sectors worn (8--10--11, fig. 2).
Replace the braking sectors.
The tractor remains braked when 1. Control return stroke obstruc- Remove obstructions. the parking p g brake is disengaged. g g ted. 2. Braking sectors (8--10--11, Release and replace the damaged fig. 2) seized on brake disks. parts.
87679925A - 12 - 2007
10
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
HANDBRAKE CONTROL Travel adjustment The parking brake lever must be adjusted whenever service operations are carried out on the assembly, and if the lever is not positioned in the third notch when the brake is engaged. Proceed as follows. 1. Loosen the locknuts (1) and (2). 2. Adjust the screw (3) so that the lever locks the brake discs on the third ratchet. 3. Lock the locknuts (1) and (2).
9
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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
11
PARKING BRAKE CASING R.I. and 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. To disassemble the support (12, fig. 2) of the parking brake proceed as follows. 1. Disconnect the battery negative lead (1). 2. Lock the front wheels with chocks. 3. Drain the oil from the gearbox--transmission casing.
10
4. Disconnect the control linkage (1) and the return spring (2), from the brake control lever (3). 5. Detach the services solenoid valve support following the description in Section 31. 6. Take out the retaining bolts and remove the parking brake casing (4).
11 7. Take out the retaining bolts (1) and remove the pin (2) together with the brake disks and gear.
1
2
26290
12
87679925A - 12 - 2007
12
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
8. Unscrew the brake sectors support bolts (1) and remove.
1
26291
13
9. Extract the retaining bolt (2) and remove the external lever (1) controlling the parking brake.
14 10. Remove the stop bolt (1) and extract the internal lever (2) controlling the parking brake.
1
2
26293
15
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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
13
11. To assemble and refit the parking brake unit, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Refer to the illustrations of fig. 2 for the correct orientation of the various parts.
--
Before reassembling the parking brake support 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 below.
--
Respect the tightening torques prescribed on page 2.
--
Insert the internal lever (1), without O--ring, on the support until the O--ring seat is fully visible. Place the O--ring (2) in the seat and push the internal lever (1) into position, securing with the screw. Assemble the parking brake external lever, securing it on the shaft with the bolt.
--
--
Fit the brake sectors and relative support screws.
--
Fit the pin, brake disk and gear unit.
--
Position and secure the brake sectors support to the transmission--gearbox casing.
--
Refit the services solenoid valves support.
--
Connect the return spring, control wire.
--
Fill up the rear transmission--gearbox casing. for products and quantities see Section 00.
--
Connect the negative cable to the battery.
1
2
26294
16
Mastic application diagram for assembly of parking brake support to the transmission casing 26283
The types of sealing compounds to be applied are specified in Section 00.
17 87679925A - 12 - 2007
14
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
BRAKES HYDRAULIC SYSTEM
1
Air bleed Air must be bled out whenever carrying out work on the brake hydraulic system. Proceed as follows. 1. Thoroughly clean the external parts of the assemblies near the bleeding screws (1, fig. 19) and the hydraulic oil reservoir cover (1). 2. Check that the right--hand brake reservoir (1) is full, both before and during bleeding.
26273
18
NOTE: Carefully filter used oil before re--using. 3. Push the left--hand brake pedal down, slowly and fully, so that the oil is put in pressure. 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 left brake pedal down again so that the oil is put under pressure: this occurs when the brake pedal stroke returns to normal. 7. Repeat the above steps for the right--hand brake pedal. 8. On completion of this procedure, fill up the reservoir with oil (1, fig. 18).
24439
19
Tractor equipped with hydraulic trailer braking valve 9. When the tractor is equipped with the trailer brake hydraulic control valve, carry out the above--mentioned operations (from operation 3. รท 6.) on the right--hand pedal and bleed the air from the screw (1 fig. 20) on the hydraulic trailer brake actuator. 10. On completion of this procedure, fill up the reservoir with oil (1, fig. 18). 26274
20
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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
15
Tractor equipped with Braking on the front axle 11. Under the bonnet on the left--hand side there is the logic valve (1) that, with the pedals coupled, enables braking on the front axle. On this valve there are two bleed screws, complete bleeding the rear brakes by using these two screws. Each one of these screws is coupled with the circuit of a single pedal; therefore repeat the operations 3. รท 6. for each pedal, bleeding the circuit with these screws.
12. On the hub of each wheel of the front axle there is a plug (1), if it is not visible then turn the wheel to bring it round to the top. On the inside there is a bleed screw, after removing the plug, turn the wheel slightly to bring the hole into position with the screw. 13. On these two screws, one on each side, it is Necessary to do the bleeding as described above except that the pedals must be paired therefore bleed first one screw and then the other one with the pedals paired. 14. On completion of this procedure, fill up the reservoir with oil (1, fig. 18).
21
22 Tractor equipped with pneumatic trailer braking valve 15. Inside the rear right wheel, on the front of the rear reduction gear, there is the pneumatic trailer brake actuator (1), also here there are two bleed screws (1, fig. 24), one for each pedal.
16. Carry out the operation described above on the right and left pedal, bleed the air from the respective screws on the rear reduction gears and complete the bleeding by using the screws (1) fitted on the pneumatic trailer brake actuator. 17. On completion of this procedure, fill up the reservoir with oil (1, fig. 18).
23
24 87679925A - 12 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
16
SERVICE BRAKE PUMP R.I.
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. Disconnect the battery negative lead (1). 2. Lock the front wheels using chocks.
25
3. Remove the knobs (2 and 3) and the guard (1).
26271
26 4. Disconnect the electrical connections: on the tank (1), pressure gauges (3) and detach the service brake lines (2).
1
2
3 26272
27
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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
17
5. Remove the spring clips and extract the brakes pump fork pivot pins (1). 6. Unscrew the bolts (2) securing the brakes pump to the cab and extract the pump from the engine side.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
26273
28
7. To refit the brake control hydraulic pump unit, proceed as follows. -- Fit and secure the pumps, and connect to the control pedals. -- Connect the lines and connections on the tank and pressure gauges. -- Connect the battery negative lead. -- Carry out the following adjustment operation and bleed the air from the circuit, as described on page 14. Adjusting the height of the service brakes pedals 8. With the brake control pedals connected to the forks and the pedal connection pin extracted, check that the height (H), from the centre of the pedals to the top of the mat, is: 162 mm for tractors fitted with a cab or 185 mm for tractors fitted with no cab.
H
24546
29
9. In order to adjust, loosen the locknuts (2), adjust the screw (1) to obtain the correct height (H) and then tighten the locknuts (2).
2
1
24547
30
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18
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
RIGHT OR LEFT BRAKE 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. To remove the final drive casing proceed as follows. 1. Disconnect the battery negative lead (1). 2. Lock the front wheels using chocks.
31 3. Detach the vertical tie--rod (1) and the LH anti--swing rod (2).
2 1 26253
32
4. Raise the rear part of the tractor and position a fixed stand under the flex bar support.
25647
33
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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
19
5. Unscrew the retaining bolts and remove the rear LH wheel. 6. Detach the window washer liquid tank from the relative support bracket, disconnect the electrical connections and delivery lines.
25646
7. Unscrew the bolt securing the cab to the bracket (1).
34
1
8. Slightly raise the cab and position a wooden block between the hydraulic lift and the cab, making sure that there is no contact with the piping.
25502
35 9. Take out the plug (1) and drain the oil from the gearbox--rear transmission casing.
1
25622
36 10. Take out the cab supporting bracket (1) retaining bolts.
1
25504
37 87679925A - 12 - 2007
20
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
11. Position a stand (1) under the rear part of the fuel tank.
1
25505
38
12. Connect the final drive casing to suitable equipment for lifting and retaining. Take out the retaining bolts and remove the final drive casing from the transmission casing.
2265 3
25507
39 13. Remove the union (2), and detach the service brake control piping (1).
1
2
25649
14. Detach the crown gear (1), the spacer (3) and the brake disk (2), from the transmission--gearbox casing.
40
1
2
3
25650
41 87679925A - 12 - 2007
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 15. Remove the differential lock piping (1) from the union (2), turn this to free the friction disk (3) and be able to remove it.
1
2
21
3
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
25651
16. To refit the final drive casing to the rear transmission casing, proceed as follows: -- Refer to the illustration of fig. 2 for the correct orientation of the various components. -- Before reassembling the final drive casing to 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 43. -- Check the seals and replace if damaged. -- Respect the tightening torques prescribed on page 2. -- Insert the wear disk, rotate the union and refit the differential lock line. -- Fit the brake disk, spacer and crown gear. -- Connect the service brake lines. -- Using tools suitable equipment for retaining and lifting, refit the final drive together with differential shaft and rear reflector. -- Fit the cab support rear bracket retaining bolts. -- Remove the wooden block from between the cab and lift body. -- Tighten the bolt securing the cab to the left--hand rear support. -- Assemble the window washer tank. -- Fit the LH wheel. -- Fit the anti--swing rod and the vertical tie--rod. -- Remove the fixed stands. -- Screw the oil drain plug and replenish (for the quantity and prescribed product see Sect. 00). -- Connect the battery negative lead. -- Bleed brakes.
42
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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
22
26254
43 Diagram of seal compound application for brake assembly and final drives on the transmission casing The types of sealing compounds to be applied are specified in Section 00
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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
1
SECTION 33 -- BRAKING SYSTEM Chapter 2 -- Pneumatic trailer brakes CONTENTS Description
Page
Main Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 View of air brake components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Diagram of air brake components, German version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Diagram of air brake components, Italian version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Operation of single air brake circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Pressure tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MAIN DATA Circuit data (for German market): Working pressure of the dual--line system German market . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Italian market . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working pressure of the single--line system . . . . . . . . . . Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . Low pressure warning light switch activation . . . . . . . . . Service: Tank condensate drainage . . . . . . . . . . . . . . . . . . . . . . . . . Transmission belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . -Tension checking frequency . . . . . . . . . . . . . . . . . . . . Compressor: -Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
bar (kg/cm2) bar (kg/cm2) bar (kg/cm2) bar (kg/cm2) bar (kg/cm2)
7,8 ÷ 8,3 (7,95 ÷ 8,46) [7,0 ÷ 7,5 (7.14 ÷ 7,65)] 5,0 ÷ 6,0 (5,10 ÷ 6,12) 12 (12,23) 4,5 ÷ 5,0 (4,59 ÷ 5,07)
Hz h
Daily 310 ± 15 300 Left hand side of engine By belt via crankshaft Single cylinder air cooled
--
Speed (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rpm
3.000
--
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
75/36
--
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cm3
159
bar (kg/cm2)
18 (18,35)
Operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . Reservoir: --
--
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right--hand side of tractor in front of final drive
--
Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
no.
1
--
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
L
15
NOTE: The data in square brackets [ ] refer to the working pressures of the air brakes for the Italian market. 87679925A1 - 02 - 2008
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
2
1
TORQUE SPECIFICATIONS PARTS TO BE TIGHTENED
Thread
Belt tensioner retaining bolt (C1, fig. 1) . . . . . . . . . . . . . . . . . . . . . . .
Tightening torque Nm
kgm
M10 x 1.5
42 ÷ 51
4.28 ÷ 5.20
Belt tensioner pivot fixing nut (C2) . . . . . . . . . . . . . . . . . . . . . . . . . .
M10 x 1.5
42 ÷ 51
4.28 ÷ 5.20
Idler pulley fixing screws (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M10 x 1.5
40 ÷ 50
4.08 ÷ 5.09
Compressor pulley fixing nut (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . .
M18 x 1.5
100 ÷ 120
10.2 ÷ 12.2
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.
380001268
Belt tension meter.
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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
3
VIEW OF AIR BRAKE COMPONENTS, GERMAN--ITALIAN VERSION
A
B
NOTE: For the key see page 7.
C 2
87679925A1 - 02 - 2008
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
4
SECTIONS OF AIR BRAKE COMPONENTS, GERMAN--ITALIAN VERSION
E G
H D
F
NOTE: For the key see page 7.
87679925A1 - 02 - 2008
3
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
5
DIAGRAM OF AIR BRAKE COMPONENTS, GERMAN VERSION
21
I
NOTE: For the key see page 7.
4
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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
6
DIAGRAM OF AIR BRAKE COMPONENTS, ITALIAN VERSION
21
J MML0169A
NOTE: For the key see page 7.
87679925A1 - 02 - 2008
5
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
7
AIR BRAKE DIAGRAM AND SECTIONS KEY GERMAN/ITALIAN VERSION NOTE: Refer to the tables on page 3, 4, 5 and 6. A. View of air brake components. B. Detail of the dual--line control valve. C. Detail of the handbrake actuator on the dual--line control valve. D. Compressor suction and lubrication. E. Detail of compressor drive belt. F.
Brake circuit pressure switch.
G. Couplers (German market). H. Couplers (Italian market). I.
Braking diagram (German version).
J.
Braking diagram (Italian version).
1.
Air intake pipe.
2.
Air delivery pipe from compressor.
3.
Compressor lubrication oil drain pipe.
4.
Condensate antifreeze pump (only available for the single--line system for the German market).
5.
Antifreeze tank (only available for the single--line system for the German market).
6.
Pressure regulating valve.
7.
Pipe delivering air to the tank.
8.
Pipe delivering air to the pressure switch.
9.
Pressure switch.
10. Reservoir. 11. Drain valve. 12. Single--line control valve (only available for the single--line system for the German market).
20. Braking pressure line between the two control valves (only available for the single--line system for the German market). 21. Dual--line control valve. 22. Compressor suction pipe. 23. Compressor. 24. Hydraulic left--hand rear brake actuator line. 25. Hydraulic brake bleed screws on the dual--line control valve. 26. Handbrake tie--rod. 27. External handbrake lever. 28. Handbrake return spring. 29. Compressor lubricating oil suction pipe. 30. Compressor pulley. 31. Belt tensioner.
13. Red line delivering air at maximum pressure to the coupler.
32. Crankshaft pulley.
14. Black line for braking (single--line) (only available for the single--line system for the German market).
34. Belt.
15. Yellow line for braking (dual--line).
33. Idler pulley. 35. Yellow connection.
16. German version connections.
36. Black connection (only available for the single--line system for the German market).
17. Hydraulic right--hand rear brake actuator line.
37. Red connection.
18. Maximum pressure line from the dual--line to the single--line control valve (only available for the single--line system for the German market).
38. Ground cable terminal.
19. Maximum pressure line from the tank to the dual--line control valve.
39. Pressure switch signal “G” cable terminal. 40. Spare “WK” cable terminal. 41. Italian version connections.
87679925A1 - 02 - 2008
8
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2 DESCRIPTION AND OPERATION
Germany configuration An air brake system designed in accordance with German TUV specifications providing both single, see connection (1), and dual line operation.
6 Italian market An air brake system designed to meet Italian legislation and providing dual line operation.
MDM0501A
7
BRAKES DISENGAGED Dual--line braking system (Germany -- Italy). The air from the compressor (23) passes from the antifreeze pump (4) and reaches the pressure relief valve (6) that regulates the system pressure in the tank (10). This pressure is supplied to the trailer via the red coupler (37) through the delivery line (13) to disengage the brakes. The air in the system acts, via line (8), on the pressure transmitter (9), which sends a variable electrical signal to the dashboard that will display the pressure gauge and indicate the pressure in the system. If the pressure drops under 4.5รท5.0 bar (4.59รท5.07 kg/cm2), it will cause the warning light (1) on the dashboard to come on.
1
8 87679925A1 - 02 - 2008
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
9
Single line braking system (Germany only). The air from the tank flows through lines (19 and 18) to reach the single--line control valve (12) and through the black line (14) to reach the black connection (36) at the maximum pressure of 5.0÷6.0 bar (5.10÷6.12 kg/cm2) to disengage the trailer brakes.
BRAKES ENGAGED Dual--line braking system (Germany -- Italy). As the tractor’s brakes are applied, hydraulic pressure is transmitted from the brake control pumps and, through lines (17 and 24), via the rear reduction gears it reaches the dual--line control valve so as to increase the pressure in the yellow pipe (15) reaching the yellow connection (35) where there will be a pressure of from 0 bar (0 Kg/cm2) up to a maximum of 7.8÷8.3 bar (7.95÷8.46 kg/cm2) (7.0÷7.5 bar (7.14÷7.65 kg/cm2) corresponding to maximum braking or to the parking brake engaged.
Single line braking system (Germany only). As pressure in the Yellow Line (15) progressively increases, it is sensed via line (18) at the Single Line Control Valve (12), to gradually vent the air pressure supplied to the trailer via the Black Line (14) to apply the trailer’s brakes in line with the tractor’s brakes. At the black connection (36) there will be a maximum pressure of 5.0÷6.0 bar (5.10÷6.12 kg/cm2), brakes not applied at a pressure of 0 bar (0 Kg/cm2) corresponding to maximum braking or to the parking brake engaged.
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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
10
OPERATION OF SINGLE AIR BRAKE CIRCUIT COMPONENTS
9
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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
11
DESCRIPTION AIR BRAKE CIRCUIT COMPONENTS A -- Compressor (23, fig. 4 and 5) Belt driven via the crankshaft. It takes the filtered air (see fig. 2 and 3) and compresses it to supply pressurized air to the tank. The compressor is lubricated from the engine lube system.
10 The drive belt is tensioned as follows: A. Loosen the screw (1) and the nut (2) on the adjustable idler pulley. Place 1/2” sq.drive into position (3) and apply pressure to tension drive belt. Tighten bolt (2) and nut (1) and remove 1/2” sq.drive. B. With the use of a special tool 380001268 measure the tension of the belt at point “X”, by “pinging” the belt. The required measurement at “X” should be 310Hz, +/--15Hz. C. If further adjustments are required, repeat steps A and B. D. Tighten screw (1) to 42÷51 Nm (4.28÷5.20 kgm) and nut (2) to 42÷51 Nm (4.28÷5.20 kgm).
11
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12
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
B -- Antifreeze pump, only available for the German version. (4, fig. 4) During the winter the fluid in the tank (2) prevents the condensate from freezing. The tank should be filled with 0.5 L of â&#x20AC;&#x153;Ambra Super Fluidâ&#x20AC;? the pump will mix it with the compressed air preventing the condensate from freezing. Periodically check the level of fluid in the tank and in the summertime shut cock (3) taking care that there is a sufficient amount of fluid in the tank to cover the bottom of it. 12 C -- Pressure regulating valve (6, fig. 4 and 5) Controls the operating pressure within the system to prevent system damage from excess pressure. The pressure is adjusted with the top portion (1). Also removes any contamination from the system during unloading, which takes place via pipe (3). On this valve it is possible to attach a quick coupler connected directly to the compressor (3) to inflate the tyres or for cleaning by blowing.
13 D -- Dual--line control valve (12, fig. 4 and 5) Controls the dual--line braking system jointly with the hydraulic pressure supplied by the pump via the connection (17 and 24) to the rear brakes. brakes. There are two screws on this control valve for bleeding the service brakes (25). A mechanical connection to the handbrake (26) provides full trailer braking when the handbrake is applied. NOTE: Remember that when bleeding the brakes on tractors with air brakes there are another two screws on the dual--line control valve to bleed.
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14
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
13
E -- Pressure switch (10, fig. 4 and 5) Connected (1) directly in line with the reservoir, provides a variable electrical signal to the dashboard that displays the pressure gauge (1, fig. 21). When the pressure drops to 4.5÷5.0 bar (4.59÷5.07 kg/cm2) or lower, the warning light on the dashboard comes on (1, fig. 8) and an active warning not displayed is stored in the control unit (1, fig. 22).
The electrical connection of the pressure switch to the dashboard (2, fig. 15) is composed of a wire with an 8 pin connection connected to the fitting for the hydraulic trailer brake. under the control panel. This cable is composed of two wires, one connected to pin 1 of colour M (brown) connected to ground (1, fig. 15) while the other cable of colour V (green) is connected to pin 2 of the connection and collects the signal on pin G (marked on the pressure switch), pin WK of the pressure switch is not used. The position of the connection for the fitting on the cab cable is found under the control panel on the left-hand side. The following table gives the resistances, which are found by measuring the values in Ohm with a tester putting one rod on pin G and the other on ground, as the pressure varies. bar Ohms bar Ohms
0
2
4
5 ÷13
52 ± 4
88 ± 4
6
8
10
124 ± 5
145÷170
184 ± 30
15
16
F -- Tank (10, fig. 4 and 5) Provides storage for the compressed air generated by the compressor. At the base of the tank there is a valve for draining off the condensate (1), at the end of a day’s work drain off the condensate from the tank.
17
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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
14
G -- Single--line control valve only available for the German version (12, fig. 4) Controls the single line trailer brake system in conjunction with the dual line control valve and brake master cylinder pressure. When the tractor leaves the factory, this control is set to allow maximum available braking effort to the trailer. Under most conditions, the control will remain in this position and will give well balanced braking. Occasionally, with some trailers this setting may provide a greater braking bias to the trailer than is ideal. In this case the braking force to the trailer may be reduced slightly by turning the adjuster inside the guard (1, fig. 18) in an anti--clockwise direction. To turn the valve, it is necessary to use a wrench (2,fig. 18). The adjuster must be reset to the fully clockwise position when a different trailer is used.
ATTENTION The brake balance adjustment is extremely sensitive; it should not be rotated more than one half turn before testing with the attached trailer fully loaded. If further adjustments are required, they should be carried out following the same procedure. Failure to do this may result in an imbalance between tractor and trailer braking forces if the valve is rotated too far in the anti-clockwise direction.
18
H -- Black connection only available for the German version (36, fig. 4) The black coupler is for single line systems. Pressure is available at the coupler (1) with the brake pedal released, 5.0รท6.0 bar (5.10รท6.12 kg/cm2) and pressure decreases as the pedal is depressed, to reach 0 bar (0 kg/cm2) with the parking brake on.
19
87679925A1 - 02 - 2008
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
15
I -- Red / yellow connection (37 and 35, fig. 4) Red and yellow couplers for dual line systems. The red one (2) is the supply coupler with full pressure available all the time, 7.8÷8.3 bar (7.95÷8.46 kg cm2). The yellow coupler (1) is the control line. Air pressure at the coupler is increased as the brake pedal is depressed, to reach 7.8÷8.3 bar (7.95÷8.46 kg/cm2) with the parking brake on.
20 L -- ADIC dashboard Pressure gauge (1) operated electrically by a signal received from the pressure transmitter assembly. With the advanced dashboard the pressure gauge is called up with the button on the keypad, with the standard dashboard, or the advanced one without the keypad provided that braking has been configured in the H3 program of the HH MENUs, the pressure gauge will always be displayed, a few seconds after starting where the engine hours will have been displayed, unless there are fault codes.
21 In the event of low circuit air pressure, lower than 4.5÷5.0 bar (4.59÷5.07 kg/cm2), besides blinking, for 5 sec., and then lighting up the warning light (1, fig. 8) there will be a warning not displayed. The warning light (2) to the right of the information monitor, amber with an exclamation mark, will come on and with the keypad or the CAL button it will be possible to call up the active warnings not displayed and, on the information monitor where the pressure gauge is normally displayed, there will be the pressure gauge (1) showing the pressure with the bars at the time of the fault warning. NOTE: This test is performed at a speed > 1000 rpm. NOTE: To configure the air brake, refer to the HH MENU chapter 11 of section 55. As regards resolving the fault codes, refer to chapter 10 of section 55. To display the active warnings not displayed, see chapter 1 section 55:
22
87679925A1 - 02 - 2008
16
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
M -- Italian version connection (41, fig. 5) The two couplers corresponding to the yellow line (15, fig. 4) and red line (13, fig. 4) are joined to the corresponding couplers inside the protective closure (1). The red one (on the left) is the supply coupler with full pressure available all the time, 7.0รท7.5 bar (7.14รท7.65 kg/cm2). The yellow coupler (on the right) is the control line. Air pressure at the coupler is increased as the brake pedal is depressed, to reach 7.0รท7.5 bar (7.14รท7.65 kg/cm2) with the parking brake on.
MDM0501A
23
87679925A1 - 02 - 2008
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
17
TROUBLESHOOTING
Meaning
Causes
Instrument cluster light illuminates 1. System pressure when system is running. running 4.5/3.5 4 5/3 5 bar. bar
Corrective action below 1. Compressor drive belt broken. 2. Check system for leaks. 3. Unload valve failed, stuck open. 4. Compressor fault. 5. Reservoir drain tap faulty.
2. Pressure switch or relayed wi- 1. Disconnect wiring to switch. ring faulty. Check it is not shorted neither to ground nor to + 12 Volt. 2. Using a tester, switched onto ohmmeter, check that the resistance values mirror the values in the table on page 13. Trailer brakes not functioning (system air pressure okay). okay)
Delay in trailer brake operation.
1. Air in braking system.
1. Bleed brakes.
2. Dual--line control valve.
1. Disconnect the supply line from the control valve. Operate the brakes, if oil is expelled, the lines are okay. If no oil is expelled, remove and inspect the control valve.
3. Dual line control valve faulty.
1. Repair/replace as required.
1. Air in braking system.
2. Bleed brakes.
System pressure too high, 1. Faulty unload valve. exceeds 12Âą2 bar (12.23 kg/cmÂą2 Kg/cm2).
1. Remove valve clean/replace.
87679925A1 - 02 - 2008
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
18
PRESSURE TESTING Tractor Preparation 1. Position the tractor on a flat, level surface and in a suitable location to allow the engine to run during the testing. 2. Chock the wheels and ensure the parking brake is in the OFF position. 3. To perform the test it will be necessary to obtain the correct trailer side couplers for the system, to couple up to the tractor connectors.
24 Use suitable fittings to connect to each trailer side coupler a 0--10 bar, undamped (100 mm), pressure gauge. Connect the appropriately coloured couplers to the corresponding tractor coupler.
25 Pre--Test Procedure NOTE: For all pressure testing illustrations the gauges represent the following coupler colours: A = Dual line control (Yellow) B = Single line supply (Black C = Dual line supply (Red) D = Cab Gauge 1. Switch tractor ignition on. 2. All test gauges, including vehicle gauge located on the left hand ’B’ pillar, must read zero pressure (drain tanks if required). NOTE: The pressure gauge on the tractor’s central pillar reads the line pressure which is the same as that shown by the red pressure gauge on the coupler. 3. Low pressure warning indicator for the air brake system must be illuminated on the instrument cluster. Warning light located in top right hand corner of the instrument cluster.
87679925A1 - 02 - 2008
26
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
19
1. Start the tractor 2. System should be fully pressurised within 40 to 60 seconds depending on engine rev setting (a maximum period of 3 minutes is permitted for the system to reach operating pressure). When the system is fully pressurised the gauges must read as follows:
Manometers (pressure gauges)
Dual line control Single line supply Dual line supply Cab
(yellow) (A) (black)
(B)
(red)
(C) (D)
Pressure bar (kg/cm2) 0 (0) [0 (0)] 5,0÷6,0 (5,09÷6,11) 7,5÷8,5 (7,6÷8,7) [6,5÷7,5 (6,6÷7,6)] 8,0 [7]
27
NOTE: Cab gauge reads 8.0 [7] bar in the green segment. 3. As the system is being pressurised, the air brake low pressure warning light on the instrument cluster should extinguish between 4.5 ÷ 5.5 bar (4.59 ÷ 5.07 kg/cm2). NOTE: Indication of malfunctioning must be investigated and the defect rectified before continuing with the test.
28
NOTE: The data in square brackets [ ] refer to the working pressures of the air brakes for the Italian market.
87679925A1 - 02 - 2008
20
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
4. Apply tractor parking brake The gauges must now read the following values:
Manometers (pressure gauges)
Dual line control
(yellow) (A)
Single line supply
(black)
(B)
(red)
(C)
Dual line supply Cab
(D)
Pressure bar (kg/cm2) 7,5÷8,5 (7,6÷8,7)[6, 5÷7,5 (6,6÷7,6)] 0 (0) 7,5÷8,5 (7,6÷8,7) [6,5÷7,5 (6,6÷7,6)] 8,0 [7]
29
In cases where the gauges do not exhibit the above values, adjust the handbrake cable to the dual line control valve as described on the following page.
Handbrake Control Cable Adjustment 1. With the handbrake off and the system (red) (C) at full pressure 7.8÷8.3 bar (7.95÷8.46 kg/cm2) [7.0÷7.5 bar (7.14÷7.65 kg/cm2)] (ignition key ON, engine off), check that the yellow pressure gauge (A) is at zero. 2. Handbrake up four clicks.
30
3. Adjust the tie--rod (by lengthening or shortening it) until the pointer of the yellow pressure gauge (A) just starts to move, then lock the locknuts with the length of the tie--rod that causes the maximum pressure on the yellow connection. 4. Check operation of handbrake. • Parking brake on 7.8÷8.3 bar (7.95÷8.46 kg/cm2) [7.0÷7.5 bar (7.14÷7.65 kg/cm2)] at the yellow connection. • Parking brake off 0 bar (0 kg/cm2) at the yellow connection. 31 87679925A1 - 02 - 2008
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
21
Leak Test 1. Engine off -- tractor parking brake applied. 2. No deterioration of the red line pressure, 7.8รท8.3 bar (7.95รท8.46 kg/cm2) [7.0รท7.5 bar (7.14 7.65 kg/cm2)] must occur over a 10 minute period. Indication of any leakage must be investigated, the defect rectified and the test repeated.
32 Brake Pedal Test Procedure 1. Start the tractor. Engine revs not to exceed 1000 rev/min. 2. Do NOT apply tractor parking brake.
33 3. Release brake pedal link pin so that pedals will work individually. 4. Apply left hand and right hand brake pedals individually. No change in pressure readings on test gauges must occur.
34
87679925A1 - 02 - 2008
22
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2
5. Reconnect brake pedal link pin, apply brake pedals fully several operations until red system pressure below 7 bar (7.13 kg/cm2) [6 bar (6.12 kg/cm2)] vehicle compressor will come back on load -- allow system to reach full pressure 7.8÷8.3 bar (7.95÷8.46 kg/cm2) [7.0÷7.5 bar (7.14÷7.65 kg/cm2)] (loud ’pop’ will be heard as unload valve opens). Gently apply pressure to linked pedals until both brake light switches have just clicked on, brake lights on and 4WD indicator on dash is illuminated. The gauges will now record the following values: 35 Dual Line Systems Manometers (pressure gauges) Dual line control
(yellow) (A)
Single line supply
(black)
(B)
(red)
(C)
Dual line supply Cab
(D)
Pressure bar (kg/cm2) 0,5÷1,0 (0,5÷1,0) 4,5÷5,0* (4,6÷5,10*) 7,5÷8,5 (7,6÷8,7) [6,5÷7,5 (6,6÷7,6)] 8,0 [7]
* slight drop in pressure must occur
37
Pressure Regulator ON/OFF Test Procedure 1. Set engine at idle revs. 2. Do NOT apply tractor parking brake. 3. With the system fully pressurised at 7.8÷8.3 bar (7.95÷8.46 kg/cm2) [7.0÷7.5 bar (7.14÷7.65 kg/ cm2)], depress the brake pedals several times until the pressure drops below 7 bar (7.14 kg/cm2) [6 bar (6.12 kg/cm2)] on the Red system pressure gauge (C) and on the gauge in the cab. 4. The unload valve, located on the left--hand side of the engine, must charge the system to 7.8÷8.3 bar (7.95÷8.46 kg/cm2) [7.0÷7.5 bar (7.14÷7.65 kg/cm2)]. 5. In cases where an unload valve is found to be faulty, a new unload valve must be fitted and the test repeated.
87679925A1 - 02 - 2008
38
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
1
SECTION 35 -- HYDRAULIC SYSTEMS Chapter 1 -- Rear mechanical hydraulic lift CONTENT Description
Pages
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Lift control oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 With pump removed to replace the seal kit D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Lift--o--matic control D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Rear lift linkage adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Rear lift external controls D.A. and adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Rear lift R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Rear hydraulic lift internal controls D.A. and adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Arm shaft and lifting cylinder D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Lift shaft bushings -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Lift control valve R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Lift control valve D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Lift pressure relief valve R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Lift pressure relief valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
2
REAR MECHANICAL 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: All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
110 x 128
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cm3
1216
Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
bar
190 ÷ 195 (194 ÷ 199 kg/cm2)
Cylinder safety valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
bar
210 ÷ 215 (214 ÷ 219 kg/cm2)
mm
109.980 ÷ 110.000
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
110.036 ÷ 110.071
Clearance between piston and liner . . . . . . . . . . . . . . . . . . . . . . . . .
mm
0.036 ÷ 0.091
--
capacity:
Lift piston diameter: --
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal diameter of cylinder liner: --
Diameter of lift arms shaft (11, fig. 3) in correspondence with bushes: --
right--hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
55.970 ÷ 55.000
--
left--hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
62.670 ÷ 62.700
Internal diameter of bushings fitted on lift body: --
right--hand side (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
55.100 ÷ 55.184 (1)
--
left--hand side (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
62.800 ÷ 62.884 (1)
Clearance between lift arm shaft and bushings . . . . . . . . . . . . . . .
mm
0.100 ÷ 0.214
Interference between bushings and their seats . . . . . . . . . . . . . . .
mm
0.065 ÷ 0.185
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.
(overleaf)
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
3
REAR HYDRAULIC LIFT DATA
(overleaf)
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
Clearance between draft control idler shaft and position control idler shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
0.016 ÷ 0.086
Clearance between control valve block pin (8, fig. 4) and the relative seat on the control valve block body . . . . . . . . . . . . . . . . .
mm
0.008 ÷ 0.012 (2)
Clearance between lift control valve (10) and the relative seat on the control valve block body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
0.008 ÷ 0.014 (2)
Check valve return spring (12): --
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): --
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 (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 (14) --
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 (1): --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
48
--
spring length under load of 65 ÷ 71 N (6.86 ÷ 7.2 kg)
mm
32
Intervention speed control valve spring (4): --
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
21
--
spring length under load of 0.9 ÷ 1 N (0.09 ÷ 0.11 kg)
mm
13
(2) During assembly the control valve block pins and control valves are carefully selected so as to obtain the required clearance.
87679925A2 - 02 - 2010
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
4
IMPLEMENT HITCHING DEVICE DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
three--point linkage
Category: --
2nd
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draft control
by means of lower arms with flex bar
Maximum load that can be lifted with vertical rods pivoting in the rear hole of the horizontal arms and three--point linkage connected to upper hole of top link, with working pressure at 90% maximum pressure: -------
at link ends of horizontal arms . . . . . . . . . . . . . . . . . . . . . . . . . . mod. 56/76 and 63/86 KW/HP (with additional jack) . . . . . . . . mod. 71/97, 78/106 and 83/113 KW/HP (with two additional jacks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with centre of gravity at 610 mm from link ends: . . . . . . . . . . . mod. 56/76 and 63/86 KW/HP (with additional jack) . . . . . . . . mod. 71/97, 78/106 and 83/113 KW/HP (with two additional jacks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
kg kg
2780 3950
kg kg kg
4690 2790 3150
kg
3450
kg kg
3860 4800
kg kg kg
5740 3510 4360
kg
5210
Maximum load that can be lifted with vertical rods pivoting in the rear hole of the horizontal arms and three--point linkage connected to upper hole of top link, with maximum working pressure: -------
at link ends of horizontal arms . . . . . . . . . . . . . . . . . . . . . . . . . . mod. 56/76 and T63/86 KW/HP (with additional jack) . . . . . . mod. 71/97, 78/106 and 83/113 KW/HP (with two additional jacks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with centre of gravity at 610 mm from link ends: . . . . . . . . . . . mod. 56/76 and 63/86 KW/HP (with additional jack) . . . . . . . . mod. 71/97, 78/106 and 83/113 KW/HP (with two additional jacks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flex bar diameter: --
mod. 56/76, T63/86 and 71/97 KW/HP . . . . . . . . . . . . . . . . . . .
mm
24.867 รท 24.900
--
Model 78/106 and 83/113 KW/HP . . . . . . . . . . . . . . . . . . . . . . .
mm
25.870 รท 26.000
--
Model 78/106 and 83/113 KW/HP (at the bushings) . . . . . . . .
mm
29.967 รท 30.000
End float of flex bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
1.9 รท 4.5
87679925A2 - 02 - 2010
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
5
LIFT HYDRAULIC PUMP DATA 61L/MIN (*)
Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
paper cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
fixed to the pump housing on suction side
Pump Assembly Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
gear type with oil suction from transmission casing
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flanged on the rear left--hand side of the engine
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bosch--Rexroth
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of the engine gears
Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . .
left--hand side
Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . .
1 : 1.088
Maximum speed of pump rotation (with engine at maximum power equivalent to 2300 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm Rated output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/turn Corresponding rated output for new pump . . . . . . . . . . . dm3/min (l/min)
2502 0.02545 63.68
(*) Standard equipment for all models with 4WD, compulsory for 2WD with power steering pump with supplementary control valve for ventral control valves.
87679925A - 12 - 2007
6
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 LIFT HYDRAULIC PUMP DATA 45 L/MIN (**)
Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
paper cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
fixed to the pump housing on suction side
Pump Assembly Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
gear type with oil suction from transmission casing
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flanged on the rear left--hand side of the engine
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bosch--Rexroth
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of the engine gears
Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . .
left--hand side
Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . .
1 : 1.088
Maximum speed of pump rotation (with engine at maximum power equivalent to 2300 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm Rated output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/turn Corresponding rated output for new pump . . . . . . . . . . . . dm3/min (l/min)
2502 0.01955 48.91
(**) For all 2WD models, not available for power steering pump with supplementary control valve for ventral control valve.
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
7
BOLT TORQUES
C1 --26 Nm
C4 --83 Nm 26368
C3 --83 Nm
26369
C2 --54 Nm 1
BOLT TORQUES
Thread
Bolts securing control valve block to lift (C1, fig. 1) . . . . . . . . . . . . . . .
Tightening torque Nm
kgm
M8x1.25
26
2,7
Control valve cap (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M20x1.5
54
5,5
Cylinder safety valve (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M20x1.5
83
8,5
Check valve union (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M24x1.5
83
8,5
Inner lift arm securing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M10x1.25
61
6,2
Nut for position control spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M10x1.25
14.7
1.5
Flex bar support retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M16x1.5
221
22.5
Limiter stabiliser strut support retaining bolts . . . . . . . . . . . . . . . . . . . .
M16x1.5
221
22.5
Towing hook support retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M16x1.5
221
22.5
Lift
Three point hitch assembly
(overleaf)
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
8
BOLT TORQUES
C6 --157 Nm C1 --88 Nm
C5 --260 Nm
C2 --25 Nm
C3 --142 Nm
C4 --147 Nm
26370
2 (overleaf)
BOLT TORQUES
Thread
Bolts securing lift to rear transmission casing (C1, fig. 2) . . . . . . . . . .
Tightening torque Nm
kgm
M12x1.25
98
10
Nuts for lever quadrant bracket stud bolts (C2) . . . . . . . . . . . . . . . . . .
M8x1.25
25
2.6
Lifting arm plate retaining bolts (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M14x1.5
142
14.5
Three--point linkage support retaining bolts (C4) . . . . . . . . . . . . . . . . .
M14x1.5
147
15
Lift cylinder retaining bolts: --
top (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M16x1.5
260
26.5
--
front (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M14x1.5
157
16
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
9
HYDRAULIC LIFT TOOLS
CAUTION
380000266
Protection device for fitting seal on arm descent speed control pin.
380000240
Universal pressure control kit.
380000215
Hand pump for valve calibration.
X
380000218
Union for cylinder safety valve calibration.
X
The operations described in this section can only be carried out with the 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
380000224
Hydraulic lift lifting hook.
380000225
Ring for fitting piston with lift seals (Mod. TL70A, TL80A, TL90A and TL100A).
X
380000217
Union for lift pressure relief valve calibration.
X
380000262
Punch for fitting lift arm shaft seal.
X
380000274
Union for checking control valve seal.
X
380000261
Punch for fitting needle bearings on control valve block control lever bushing.
X
380000267
Wrench for arm height adjustment.
X
380000260
Punch for fitting needle bearings to lower draft control lever and to draft control link rod.
X
380000275
Guard for pilot valve seal.
X
380000263
Controlled draft setting tool.
X
380000264
Position and draft control setting tool.
380000238
Adapter (use with 380000224).
X
380000230
Wrench for cylinder safety valve setting ring nut.
X
380000231
Wrench for lift pressure relief setting ring nut.
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
10
1
18
2 3 17
4
19
16 G
20 23 22 21
15
26513
26512
14 13 12 11 10
9
8
7
6
5
3 Lift cross--sectional views G. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
0.2 รท 1.4 mm. Shaft axial clearance. Travel limit adjuster screw. Sunken locknut for travel limit adjuster screw. Travel limit shift rail. Lift--O--Matic control valve tie--rod arm pin--lever. Arm thrust plate. Thrust washer. Right--hand seal. Right--hand bushing. Top link support. Internal arms. Arm control shaft.
87679925A - 12 - 2007
12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Left--hand bushings. Left--hand seal. Lift arms. Arm thrust plate. Thrust washer. Gudgeon pin top link pin. Internal draft control lever. Bracket. Retaining bolt. Lock washer. Lever pivot eccentric pin (18). Threaded grub screw.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
1
2
3
11
4
26514
5
15
6 14 10
7 26515
9 26516
8
13 12 11 4 Hydraulic lift control valve block cross--sectional views
1. 2. 3. 4. 5. 6. 7. 8.
Intervention speed adjustment valve spring. Seal and ring. Seal and ring. Intervention speed adjustment valve spring. Control valve block pin return spring. Seal and ring. Control valve block pin seat. Control valve rod.
9.
Control valve return spring.
10. Control valve. 11. Check valve ball. 12. Check valve return spring. 13. Cylinder safety valve. 14. Arm descent speed control valve spring. 15. Seal and ring.
NOTE: When fitting seals 2, 3, 6 and 15, heat the corresponding support disks in oil at a temperature of approximately 50 °C. When fitting seal (15) and its support disk, use protection device 380000266. When fitting seal (6) and its support disks, use protection device 380000275. The seals (2 and 3) and the supporting disks can be fitted without any protection, only taking the due precautions so as not to damage them. 87679925A - 12 - 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 casing mounted under the rear transmission. The lower lift arms and corresponding control rods are connected to the flex bar.
2 1
3
5
4
Oil at static rest
Discharge oil
Intake oil
Brake circuit oil at rest
Pressure oil
Pilot oil (load sensing)
MDF1513A
5 HYDRAULIC LIFT CIRCUIT 1. 2. 3.
Hydraulic Pump. Auxiliary control valves (with UNLOAD valve). Lift hydraulic control valve.
87679925A - 12 - 2007
4. 5.
Trailer brake valve. Filter.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
1
2
13
A
3
4
6
5 7
Discharge oil Pressurised oil MDE0057A
6 ARM LIFT PHASE A. 1. 2. 3.
Detail of operation with controlled draft. Non--return valve. Arm descent speed control valve. Cylinder safety valve.
When the operator uses the position control lever (located on the right--hand side) to raise the arms; the internal lever mechanisms transmit the motion, shown by the arrows, to the control valve block pin (4). This pin interrupts the oil flow to the control valve (5). The valve (5) is moved by the relative spring, and the intervention speed valve (6), allowing
4. 5. 6. 7.
Control valve rod. Control valve. Intervention speed adjustment valve. Draft transmission rod.
the pressurised oil to open the check valve (1) and act on the arm raise piston. With controlled draft operation (part A), 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 (4) via the transmission rod (7). 87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
14
1
2
3
4
6
5
Oil at static rest Discharge oil Pressure oil MDE0058A
7 NEUTRAL PHASE 1. 2. 3.
Non--return valve. Arm descent speed control valve. Cylinder safety valve.
When the lift arms have reached the predetermined height, the internal lever mechanisms stop. The position of the control valve block pin (4), allows the oil to be directed to the control valve piston (5) through the intervention speed adjustment valve (6).
87679925A - 12 - 2007
4. 5. 6.
Control valve rod. Control valve. Intervention speed adjustment valve.
The pressurised piston moves the valve, overcoming the resistance of the spring and opening a drainage line, allowing the oil to flow to the transmission casing instead of the lift cylinder.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
1
15
2
3 4
6
5 7
A
Discharge oil Pressure oil
MDE0059A
8 A. 1. 2. 3.
Detail of operation with controlled draft. Non--return valve. Arm descent speed control valve. Cylinder safety valve.
ARM LOWER PHASE
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) to the control valve block pin (4). The control valve block pin (4), is pulled downward by the spring, allowing the cylinder oil, under the thrust of the piston, to discharge through the arm descent speed control valve (2). The discharge oil passes through the valve (2) and pushes on the control valve piston (5). 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 controlled draft operation (part A), the lowering
4. 5. 6. 7.
Control valve rod. Control valve. Intervention speed adjustment valve. Draft transmission rod.
command is sent to the flex bar, which in turn transmits the movement (shown by the arrows) to the control valve block pin (4) via the transmission rod (7).
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). Loosening 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 faster.
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
16
HYDRAULIC LIFT TROUBLESHOOTING
Problems The lift does not rise.
Possible causes
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.
The lift makes sharp movements.
1. Foreign bodies between the Disassemble the valve, eliminate ball and relative seat on the foreign bodies and check the oil delivery control valve. filter. 2. Faulty seal on the delivery Replace the delivery control valve. control valve ball. 3. Delivery control valve piston Disassemble the valve and remove jammed. the cause of the piston jam. (overleaf)
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
17
HYDRAULIC LIFT TROUBLESHOOTING (overleaf) Problems The lift moves too slowly.
Possible causes
Solutions
1. Blocked discharge holes on Disassemble the valve, eliminate delivery control valve. the cause of the obstruction and check the oil filter. 2. Delivery control valve piston Disassemble the valve and remove jammed. the cause of the piston jam.
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 2. Oil leaking past the seals on Replace seals. turned off, the load lowers). 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 Renew it. safety 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 Overhaul or replace the pump. efficiency (generally combined with a considerable increase in lift time).
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
18
LIFT CONTROL OIL PUMP
MDF1821A
9 Power steering and hydraulic lift pump components 1. 2.
Lift pump body. Pump retaining bolts.
3. 4.
Seal. Power steering pump body.
NOTE: The power steering and lift hydraulic pumps are mounted in tandem. They are maintenance free. If even just one pump works badly, it is necessary to replace the complete tandem. If there is any oil leakage, replace the kit of seals as described in the following operation.
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
19
MDF1822A
10 Hydraulic lift pump components 1. 2. 3. 4. 5. 6. 7.
Retaining snap ring. Driving shaft seals. Seals. Front cover. Seals. Centring pins. Gear support bushings.
LIFT OIL PUMP Disassembly -- Assembly with pump removed to replace the seal kit
ATTENTION
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows: 1. Remove the retaining tie--rods (2, fig. 9), seal (3) and remove the pumps (1) and (4). 2. Remove the retaining ring (1, fig. 10) and dismantle the hydraulic lift pump, as directed in the above figure.
8. 9. 10. 11. 12. 13. 14.
Centring pins. Driven and driving gears. Protective cap. Pump body. Seal. Seal. Rear cover.
Once the parts are removed, proceed as follows: 3. Always ensure maximum cleanliness to prevent foreign matter from entering and damaging the pump and clean all the component parts thoroughly. 4. Replace the old seals with those of the new kit. 5. Lubricate the parts with the oil used in the system and refit the lift pump, referring to the above figure. 6. Fit the pumps (1) and (4, fig. 9), inserting the seal (3) and the retaining tie--rods (2).
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
20
LIFT--O--MATIC CONTROL D.A.
1
ATTENTION
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. To remove the gearbox, proceed as follows: 1. Perform the disassembly sequences described in the operation, see section 90, for the RH WALL FIXED PADDING and remove all the padding. 24844
11
2. Disconnect the electrical connections on the lift--o--matic control unit (1).
24845
1 12
3. Unscrew the bolts securing the lift--o--matic switch (1).
24846
1 13
4. Remove the ring nut (1) securing the PTO controls. 5. For assembly, perform the above operations in reverse order and fit all the rh padding, performing the assembly sequences described in the operation, see section 90, for the RH WALL FIXED PADDING.
1
24847
14 87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 LINKAGE ADJUSTMENTS Position control rod adjustments
21
1
ATTENTION
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Move the position control lever (1) forward completely on the quadrant and check that the distance (L) is 15 ÷ 20 mm.
L
26359
15
2. Move the external position control lever (1) completely back against the spacer. 3. Connect the control rod and adjust the length, if necessary. 4. Secure the rod in position using the locknuts.
1 2 26360
16 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 15 ÷ 20 mm from the beginning of the slot. 6. Move the external draft control lever (2) completely back against the spacer.
1 2
L1 26361
17
7. Connect the control rod and adjust the length, if necessary.
1 2 26360
18 87679925A - 12 - 2007
22
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
8. Move the draft control lever (2) to a distance (L2) of 185 รท 195 mm from the beginning of the slot and check that in this position the arms start to rise.
1
2
9. If the arms do not rise, adjust the eccentric pin (1, fig. 83) to reset this distance. 10. Secure the eccentric pin in position with the grub screw (1, fig. 84).
L2 26362
19
LIFT--O--MATIC device adjustments Proceed as follows.
1
11. Move the position control lever (1) and the draft control lever (2) completely forward on the quadrant.
2
26361
20 12. Raise the arms by means of the lever (1).
1
2
MDF1515A
21
13. Tighten the nut (1) until the arms lower. 14. With the lever (1, fig. 21) 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. 21) lower and raise the arms a few times to ensure that the device is operating correctly.
26364
22 87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 OPERATIONS TO BE PERFORMED TO ADJUST THE UPPER STROKE LIMIT OF THE LIFT--O--MATIC DEVICE
23
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.
ATTENTION
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
MDF1516A
23
Proceed as come follows: 1. Apply a load to the link ends of the lower implement attachment arms.
1
2. Start the engine and keep it running at medium speed.
2
3. Press the button (1) into the position (with the arms fully lowered).
coupling
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. Height limiter cam. --
The height limiter cam is on the right end of the hydraulic rock shaft. Turn the cam adjuster (1) clockwise to decrease implement height, turn anti--clockwise to increase implement height.
--
The cam adjuster is self locking and will remain in position once set.
26361
24
The figure shows the cam (2, fig. 25 bis) in contact with the lever (3, fig. 25 bis) in the maximum height position. To achieve full lift height, turn the cam adjuster fully anti--clockwise until the cam is clear of the lever when the front arms are fully raised.
25
NOTE: The height limiter cam only affects lifting the Lift--o--matic. When the cam comes into contact with the lever, it cancels the signal from the Lift--o--matic and stops the 3--point linkage from raising further.
25 bis 87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
24
Repeat the previous step to check for implement to cab clearance. If clearance is inadequate, move the cam further in a clockwise direction. When clearance is satisfactory, proceed to operate.
REAR LIFT EXTERNAL CONTROLS D.A.
DANGER
1
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. Disassemble the external controls of the hydraulic lift as follows: 25624
26 1. Position the hydraulic lift on a rotating stand (1, fig. 26).
2
2. Unscrew the nuts (2) and remove the spring and the retaining bracket (4). 3. Remove the circlip and extract the lever (3), friction disks, lever (5) and the stud bolts.
3
4. Take out the screws (1) securing the lever support spacer (2). MDE0761A
5
4 27
5. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
1
2
Perform the above--described operations in reverse order for disassembly.
25630
Make the adjustments described on page 37. NOTE: The adjustments must be carried out in the order specified.
87679925A1 - 02 - 2008
28
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
25
REAR LIFT 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. To detach the hydraulic lift from the rear transmission casing, proceed as follows.
1. Remove the top link (1) of the three--point linkage. 2. Take out the bolts (1) and, using a chain and hoist, remove the hitch hook unit (2) from the PTO housing.
1
25534
29
2
1
25620
30 3. Remove the split pins and extract the pins (1), remove the vertical tie--rods (2) and anti--swing rods (3).
1
2
3
25531
31
87679925A - 12 - 2007
26
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
4. Take out the bolts (1) and remove the bracket (2) supporting the right--hand tie--rod adjustment crank.
1
2
25532
5. Unscrew the nuts (1) and remove the bracket (2) supporting the lever (3) governing the lift ground control.
32
1
2
3
25533
33 6. Disconnect the electrical connections and the delivery lines and remove the window washer liquid tank (1).
1
25503
7. Remove the trailer brake piping (1) and the auxiliary control valves lines from the support plate (2).
34
1
2
25537
35 87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 8. Disconnect the electrical connection (1) of the seven--pin socket (2), remove the two--pin socket (3) from its support, take out the screws (2 and 4) to free the filler pipe and disconnect the ground cables.
1
27
2 3
4 25536
9. Unscrew the two top link third point support retaining bolts (1) and remove together with the support plate (2).
36
1
2
25544
37 10. Detach the fuel (1) and transmission oil (2) breather pipes from the cab upright.
1
2
25540
11. Disconnect the electrical connection (1) on the PTO rev counter.
38
1
25545
39 87679925A - 12 - 2007
28
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
12. Extract the spring clips (1) and detach the two lift levers tie--rods (2).
1
2
25547
40
13. Detach the tie--rod (1) on the LIFT--O--MATIC.
1
25557
41 14. Unscrew the union (2) and disconnect the gearbox--transmission casing oil filler pipe (1), unscrew and remove the trailer brake control pipe (3).
1
2
3
25549
15. Position tool 380000294 (1) inside the cab, hitch to a hoist using 2 nylon slings and take up the slack.
42
1
25552
43 87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 16. Take out the two bolts (1) securing the cab at the rear.
29
1
25502
17. Raise the cab by approximately 5 รท 6 cm and place two wooden blocks (1) between the cab upright and the relative bracket (2), lower the hoist and leave tool 380000294 inside the cab.
44
1
2
25553
45 18. Remove the union (1) and detach the pipe (2) from the control valve.
1
2
25554
19. Extract the electrical cables (1) from the clip (2) on the lift.
46
1
2
25555
47 87679925A - 12 - 2007
30
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
20. Take out the bolts (1) securing the hydraulic lift to the gearbox--transmission casing.
1
25556
21. Fit tool 380000238 (1) on the lift, tightening the four bolts (2).
48
2
1
25558
49 22. Fit tool 380000224 (1) on tool 380000238 (2). Attach tool 380000224 to the hoist, raise the hydraulic lift by a few centimetres and pull back in order to pass over the breather pipe (3) without causing damage.
1
2
3 25559
50
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
31
23. To refit the hydraulic lift on the rear transmission--gearbox casing proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
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. -- Apply the torque settings listed on page 7 and 8. -- Using tools 380000224 and 380000238 fit the hydraulic lift on the transmission--gearbox casing and secure with the relative bolts. -- Insert the electrical cables in the clip on the lift body. -- Fit the lift control pipe. -- Raise the cab slightly, remove the wooden blocks and secure the cab with the relative bolts. -- Assemble the trailer brake pipe and the oil filler pipe. -- Connect the Lift--o--Matic control tie--rod. -- Connect the lift levers to the relative tie--rods. -- Connect the PTO revs counter electrical connection. -- Attach the fuel tank and transmission--gearbox breather pipes to the cab upright. -- Assemble the three--point top link and the quick--fit coupling support plate for the auxiliary control valves. -- Fit the two pole socket, seven pole socket, ground connections, quick--fit couplings and the trailer brake piping to the support bracket. -- Fit the window washer tank, connect the connections to the pump and the delivery lines. -- Assemble the right--hand vertical tie--rod adjustment unit. -- Fit the lift ground control lever. -- Assemble the vertical tie--rods and anti--swing rod. -- Fit the towing hook and the three--point top link. Diagram showing application of sealing compound when fitting the hydraulic lift on the transmission--gearbox casing The types of sealing compounds to be applied are specified in Section 00. 26295
51
87679925A - 12 - 2007
32
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
REAR HYDRAULIC LIFT D.A. Adjustments
1 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. Disassemble the external controls of the hydraulic lift as follows: 25624
1. Position the hydraulic lift on a rotating stand (1, fig. 52). 2. Take out the fixing screws (1) and retrieve the control valve (2).
52
2
1
25625
53 3. Take out the two cylinder retaining bolts located outside the lift body, turn the lift and remove the side bolt (3). 4. Unscrew the bolts (1) securing the internal levers (2) to the lift cylinder.
1
2
3 25626
54
5. Remove the cylinder (1) and piston.
1
25627
55 87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 6. Extract the pin from the draft internal lever, unscrew the nut (1), recover the internal lever assembly and the LIFT--O--MATIC lever.
33
1
25628
56
7. Remove the circlip and the position control internal lever (1).
1
2
8. Perform the disassembly sequences 2 รท 4 described in the operation, see page 24, for the
REAR LIFT EXTERNAL CONTROLS.
3 25629
4
5
57 9. Loosen the grub--screw (1) on the eccentric pin (2), extract and recover the internal levers. 10. Unscrew the screw (3), remove the washer (4), extract the lift arm (5) and remove the thrust washer (on both arms).
1 2 3 4 5 25631
58
11. Remove the safety tab on the internal arm setscrew (1) and unscrew. Extract the shaft (2) and remove the seals (3).
1
25632
2
3 59 87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
34
12. Use compressed air to remove the piston (2) from its cylinder (1).
1
2
26297
13. Using the drift 380000260 (1), replace the draft control internal lever bearings (2).
60
2
1
14. Using the drift 380000261, replace the control valve lever bearings. 15. To assemble the hydraulic lift, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 26298
61 16. Using tool 380000225 (2), insert the piston (1) into its cylinder (3).
1
2
3
25634
62
17. Assemble the lift arms shaft (2) and the internal arm (1) inside the lift casing, matching up the reference marks and tighten the retaining bolt.
1 2 26299
63 87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 18. To avoid damaging the internal seal lips, 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 brass sheet.
35
1
2 26300
19. Using the drift 380000262 (1), complete the fitting of the seals into the relative seats on the arm shaft.
64
1
26326
65 20. Fit the lift arms (1) on the shaft, matching up the reference marks. Secure in position with the bolts.
1
25633
66
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
36
21. Assemble the internal levers and the eccentric pin, and secure with the grub--screw.
22. Carry out the assembly sequences described in the operation, see page 24, for the REAR LIFT
EXTERNAL CONTROLS.
26327
23. Fit the internal position control lever.
24. Assemble the internal Lift--O--Matic lever.
levers
67
and
the
25. Assemble and secure the cylinder and piston. 26. Assemble the internal levers and secure to the cylinder. 27. 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 compounds to be applied are specified in Section 00. Fit the hydraulic lift on the lift box and secure in position with the relative retaining bolts. Carry out the adjustments described below. NOTE: The adjustments must be carried out in the order specified.
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 LIFT ADJUSTMENTS The following adjustments refer to a lift without hydraulic control valve block and mounted on a rotating stand. These adjustments must be carried out in the order specified. The LIFT--O--MATIC device must be kept in the OFF position (external lever (1) locked in the vertical position) unless otherwise indicated.
37
1
25635
68
Adjusting position control Proceed as follows. 28. Move the external position control lever (1) completely forward against the spacer for the stud bolt securing the spring retaining bracket, and the external draft control lever (2) completely back against the spacer. 29. Turn the arm control shaft so that the internal arm comes into contact with the lift body.
2
1
25636
69 30. Using wrench 380000267 (1) loosen the locknut (4, figure 71) and totally unscrew the adjustment screw (5) until it no longer makes contact with the control valve lever (3).
1
25637
70
1
2
3
F1
4 5
L1
25638
71 87679925A - 12 - 2007
38
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
31. Assemble tool 380000264 (4) on the lift body. 32. Using wrenches (2 and 3) unscrew the locknut (1, fig. 71) and tighten or loosen the adjustable push rod (2, fig. 71), so that the end of the mobile cap (5) is on exactly the same external contact plane (6) as the tool (4), as shown in the figure. NOTE: This corresponds to a distance (L1, fig. 71) of 82.0 รท 82.1 mm between the end of the lever (3, fig. 71) and the front plane of the lift body, measured applying a force (F1, fig. 71) of 4 รท 4.5 da N (kg) on the end of the lever.
1
2
3
6 5 4 25639
33. Tighten the locknut (1, fig. 71). 34. Move the external position control lever (1) completely back against the stud bolt spacer, rotate the arms shaft so that the piston is fully forward and check that the mobile cap (5, fig. 72) is on the same plane or re--enters in relation to the internal contact surface (1, fig. 72) of the tool (4, fig. 72). NOTE: This corresponds to a value (L1, fig. 71) greater than 86.5 mm between the end of lever (3, fig. 71) and the front plane of the lift body, measured applying a force (F1, fig. 71) of 4 รท 4.5 da N (kg) on the end of the lever. Lift arms maximum raise position adjustment. Proceed as follows. 35. With tool 380000264 (2, fig. 72) fitted on the lift body, position the external draft lever (2) fully back against the spacer, and the position control external lever (1) fully forward, against the spacer. 36. Turn the arm control shaft so that the internal arm comes into contact with the lift body.
72
1
25640
73
1
2
25636
74
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 37. Connect the union (5) on the tool (2) to the workshop compressed air supply and inject air into the cylinder sleeve, so that the piston carries out the lifting stroke, and maintain in this position by means of the air pressure. 38. Using wrench 380000267 (1) tighten the screw (5, fig. 71), until the end of the mobile cap (4) is on the same level as the internal contact surface (3) of the tool (2) or it re--enters up to a distance of 0.5 mm in relation to the contact surface.
39
1
5 4
2
3 25641
75 NOTE: This corresponds to a distance (L1) of 86.3 รท 86.7 mm between the end of the lever (3) and the front plane of the lift body.
1
2
3
39. Tighten the bushing locknut (4) to a torque setting of 15 Nm (1.5 kgm).
F1
4 5
L1
25638
76 Adjusting draft control Proceed as follows: 40. Disassemble the end part of the draft control rod (3) and fit on the rod (5) of tool 380000263 (1), securing in position with the relevant locknut (4). 41. Position tool 380000263 (1) complete with rod (5) and the end part of the draft control rod (3) on a reference plane and, using a depth gauge (2), read the value (L3) between the upper surface of the rod and the gauge resting on the tool (always tighten rod 3 on rod 5 so that the surface of rod 5 is slightly lower than the gauge on the tool).
1
2 L3
5 4 3 25645
77
1
2
42. With tool 380000264 (4, fig. 72) fitted on the lift body and disconnected from the compressed air system, move the position control lever (1) and draft control lever (2) fully forward, against the spacer. 43. Position the draft control internal lever eccentric pin (1, fig. 83) in the horizontal position with the cam facing towards the rear part of the lift.
25640
78 87679925A - 12 - 2007
40
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
44. Assemble tool 380000263 (1) on the lift body, attaching it to two holes on the casing, as indicated in the figure.
1 2 3
25642
45. Adjust the screw (2, fig. 79) on the draft control internal lever (3, fig. 79) until the end of the mobile cap (1) is as near possible to the internal surface (2) of tool 380000264 (3).
79
1 2 3
25643
80 46. Slightly rotate the eccentric pin (1) to fully insert the mobile cap on tool 380000264. 47. Adjust the screw (2, fig. 79) on the draft control internal lever (3, fig. 79) until the end of the mobile cap is on the same plane as the internal surface (3) of tool 380000264. 48. Rotate the eccentric pin (1) until the end of the mobile cap is on the same plane as the external surface (2).
3
1
2
26349
49. Insert the rod of tool 380000263 (1) in the seat of the draft control internal lever (2). 50. With the end of the mobile cap on tool 380000264 on the same plane as the external surface (2, fig. 81), adjust the tie--rod (3) and, using a depth gauge, read the value (L2) between the upper surface of the rod and the contact surface of the gauge on the tool 380000263 (1).
81
1
L2 2 3
26348
82 87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
41
51. The distance (L2, fig. 82) must be: L2 = L3 + L4 where: L3 = distance measured with tool 380000263 fitted on the reference surface; L4 = 22.9 รท 23.1 mm. Operating value between lift body surface on transmission casing and rod contact surface on lever (3, fig. 82). NOTE: This corresponds to a value (L1, fig. 71) of 82.0 รท 82.1 mm between the end of the lever and the lower plane of the lift body, measured applying a force (F1) of 4 รท 4.5 da N (kg) on the end of the lever.
3 1
2
ATTENTION Always check that when the mobile cap is positioned exactly on the same plane as the external surface (2) of tool 380000264 the distance (L2, fig. 82) is: L2 = L3 + L4
26349
83
where: L3 = distance measured with tool 380000263 fitted on the reference surface; L4 = 22.9 รท 23.1 mm. Operating value between lift body surface on transmission casing and rod contact surface on lever (3, fig. 82).
1
If not, adjust the eccentric pin (1) and the knurled screw (2, fig. 82) on tool 380000263 until the aforementioned values are obtained. 52. Fit the threaded grub screw (3) and tighten the screw (1) without beading the safety washer (2).
3
2
26350
84
53. Disassemble tools 380000264 and 380000263 and assemble the hydraulic control valve on the lift body.
1
Fit the lift on the tractor as follows.
2
CAUTION
First position tool 380000263 (1) on a reference surface and use a micrometer depth gauge (2) 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.
L5
26352
85
87679925A - 12 - 2007
42
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
54. Fit the draft measuring device, complete with drive lever (3) and draft control rod (2) but without the flex bar, on the rear transmission housing. 55. Rest the drive lever (3) on the draft measuring device casing and assemble tool 380000263, securing in the two holes on the casing so that the draft control rod (2) is precisely inserted in the hole on the tool, as indicated in figure 87. 56. Using a depth gauge (2, fig. 87), measure the distance (L8, fig. 87) between the top end of the rod (3, fig. 87) and the contact surface of the gauge on the tool. NOTE: The distance (L6 ) of the upper end of the rod (2) in relation to the transmission casing (with flex bar disassembled) will be given by: L6 = L5 - L8 where: L5 and L8 = distances measured with tool 380000263 fitted on the reference surface (L5 , fig. 85) or on the transmission housing (L8 , fig. 87).
L6
2
3
26353
86
57. Assemble the flex bar and measure the new value (L9) between the upper end of the rod (3) and the depth gauge contact surface on the tool. NOTE: The distance (L7 , fig. 86) of the upper end of the rod (2, fig. 86) in relation to the transmission casing (with flex bar assembled) will be given by: L7 = L5 - L9 where: L5 and L9 = distances measured with tool 380000263 fitted on the reference surface (L5 , fig. 85) or on the transmission housing (L9 ). 58. Check that the distance (L7) is at least 5 mm greater than the distance (L6). 59. Loosen the locknut (1, fig. 86) and adjust the length of the draft control rod until a new protrusion of (L7 = 18.3 รท 18.5 mm) is obtained. 60. This protrusion (L7) can be calculated by subtraction using tool 380000263: L10 = L5 -- L7 where: L7 = 18.3 รท 18.5 mm. The distance the end of the rod (2, fig. 86) protrudes in relation to the transmission casing. L5 = value measured with tool 380000263 fitted on contact surface. L10 = distance to be measured with the micrometer gauge on the tool 380000263. 61. Tighten the locknut (1, fig. 86) and assemble the lift on the tractor.
87679925A - 12 - 2007
1
L7
1 2 L8/L9 3 26354
87
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
43
LIFT CONTROL VALVE R.I.
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 driving seat occupied/safety and pneumatic seat height adjustment electric cable (2). 2. Take out the four bolts (1) securing the seat to the platform.
88
3. Move the seat (1) to the front part of the platform so that it does not obstruct the following disassembly operations.
89 4. Lift the mat (1) located on the rear part of the platform. 5. Remove the retaining bolts (2) and the cover (3) installed on the platform.
MDE0062A
90
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
44
6. Disassemble lines (1) and (4) connected to the control valve, unscrew the securing bolts (2) and the control valve (3).
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 7. To refit the control valve to the hydraulic lift body, proceed as follows: --
For the correct orientation of the various parts, refer to the previous illustrations.
--
Before reassembling the control valve on the lift body, carefully clean and degrease the mating surfaces, then apply sealing compound (approx. 2 mm) along the marked line shown in the drawing 67.
--
Refit the control valve on the hydraulic lift body, tighten the bolts to the torque values listed on page 7.
--
Reconnect the hydraulic lines to the control valve.
--
Reassemble the cover on the platform and tighten the retaining bolts.
--
Reposition the mat on the rear part of the platform.
--
Refit the seat and tighten the retaining bolts.
--
Reconnect the safety cable.
87679925A - 12 - 2007
91
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
45
LIFT CONTROL VALVE D.A. with control valve removed 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. 1. Before disassembly, thoroughly clean the surfaces of the control valve, clamp the control valve in a vice and unscrew bolts (1) and (2).
1
2
25704
92 2. Remove the cover (1) from the control valve body (2).
1
2 25705
3. Unscrew the cap (1) and remove the spring (2) and the control valve (3).
93
1
2
3
25707
94
87679925A - 12 - 2007
46
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
4. Remove the cylinder safety valve (4) and recover the arm lowering speed adjustment valve (3), the spring (2) and the pin (1).
1
2
3
4
25709
95
5. Remove the check valve: ball (1), spring (2) and union (3).
1
2
3
25711
96 6. Extract the control valve pin (1) its seat (3) and the spring (2).
1
2
3
25713
97
7. Remove the cap (1) and spring and the delivery control valve shutter.
26296
98 87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
47
8. Remove the piston (1), spring (3), ball (2) and shutter (4) of the delivery control valve.
25208
99
9. 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
10. To check the efficiency of the control valve block pin, proceed as follows.
25714
100 11. Fit the control valve block pin (2) complete with seat (3) on tool 380000274 (1).
1
2
3
25715
101
12. 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
102 87679925A - 12 - 2007
48
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
13. Fit tool 380000274 (2) on the hand pump 380000275 (3), supplied with ISO VG 68, DIN 51524 / 51525 oil (for outside temperatures of 0 °C to 50 °C). Connect a dial gauge (1), securing in position with the screw.
1 2 3
25717
103
14. Operate the hand pump and at the same time tighten screw (1) on the tool until oil stops flowing out through the control valve block pin seat outlet. 15. Zero--set the dial gauge. 16. Tighten the screw (1) on the tool further to move the control valve block pin by 1.8 ÷ 2 mm, using the dial gauge to read this distance.
1
25718
104 17. Operate the hand pump until the oil in the system is at an initial pressure of 245 bar -- 250 kg/cm2. Using the pressure gauge, check that it takes more than six seconds for the pressure to fall 196 bar -- 200 kg/cm2 to 98 bar -- 100 kg/cm2. 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
18. Check the control valve cover seals (1) and replace if necessary.
105
1
25721
106 87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 19. Check the control valve seals (1) and replace if necessary. 20. Check the arm descent speed control pin seal and replace if necessary, following the instructions in the note on page 11. 21. Check the cylinder pressure relief valve calibration as follows.
49
1
25722
22. Fit the cylinder safety valve (1) on the valve union 380000218 (2) and connect to the hand pump 380000277 (3). 23. 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. 24. To refit the hydraulic control valve block, proceed as follows:
107
1
2
3
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 torques prescribed on page 7. Fit the control valve block pin. Fit the check valve. Fit the cylinder safety valve. Fit the control valve. Fit the pressure control valve unit. Fit the cover on the control valve block.
NOTE: Adjust the arms descent speed as follows: -- fully screw on the adjusting pin; -- unscrew the pin by: 3 รท 3.5 turns for mod. 56/76, 63/86, 71/97, 78/106 and 83/113 KW/HP. 1 รท 2 turns for mod. 71/97, 78/106 and 83/113 KW/HP, fitted with the additional cylinder. -- secure with the relative locknut.
25720
108
87679925A2 - 02 - 2010
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
50
LIFT PRESSURE RELIEF VALVE R.I.
ATTENTION
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. On models fitted with BOSCH auxiliary control valves the lift pressure relief valve (1) is located on the lift pump (2). If faulty, remove and change the valve.
LIFT PRESSURE RELIEF VALVE Setting
109
ATTENTION
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Run the engine until oil reaches a temperature of approximately 50 °C. 2. Insert the fitting 293449 (1) in a quick--fit female half--coupling and connect it to the 0 ÷ 250 kg/cm2 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/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 380000231, tighten to increase the valve setting value or loosen to reduce the value.
87679925A2 - 02 - 2010
110
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
1
SECTION 35 -- HYDRAULIC SYSTEMS Chapter 2 -- Open centre system auxiliary control valves CONTENT Description Page Data -- Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (see section 35 chapter 1) Auxiliary control valves D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Quick coupler maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (see section 35 chapter 3) SPECIFICATIONS Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
full--flow, with replaceable paper cartridge, (common to the hydraulic lift circuit)
Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
gear pump (common to the hydraulic lift circuit see Chapter 1)
AUXILIARY CONTROL VALVES Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
valve stack up to a maximum of 3 control valves.
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by hand lever
Pressure release valve calibration . . . . . . . . . . . . . . . . . .
bar
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
190 รท 195 (194 รท 199 kg/cm2) 1 single and double--acting, convertible. 1 double--acting with float 1 double--acting with float and automatic detent release
SPECIAL TOOLS
CAUTION The operations described in this section can only be carried out with the 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. 380000240
Universal pressure testing kit.
380000241
Seal guard for Kontak control valve check valve.
380000701
Flow control valve adjustment tool.
87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
2
C4 -- 20,2 Nm
C1 -- 20,4 Nm
C3 -- 59 Nm
C2 -- 11 Nm MDM1540A
1
BOLT TORQUES Parts to tighten
Thread
Tightening torque
Control valve elements locknuts (C1) . . . . . . . . .
3/8” -- 24 UNF
Nm 20.4
kgm 2.1
Front and rear cover retaining bolts (C2) . . . . . . .
1/4” -- 20 UNC
Nm 11
kgm 1
Auxiliary control valve retaining bolts (C3) . . . . . .
M10x1.25
Nm 59
kgm 6
Excess oil delivery union to the control valve (C4)
3/4” GAS
Nm 20.2
Kgm 2.06
87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
2
3
3
4
5
1
7
6
8
9
A
8
B 9
MDM1541A
10 2
Auxiliary control valves sectional view A. Control valve: 1 Single/double--acting convertible + 1 Double--acting with float + 1 double--acting with float and automatic detent release. B. Control valve: 1 Single/double--acting convertible + 1 Spacer + 1 double--acting with float and automatic detent release. 1.
Excess oil delivery union at the control valve to the other users: mechanical lift.
2.
Control valve end piece.
3.
Single-- to double--acting switching device.
4.
Control valve inlet/outlet end piece.
5.
Drain union for oil used by the control valve.
6.
Oil inlet union to the control valve.
7.
Spacer.
8.
Switchable single/double--acting control valve.
9.
Double--acting control valve with float and automatic detent release.
10. Double--acting control valve with float. 87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
4
Auxiliary control valve cross--sectional views
1
2
3
4
5
6
7
8
16
9
1
10
16
11
15
2
3
4
5
6
7
8
9 10 11
15 14
13
12
14
A 5
27
28
29
30
13
6
12
7
B 8
9
10
11
31
26
25
24
23
22
21
C
20
19
5
18
6
17
7
8
9
10
11
D 30
32
33
28
25 24
20
18
17
MMM1548A
3
87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
5
Auxiliary control valve cross--sectional views
A. Auxiliary control valve configured for operation of a double--acting cylinder. B. Auxiliary control valve configured for operation of a single--acting cylinder. C. Double--acting auxiliary control valve with float and automatic detent release. D. Double--acting auxiliary control valve with float. 1.
Single/double--acting switching valve.
18. Spring.
2.
Seal.
19. Seal.
3.
Valve retaining plug.
20. Coupling balls.
4.
Seal.
5.
Seal.
6.
Non--return valve seat.
7.
Non--return valve.
8.
Seal.
9.
Seal.
21. Seal. 22. Seal. 23. Internal plunger. 24. Spring. 25. Cover. 26. Detent release pressure adjuster screw.
10. Control support. 11. Control valve rod. 12. Seal. 13. End Cap. 14. Control valve rod return spring.
27. Control valve rod return spring. 28. End Cap. 29. Seal. 30. Detent notch body.
15. Cover.
31. Ball support.
16. Spacer.
32. Seal.
17. Tapered needle.
33. Seal.
87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
6
DESCRIPTION AND OPERATION
The auxiliary control valves serve for control of hydraulic loads external to the tractor. Up to a maximum of 5 auxiliary control valves can be fitted, fixing 3 on the cover of the gear control rod support and 2 on the support fitted on the right--hand side of the engine. The rear auxiliary control valves are operated by the hand levers located on the right--hand side of the driving position, while the front auxiliary control valves on the right--hand side of the engine are operated by a joystick on the right--hand side of the mudguard. The levers and respective control valves are identified by colour as described below: Lever colour
Control valve position
no.
Green
RH external
I
Blue
RH internal
II
Brown
RH central
III
Each auxiliary control valve lever has three or four positions, depending on the type of control valve. 1. Lifting -- Pull the lever backwards to extend the connected cylinder and lift the implement. 2. Neutral -- Push the lever forwards leaving the lifting position to select neutral and stop the flow of oil to the connected cylinder.
3. Lowering -- Push the lever further forwards, beyond the neutral position, to return the cylinder and lower the implement.
4. Float -- Push the lever beyond the “lowering” position to select the “float” function. This will allow the cylinder to extend or return freely, permitting implements (such as blades) to follow the profile of the ground surface. The auxiliary control valves on the right--hand front side of the tractor are operated with the joystick. Moving the joystick lengthways operates the second front auxiliary control valve, crossways it acts on the first front auxiliary control valve. The joystick has the advantage of being able to operate two auxiliary control valves simultaneously. The flow control valve, on tractors fitted with auxiliary control valves located on the right--hand front side of the tractor, is installed between the first and second control valve. The flow control valve can be used to change the flow rate of oil to the front control valve. Turning the control knob anticlockwise decreases the flow rate, whereas turning it clockwise increases it. The operation of the hydraulic control valves is described on pages 7, 8 and 9.
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).
1
L
H
3
E
G
L
2
22123
M 4
87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 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).
L
H
3
7
E
G
L
2
22124
5 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).
1
L
H
3
E
G
L
2
Pressurised oil Oil in suction, delivery or return Oil at static rest 22125
6 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).
NOTE: For operation of a double--acting cylinder, tighten the screw (1). For operation of a single--acting cylinder, loosen the screw.
L
H
3
E
G
L
2
22126
7
87679925A -- 12 -- 2007
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 Pressurized 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
170 รท 175 bar (173 รท 178 kg/cm2), acting through the port (Y), it overcomes the resistance of the spring of the tapered cap (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).
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
L
H
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 87679925A -- 12 -- 2007
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.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
9
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
H
G
L
26
2
24
M
22129
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 Single/double--acting switching valve (of control valve fig. 10 -- 11 -- 12)
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.
1
2
3
4
1. Single/double--acting switching valve. 2. Seal. 3. Valve retaining plug. 4. Seal. NOTE: For operation of a double--acting cylinder, tighten the screw (1). For operation of a single--acting cylinder, loosen the screw. 25726
11
87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
10
AUXILIARY CONTROL VALVES D.A. 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 fig. 3 and the following instructions: 1. Remove the cover (5), recover the spring (4) and the relative 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
Single/double--acting auxiliary control valve float and automatic detent release Disassemble the auxiliary control valve into its component parts, referring to fig. 3 and the following instructions: 1. Take out the retaining bolts, remove the cover (4) and the spacer (3). 2. Unscrew the retaining screws and remove the control lever support (1) and its seal (2).
12 1
2
3
4
24453
13
87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 3. Extract the control valve stem (1). 4. Remove the valve housing and recover the check valve and relative spring. 5. Check the condition of the seals before assembly.
11
1
24454
14
Diagram showing the installation of the tools and equipment required for the stem sticking test for control valves configured for double--acting operation (fig. 15) and control valves configured for single--acting operation (fig. 16). Control valve stem sticking test (figs. 15 and 16). NOTE: With the test equipment filled with ISO VG 68, DIN 51524/51525 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). 24465
15
Install the auxiliary control valve assembly and the test equipment as indicated in the diagrams (figs. 15 and 16) and referring to the following instructions: -- on control valves configured for double--acting operation (fig. 15), the two cylinder delivery ports must be connected to the ball connector (3) by way of the pipes (2) and unions (1); -- on control valves configured for single--acting operation (fig. 16), 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. 24466
After having made the connections indicated in the diagram, carry out the test as follows: -- start the hydraulic pump and operate the hand lever to move the control valve 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.
16
87679925A -- 12 -- 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. 17) bearing in mind that the 3--way union (1) must be connected to single and double acting control valves using suitable adapters. 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 control 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. 3) until a pressure of 170 รท 175 bar (173 รท 178 kg/cm2) is obtained in front of the tapered cap (17). Lock the screw (26) in position by tightening the locknut.
87679925A -- 12 -- 2007
17
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
1
SECTION 35 -- HYDRAULIC SYSTEMS Chapter 3 -- Remote control auxiliary control valves (BOSCH) CONTENT Description
Page
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Auxiliary control valve components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Control valve inter--connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Lifting oil flow (Cylinder extension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Lowering oil flow (cylinder retraction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Oil flow in neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Oil flow in float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Automatic release pressure regulating valve operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Operation of two or more control valves simultaneously . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Auxiliary control valves R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Auxiliary control valves. D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Quick coupler maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
87679925A - 12 - 2007
2
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 SPECIFICATIONS
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
groups of 2 or 3 control valves
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by hand lever
Nominal flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
litres /min
70
Maximum flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
litres /min
80
Automatic release valve calibration . . . . . . . . . . . . . . . . . . . . . . . . .
bar
175
Pressure release valve calibration . . . . . . . . . . . . . . . . . . . . . . . . . .
bar
190 รท 195
Control valve types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single-- and double--acting cylinders, with automatic detent release and with float and flow--rate regulator. Single and double--acting, with automatic release and float mode.
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.
87679925A - 12 - 2007
List of specific tools required for the various operations described in this Section.
380000240
Universal pressure testing kit.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
3
BOLT TORQUES
TIGHTENING SEQUENCE
MPE0221A
1
Tightening torque P t tto ti Parts tighten ht
Th d Thread
Control valve elements locknuts (C1) Control valve locknuts (C2) Front and rear cover retaining bolts (C3) Blanking plug (C4)
Nm
kgm
M8x1.25
30 ÷ 33
3 ÷ 3.4
M22x1.5
67 ÷ 89
6.8 ÷ 9.1
M6x1
5.5 ÷ 7.3
0.6 ÷ 0.75
M22x1.5
67 ÷ 89
6.8 ÷ 9.1
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
4
MPE0231A
2 Auxiliary control valve unit 1. 2. 3.
Connecting plate Third auxiliary control valve Second auxiliary control valve
4. 5. 6.
First auxiliary control valve End Cover Flow control valve adjuster
DESCRIPTION AND OPERATION The auxiliary control valves serve for control of hydraulic loads external to the tractor. Up to a maximum of 3 auxiliary control valves can be fitted. The rear auxiliary control valves are operated by the levers to the right of the operator. The levers and respective control valves are identified by colour, i.e.: a lever in a specific colour will operate the control valve and engagement half--coupling of the same colour. 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. 87679925A - 12 - 2007
2. Neutral -- Push the lever away from the operator, leaving the lifting position, in order to select the neutral position and disconnect the connected cylinder. 3. Lowering -- Push the lever further away from the operator, beyond the neutral position, to return the cylinder and lower the implement. 4. Float mode -- Push the lever away from the operator, beyond the “lowering” position to select the “float” function. This will allow the cylinder to extend or return freely, permitting implements (such as blades) to follow the profile of the ground surface. The operation of the hydraulic control valves is described on the following pages.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
5
The main hydraulic components inside each of the auxiliary control valves are:
before the pressure in the system increases to maintain and further lift the load.
Flow control valve adjustment (1, fig. 3)
The load check valve prevents this from happening.
Flow control valve adjustment is carried out manually and controls the oil flow by means of the auxiliary control valve.
By turning the adjuster, the oil flow throttle clearance is varied by means of the flow control valve.
Flow control valve (2, fig. 3)
The flow control valve reads the throttle pressure differential with the relative adjuster, and controls the flow by means of the auxiliary control valve.
Lockout valve (5, fig. 3)
The lockout valve is located in the auxiliary control valve lifting duct and is closed when the valve is in neutral.
The valve prevents the implement from returning spontaneously, in the event of the pin grooves leaking when in the neutral position.
The lockout valve opens automatically when the control valve pin is moved from the neutral position.
As each flow control valve individually reads the pressure differential of the operating auxiliary control valve, two or more circuits can be simultaneously controlled by working at different pressures.
Control valve pin (4, fig. 3)
Load check valve (3, fig. 3)
The control valve pin is kept centred in neutral; when it moves, it sends the flow of oil to the control valve lifting or lowering orifices.
The check valve impedes pressure backflow from the auxiliary control valve circuit when the control pin is activated and the pump system pressure is less than the counterpressure in the circuit.
Pin centering and automatic release mechanism (6, fig. 3)
The following example explains operation:
When a cylinder is under a consistent load and the control valve pin is moved from the neutral position to the lifting position, the pump pressure could be less than the counterpressure in the auxiliary control valve circuit.
In this event, the counterpressure would force the oil back into the circuit, momentarily reducing the load,
The spring centering mechanism holds the control valve pin in the neutral position. When the pin is moved to the lifting, lowering or float mode position, the mechanism holds the pin in position by means of two ball bearings that engage in a groove inside the control retainer. A pre--set release valve automatically releases the ball bearings, returning the pin to the neutral position each time the working pressure exceeds the predefined value.
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
6
MPE0239A
3 Auxiliary control valve components 1. 2. 3.
Flow control valve adjustment Flow regulator Load Check
87679925A - 12 - 2007
-
4. 5. 6.
Control pin Lock Valve Pin centering mechanism
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
7
4 Flow control valve and check valve components 1. 2. 3. 4. 5. 6.
Flow regulator Retainer Spring Spring guide Cap and seal Plastic cap
7. 8. 9. 10. 11. 12.
Retainer Plug Thrust washer Seal Spring Check valve ball
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
8
5 Control pin 1. 2. 3. 4. 5. 6. 7.
End Plug Seal Spacers Pin centering mechanism Pin Seal Seal
87679925A - 12 - 2007
8. 9. 10. 11. 12. 13. 14.
Spacer Thrust washer Release pin Ball Piston Spring Spring cover
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
9
MPE0246A
6 Lockout valve components 1. 2. 3. 4.
Piston Load Check Ball Spring
5. 6. 7. 8.
Washer Spring Spring seat Spring centering
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
10
3 2 1
Pump pressure
Return to Reservoir
Load sensing
MPE0222A
7 Connection between auxiliary control valves 1. 2.
Parallel supply duct Load sensing duct
3.
Return to Reservoir
All elements on the control valves use the same infeed and return to reservoir duct, positioned in parallel. The load sensing duct passes through the centre of the control valve unit. The parallel ducts and load sensing system allows two or more control valves to be used simultaneously, with no loss of efficiency. The seals (1) and the check valves on the load sensor (2), fitted between each element, ensure that the highest load sensing pressure in the circuit is directed to the hydraulic pump to control the supply. 87679925A - 12 - 2007
MPE0244A
8
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
11
LIFTING OIL FLOW (Cylinder extension)
When the control valve lever is moved to the lifting position, the control pin (5, fig. 9) moves to the left allowing the spring balls to engage in the groove on the left--hand side of the automatic release mechanism (10). By moving the pin to the lifting position, the peg (6) on the lockout valve (7) will rise on the pin and hold the valve in the open position. Duct (B) is now connected to duct (C) and duct (E) is connected to duct (F). The flow from duct (C) is stopped by the ball (4) on the check valve until the pressure in the duct can lift the ball in its seat, countering the pressure in duct (E) in the lifting duct. Oil can flow from: In duct (C), through the check valve and to duct (E).
Along the flat part of the control pin and to duct (F).
Through the lock valve (7).
On the outside, through the lifting duct (8) of the auxiliary control valve.
The oil from the extended cylinder returns through the lowering duct and duct (H), around the control pin groove and flows to the reservoir through shared duct (G). If the check valve (4) is not installed, the pump pressure may be unable to support the load in the lifting duct when the auxiliary control valve is moved from neutral to the lifting position. In this event, the load will momentarily lower until the pressure in the pump can sustain it. The quantity of oil that flows through the auxiliary control valve is controlled by the flow rate manual adjustment knob (1), which manually alters the throttle clearance (11). To maintain a constant flow rate in the auxiliary control valves when the pressure varies at the parallel duct pump infeed (A), the flow control valve reads the pressure difference at the throttle (11), manually adjusted between ducts (A) and (B). The difference in pressure at each end of the pin makes it move to re--balance and continuously controls the flow rate on the pin grooves (2) in order to maintain a constant flow rate through the throttle (11), regardless of the pressure in the other hydraulic circuits. The pressure in duct (C) is also directed to load sensing duct (D) and the flow rate compensating valve.
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
12
1
2
3
4
11
5
6 10 7
9
8
Pressurised oil MPE0235A
Discharge oil
Auxiliary control valve working pressure Auxiliary control valve operation -- Lifting (cylinder extension)
1. 2. 3. 4. 5. 6.
Flow control valve adjuster Metering Land Flow regulator Load check valve Control pin Roll Pin
87679925A - 12 - 2007
7.
Lock Valve
8.
Lifting duct (cylinder extension)
9.
Lowering duct (cylinder retraction)
10. Centering pin and release mechanism 11. Manually adjusted flow rate throttle
9
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
13
LOWERING OIL FLOW (cylinder retraction) When the control valve lever is moved to the lowering position, the control pin (5, fig. 10) moves to the right, allowing the spring balls to engage in the central groove on the automatic release mechanism (10). As with the lifting cycle, the position of the pin allows the lockout valve (7) pin (6) to maintain the valve in the open position. Duct (B) is now connected to duct (C) and duct (E) is connected to duct (H). The oil from the parallel duct (A) is directed through the flow control valve and the throttle (2) and then to ducts (B), (C) and to load sensing duct (D). The ball (4) on the check valve of the load stays
closed until the pump system pressure in the duct can overcome the backpressure in duct (E). When the ball on the check valve lifts, the oil flows to duct (E), around the control pin, to duct (H) and is directed out through the lowering duct on the auxiliary control valve. The oil from the retracted cylinder flows to duct (G) and returns to the reservoir through the lifting duct and the lockout valve (7). The flow rate through the auxiliary control valves is controlled in the same way in the â&#x20AC;&#x2DC;Lifting oil flowâ&#x20AC;&#x2122; heading, i.e: reading the pressure difference inside the manually adjusted throttle (11). 2
1
3
4 11
5
6 10 7
9
8
Pressurised oil MPE0237A
Discharge oil
Auxiliary control valve working pressure 10
Auxiliary control valve operation -- Lowering (cylinder retraction) 1. 2. 3. 4. 5. 6.
Flow control valve adjuster Metering Land Flow regulator Load Check Control pin Roll Pin
7.
Lock Valve
8.
Lifting duct (cylinder extension)
9.
Lowering duct (cylinder retraction)
10. Centering pin and release mechanism 11. Manually adjusted flow rate throttle
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
14
OIL FLOW IN NEUTRAL When the auxiliary control valves are in neutral, the control pin (5, fig. 11) is held in the central position by the centering spring.
The ducts to the lifting and lowering ducts are stopped by the control pin grooves (5).
The oil flow from the parallel duct (A) to the lifting and lowering ducts is stopped by the control pin grooves.
The lockout valve pin (7) is inserted in the restriction on pin (5), keeping the valve in the closed position with the spring, to prevent an extended cylinder from retracting under load in the event of slight losses from the control pin.
Duct (C) and load sensing duct (D) outfeed to the reservoir through duct (G).
2
1
3
4 11
5
6 10 7
9
8
Pressurised oil MPE0234A
Discharge oil
Oil at static rest Auxiliary control valve operation -- Neutral
1. 2. 3. 4. 5. 6.
Flow control valve adjuster Metering Land Flow regulator Load Check Control pin Roll Pin
87679925A - 12 - 2007
7.
Lock Valve
8.
Lifting duct (cylinder extension)
9.
Lowering duct (cylinder retraction)
10. Centering pin and release mechanism 11. Manually adjusted flow rate throttle
11
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
15
FLOAT MODE OIL FLOW The float mode position allows the oil to flow from both the lifting duct and the lowering duct on the auxiliary control valve, permitting the cylinders to extend or retract freely. This is particularly useful for implements such as leveller blades, allowing them to â&#x20AC;&#x153;floatâ&#x20AC;? whilst following the profile of the ground surface. When the control valve lever is pushed fully forwards to the float mode position, the control pin (5, fig. 12) moves fully to the right allowing the spring balls (10) to engage in the groove on the right hand side of the
automatic release mechanism. The oil flow from duct (B) to the lifting and lowering ducts is stopped by the pin grooves. As a result of the position of the pin, the lockout valve (7) pin (6) keeps the valve in the open position. The auxiliary control valve lifting and lowering ducts are connected to duct (G) on the reservoir, allowing the oil to flow freely from one duct on the cylinder to the other. If there is a vacuum in the circuit, the oil is sucked from one end of the cylinder to the other.
2
1
3
4 11
5
6 10 7
9
MPE0236A
8
Pressurised oil
Outlet oil 12
Auxiliary control valve operation -- Float mode 1. 2. 3. 4. 5. 6.
Flow control valve adjuster Metering Land Flow regulator Load Check Control pin Roll Pin
7.
Lock Valve
8.
Lifting duct (cylinder extension)
9.
Lowering duct (cylinder retraction)
10. Centering pin and locking mechanism 11. Manually adjusted flow rate throttle
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
16
AUTOMATIC RELEASE PRESSURE REGULATING VALVE OPERATION Under normal working conditions, the auxiliary circuits are protected from excess pressure by the release pressure control valve, which moves the control pin to neutral when the working pressure of the cylinder exceeds the pre--set value. If the auxiliary control valve lever is kept stationary by the operator to prevent the pin (3, fig. 13) gong back to neutral, the maximum working pressure is limited to a maximum of 195 bar by the pressure compensating valve in the hydraulic pump. The operation of the release adjustment valve is as follows: When the control valve pin is moved to the lifting or lowering position, the centering pin and automatic release mechanism retaining balls (1) are locked by the conical part of the spring piston.
When lifting or lowering, the working pressure of the auxiliary control valve circuit is also detected in the central hole of the pin through the small radial orifices (2). As the pressure increases, the force applied on the smallest ball (4) on the end of the pin (3) pushes the automatic release control valve piston (5) and the spring piston (6) to the left. When the automatic release pressure (175 bar) is reached, the centering mechanism balls are no longer held by the conical part of the pre--loaded piston, and the centering spring (8) moves the pin to neutral.
1
2
3
8 7
MPE0238A
6
5
4
Auxiliary control valve pressure at 175 bar
Outlet oil
Automatic release pressure regulating valve operation 1. 2. 3. 4.
Centering pin and automatic release mechanism Radial ducts Control pin Ball
87679925A - 12 - 2007
5. 6. 7. 8.
Stop piston Pre--loaded spring piston Stop balls Centralising Spring
13
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
OPERATION OF TWO OR MORE AUXILIARY CONTROL VALVES SIMULTANEOUSLY
17
1 6
As the auxiliary control valves are provided with a shared parallel inlet duct and individual flow rate control valves, two or more auxiliary control valves can operate at the same time, with no loss of efficiency.
6
2
4
This is carried out by the flow rate adjusters, which regulate the flow through each auxiliary control valve, regardless of the pump pressure.
If theses valves were not fitted and two auxiliary control valves worked at the same time at different pressures, the oil would tend to flow to the circuit with the lighter load.
5
4
3
5
3
There follows a detailed explanation of single auxiliary control valve operation and combined operation with another auxiliary control valve.
When only one auxiliary control valve is used, the pressure in the parallel duct is the same as the pump pressure.
A
B
The auxiliary control valve flow rate is set by the flow rate adjusting knob, controlling the limiter clearance (3).
The limiter pressure differential (3) is taken at each end of the flow rate control pin (5), which moves to a balanced position to dose the flow rate on the grooves (4).
Pressurised oil
Discharge oil
Auxiliary control valve working pressure
Oil at static rest
MPE0232A
Operation with a single auxiliary control valve
Control of the flow rate on the grooves (4) produces a constant flow rate through the flow rate manual limiter (3) and through the auxiliary control valve.
A. Auxiliary control valve operating 1. 2. 3.
Parallel duct (connecting the auxiliary control valve elements) Load sensing line (connecting the auxiliary control valve elements) Manual flow rate limiter
87679925A - 12 - 2007
B. Remote Valves in Neutral 4. 5. 6.
Metering Lands Flow regulator Load sensing line check valve
14
18
It is essential that oil flow is controlled singularly through two or more auxiliary control valves, working simultaneously at different pressures, otherwise the oil will tend to flow towards the circuit with lower pressure.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
1 6
6
2
When using two or more hydraulic services, the working pressure in the parallel duct is at the maximum value of the hydraulic system, as read through load sensing line.
4
5
4
3
5
3
A
B
Pressurised oil
Auxiliary control valve operation at lower pressure
Auxiliary control valve operation at high pressure
Discharge oil
MPE0233A
Operation with two auxiliary control valves
A. Auxiliary control valve operating at high pressure 1. 2. 3.
B. Auxiliary control valve operating at low pressure
Parallel duct (connecting the auxiliary control valve elements) Load sensing line (connecting the auxiliary control valve elements) Manual flow rate limiter
87679925A - 12 - 2007
4. 5. 6.
Metering Lands Flow regulator Load sensing line check valve
15
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
19
AUXILIARY CONTROL VALVES D.A.
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. Clean the auxiliary control valve unit before removing. 2. Lower the hydraulic arms. 3. Disconnect the auxiliary control valve tie--rods. 4. Disconnect the auxiliary control valve hydraulic piping. 5. To facilitate assembly operations, mark a diagonal line on the control valve unit. Close the hydraulic ducts with plastic caps (1) to prevent foreign matter from entering. 6. Using a suitable hoist, support the auxiliary control valves unit, unscrew the retaining bolts and extract the unit from the tractor. 7. Position and secure the control valves unit (1) on the workbench (2).
MPE0240A
16
MPE0241A
17
8. Unscrew the retaining nuts (1) on the control valve elements.
MPE0228A
18
87679925A - 12 - 2007
20
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
9. Remove the end plate (1).
MPE0227A
19
10. Extract the first auxiliary control valve (1).
MPE0226A
20 11. Extract the second auxiliary control valve (1).
MPE0225A
21
12. Extract the third auxiliary control valve (1).
MPE02224A
22 87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
21
13. If necessary, remove the threaded tie--rods (1) on the connecting plate (2).
MPE0223A
23
14. To refit the auxiliary control valves, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. ---
For the positioning of the various parts refer to figure 2 and the previously illustrated figures Before reassembling, clean and degrease the mating surfaces.
--
Respect the tightening torques prescribed on page 3.
--
Tighten the threaded tie--rods on the connecting plate (1, fig. 2).
--
Make sure that the seal (1, fig. 8) and check valve (2) are correctly seated.
--
Fit the control valves in the order indicated in figure 2 according to the diagonal line marked before disassembly.
---
Position the end plate. Tighten the retaining nuts to 30 รท 33 Nm in order 1, 2, 3.
--
Position and secure the auxiliary control valves in the seat.
--
Connect the hydraulic piping.
MPE0242A
24 TIGHTENING SEQUENCE
MPE0243A
--
Connect the tie rods.
25
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
22
AUXILIARY CONTROL VALVES D.A. 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. Disassemble the control valve, referring to the following figures: 1. Remove the seal (1) and the load sensing check valve (2).
MPE0244A
26 2. Remove the threaded parts on the ends and extract the flow adjuster (2) from the valve body.
Auxiliary control valve components 1.
Flow control valve adjustment
2.
Flow regulator
3.
Load Check
4.
Control pin
5.
Lock Valve
6.
Pin centering mechanism
MPE0362A
27
3. Remove the control pin (1). NOTE: Before removing the pin, make sure that the flat sides (1) at the end of the pin are in the vertical position, as shown. If necessary, rotate the pin but do not use force as this may damage the pin and the lock valve pin (5).
MPE0245A
28
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
23
4. Remove the lock valve from the lifting duct as follows: Using a small screwdriver, open the two slots (1) on the retaining device (2) and rotate through 90 degrees. Remove the spring seat (3) from the housing. Remove the lock valve and piston.
MPE0247A
29
5. Remove in succession: retaining device (8), spring seat (7), spring (6), washer (5), spring (4), ball (3), lock valve (2) and piston (1).
MPE0363A
30 6. Carefully remove the flow control plug.
ATTENTION Take care when removing the plug as it is under the pressure of spring (1).
7. Remove in succession: plug (5) with seal, spring guide (4), spring (3), retainer (2) and flow control valve (1).
31
8. Then disassemble the lock valve removing the guard (6), retainer (7), plug (8), ring (9), gasket (10), spring (11) and ball (12).
MPE0364A
32 87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
24
33 Control pin
1. 2. 3. 4. 5. 6. 7.
End Plug Seal Spacers Pin centering mechanism Pin Seal Seal
9. Remove the control pin by unscrewing the centering mechanism. Do not disassemble the mechanism. 10. The release pin is at the centre of the pin (5). It is a pre--set mechanism which only requires washing with an approved degreasing product, without removing the release pin (10).
87679925A - 12 - 2007
8. 9. 10. 11. 12. 13. 14.
Spacer Thrust washer Release pin Ball Piston Spring Spring cover
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
25
Assembly Procedure 1. For assembly operations, follow the disassembly operations in reverse order. Remember to fit the lock valve before the control pin. 2. Before inserting the control pin in its seat, make sure that the flat sides (1) at the end of the pin are in an upright position, as in the figure. DO NOT rotate the pin once inserted in the seat, this would damage the pin and the lock valve piston.
34
CONNECTING PLATE Disassembly 1. Unscrew the closing cap (1).
MPE0229A
35 2. Remove the plug (1) and the piston (2).
MPE0248A
3. Remove the adjustment shims (3).
36
MPE0249A
37 87679925A - 12 - 2007
26
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
4. Extract the pin (1) and spring (2). Assembly Procedure 1. For assembly operations, follow the previously described disassembly operations in reverse order.
MPE0230A
38
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
27
QUICK COUPLER MAINTENANCE INTRODUCTION The main causes for poor operation or breakage of the quick couplers are: -- dirt; --
type of male quick coupler not compatible, or damaged (dents, for instance);
--
forced extraction of the mail coupler when there is pressure in the hydraulic system.
ATTENTION Before removing the protective caps for the male connections, remove all the debris that has accumulated on the pressure points to avoid contaminating the hydraulic system. Before disconnecting the couplers you must: -- lower the connected attachments; -- stop the engine; -- move the relevant levers forwards and backwards to discharge pressure from the hydraulic system.
MAINTENANCE OPERATIONS The correct procedure in using and servicing the hydraulic connections is vital for their durability and efficiency. There follow helpful tips for using the quick couplers correctly and avoiding operational trouble. If the female couplers are not used, always protect the male ones with the special plugs provided.
1.
87679925A - 12 - 2007
28
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
Spray solvent for a few seconds into the gap between the movable outer portion (1) of the male connection and the inner portion (2) supporting the balls.
Spray solvent for a few seconds into the coupling zone and on the locking balls.
2.
3. Perform some hooking/unhooking operations and if necessary do the cleaning again to make the coupling fluid.
4.
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
29
Troubleshooting FAULT Engagement impossible.
POSSIBLE CAUSE
PERSISTENT TROUBLE
SOLUTION
The male coupler is not Replace the compatible. connection.
male
--
Dirt or soil in the female Spray solvent inside and coupling. outside the female pressure point (see figs. 2. -- 3.), wait for a few seconds for the solvent to If coupling is still not react. possible, replace the Perform some hooking/ connector. unhooking operations (see fig. 4.) and if necessary do the cleaning again to make the coupling fluid. Difficult engagement.
Dirt or soil in the female Spray solvent inside and coupling. outside the female pressure point (see figs. 2. -- 3.), wait for a few seconds for the solvent to If coupling is still not react. possible, replace the Perform some hooking/ connector. unhooking operations (see fig. 4.) and if necessary do the cleaning again to make the coupling fluid.
Oil leakage from the Dirt or soil in the female Spray solvent inside and female coupling after coupling. outside the female disengagement of the pressure point (see figs. male connector. 2. -- 3.), wait for a few seconds for the solvent to If coupling is still not react. possible, replace the Perform some hooking/ connector. unhooking operations (see fig. 4.) and if necessary do the cleaning again to make the coupling fluid. Valve gasket damaged. Oil leakage from the Internal female coupling after damaged. disengagement or engagement of the male connector.
Replace.
--
gaskets Replace. --
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
30
FAULT Oil leakage from the couplings after engagement.
POSSIBLE CAUSE
PERSISTENT TROUBLE
Dirt or soil in the seal area. Spray solvent inside and outside the female pressure point (see figs. 2. -- 3.), wait for a few seconds for the solvent to If coupling is still not react. possible, replace the Perform some hooking/ connector. unhooking operations (see fig. 4.) and if necessary do the cleaning again to make the coupling fluid. Gasket damaged.
87679925A - 12 - 2007
SOLUTION
Disconnect the connectors, replace the damaged gasket and, if necessary, the anti--extrusion ring.
--
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
1
SECTION 35 -- HYDRAULIC SYSTEMS Chapter 4 -- Trailer brake auxiliary control valve CONTENT Description
Page
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Trailer brake control valve hydraulic circuit diagram with KONTAK control valves . . . . . . . . . . . . . . . . . . . . . 2 Trailer brakes control valve hydraulic circuit diagram with BOSCH control valves . . . . . . . . . . . . . . . . . . . . . 3 Functional testing and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cross--sectional view of auxiliary control valve for trailer brakes. (Open--centre circuit) 1. Non--return valve. 2. Flow regulator. 3. Pilot valve casing. 4. Pilot valve piston. 5. Pressure limiter. 24451
1
6. Slide piston.
DESCRIPTION AND OPERATION
The trailer brake valve is located on the right--hand side of the rear transmission casing, controlled by the lift control pump and has priority over both the auxiliary control valves and the hydraulic lift. The trailer brake valves mounted in the outfit with Kontak auxiliary control valves or in the outfit with Bosch auxiliary control valves are the same. For the hydraulic operation of the trailer brake valve, see pages 4 and 5.
The ITALIA trailer brake valve provides the advantage and safety of having the trailer brakes applied even with: -- engine off; -- pump faulty (or with low delivery). A description of the ITALIA trailer brake valve can be found on pages 6 รท 9.
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
2
TRAILER BRAKE AUXILIARY CONTROL VALVE Oil at static rest Intake oil Tractor brake circuit oil at rest Pressurised oil Discharge oil
1
3
2
4
5 9
8
7
6
MDF1518A
2 Diagram of the trailer brake auxiliary control valve hydraulic circuit (with KONTAK auxiliary control valves) 1. 2. 3. 4. 5.
Delivery line to the control valve (3). Trailer brake auxiliary control valve. Auxiliary control valves. Auxiliary control valve lines. Trailer brake control valve line.
87679925A - 12 - 2007
6. 7. 8. 9.
Lift control valve. Intake line. Oil filter. Hydraulic Pump.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
3
TRAILER BRAKE AUXILIARY CONTROL VALVE Oil at static rest Intake oil Tractor brake circuit oil at rest Pressurised oil Discharge oil Piloting oil (load sensing)
1
2
3
4
5 9
8
7
6
MDF1519A
3 Diagram of the trailer brake auxiliary control valve hydraulic circuit (with BOSCH auxiliary control valves) 1. 2. 3. 4. 5.
Delivery line to the control valve (3). Trailer brake auxiliary control valve. Auxiliary control valves (with UNLOAD valve). Auxiliary control valve lines. Trailer brake control valve line.
6. 7. 8. 9.
Lift control valve. Intake line. Oil filter. Hydraulic Pump.
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
4
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. 4. The oil from the hydraulic pump (9, figs. 2 -- 3) flows to port (P1, fig. 4) and passes through the diaphragm (1) and restriction (3) where there is a drop in pressure, pushing the flow control valve (2) to the right. The majority of the oil flows through the port (N) to the auxiliary control valves, while the rest of the oil is discharged to the hydraulic lift through the line (4), slide piston (7) and port (R). Pressurised oil Oil in suction, delivery or return Oil at static rest Tractor brake circuit oil at rest
1
2
3 4
P1 N
5
6
B 7
R
Y
25259
4 Trailer brakes off N. To the auxiliary control valves. P1. From the hydraulic pump to the lift circuit. R. To the return line in the lift. Y. From the tractor brakes.
Pressurised tractor brake circuit oil
START OF BRAKING When the tractor brake pedals are pressed, the hydrostatic circuit oil enters union (y) under pressure, moving the piston (7, fig. 5), pressure limiter (6) and spool (8) to the left. This interrupts the communication with the oil discharge union (R), trailer brake union (B) and line (5). 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 the drawing.
1
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. 87679925A - 12 - 2007
3
4
P1
5
6
7
N
B
25261
Part of the oil from the hydraulic pump in port (P1), flows to the auxiliary control valves through port (N), while the remaining part arrives at the tractor braking element via the diaphragm (2), line (3), check valve (1) and port (B).
2
9
R
8
Y 5
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. From the tractor brakes.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
5
BRAKING
If the driver continues to operate the tractor brake pedals, the pressure of the oil in the trailer brake port (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. 12 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
5 6
P1 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).
8
B
25260
Further pressure on the tractor brake pedals shifts the piston (7, fig. 5), the pressure limiter (8, fig. 12) and the slide piston (9) to the left, thus causing an increase in the trailer brake circuit pressure, repeating the stages described in the paragraph START OF BRAKING.
7
10
R
Y
9
12
Braking B. To the trailer brake. P1. From the hydraulic pump to the lift circuit. R. To the return line in the lift. Y. From the tractor brakes.
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 pressure limiter springs (7).
Pressurised oil Oil in suction, delivery or return Oil at static rest
On releasing the tractor brake pedals, the pressure in port (y) drops and the conditions illustrated in fig. 4 are restored.
Pressurised tractor brake circuit oil
87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
6
20
23
2
1
4 21
5a 3
18
19
5b
16 22 17
24
15
6
14 12
13
Oil in suction or delivery
7
11
Discharge oil
8
Tractor brake circuit oil at rest
9
Oil at trailer brake release pressure
10
MMN1104A
13 ELECTRO--HYDRAULIC OPERATION OF TRAILER BRAKE VALVE (ITALIA 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. 4 and 5) -- 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 -- 23. Starter switch -- 24. Relay governing relay (2). 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 11รท 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.
CAUTION: 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.
87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
20
23
7
2
1
4 21
5a 3
18
19 5b
16 22 17
24
15
6
14 12
13
Oil in suction or delivery Discharge oil
A
7
11
8
Pressurised tractor brake circuit oil Oil at tractor brake release pressure
9 10
MMN1105A
14
ELECTRO--HYDRAULIC OPERATION OF TRAILER BRAKE VALVE (ITALIA 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 4 and 5) -- 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 -- 23. Starter switch -- 24. Relay governing relay (2). 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.
87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
8
20
23
2
1
4 21
5a 3
18
19 16
5b
22 17
24
15
6
14 12 Oil in suction or delivery Discharge oil
13
7
11
Tractor brake circuit oil at rest
8 9 10
MMN1106A
15
ELECTRO--HYDRAULIC OPERATION OF TRAILER BRAKE VALVE (ITALIA 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. 4 and 5) -- 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 -- 23. Starter switch -- 24. Relay governing relay (2). 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.
87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
20
23
9
2
1
4 21
5a 3
18
19 16
5b
22 17
24
15
6
14 12
13
Oil in suction or delivery Discharge oil
7
11
8
Tractor brake circuit oil at rest
9 10
MMN1107A
16 ELECTRO--HYDRAULIC OPERATION OF TRAILER BRAKE VALVE (ITALIA 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. 4 and 5) -- 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. Turning on the starter switch (23) delivers current to the relay coil (24) energizing it. Operating the parking brake turns on the magnetic switch (21), the current flowing through the switch reaches the relay coil (2) energizing it. This enables the current to get to energize 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.
CAUTION: 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.
87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
10
FUNCTIONAL TESTING AND TROUBLESHOOTING OF TRAILER BRAKE VALVE -- ITALIA VERSION Test conditions Oil temperature 40° ÷ 50° C.
Electrical system powered.
Engine speed: 1000 rpm.
Parking brake disengaged.
Trailer brake release pressure test. Proceed as follows:
1
1. Insert union 293190 (1) in the trailer brake coupling and connect to the pressure gauge with scale 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. 10) is not illuminated. 4. Apply the parking brake and disconnect the pressure gauge and union 293190 (1).
26431
17
TROUBLESHOOTING
Problems Trailer brake release pressure = 0 bar (warning ( g light g 22,, fig. g 10 ON) ON).
Possible causes
Solutions
6. Parking brake (1, fig. 10) Disengage parking brake. engaged. 7. Trailer brake release pressure Renew it. control valve (6) incorrectly adjusted. 8. Trailer brake circuit safety Replace switch. switch (8) faulty. 9. Hydraulic pump (9) faulty.
Overhaul or replace hydraulic pump.
10. Delivery line solenoid valve Free or replace the solenoid valve. (5a) locked in closed position. 11. Discharge line solenoid valve Free or replace the solenoid valve. (5b) locked in open position. Trailer brake pressure release 0 ÷ 11 bar (0 ÷ 11.2 kg/cm2).
6. Trailer brake release pressure Renew it. control valve (6) incorrectly adjusted.
Trailer brake release pressure correct, but warning light (22) illuminated.
6. Trailer brake warning light Replace switch. switch (16) faulty.
Trailer brake release pressure p in- 6. Warning light (22) bulb faulty. Change the lamp bulb. correct, t b butt warning i lilight ht (22) nott 7. Trailer brake warning light Replace switch. illuminated. switch (16) faulty. NOTE: The switch (8) can be identified by the red paint mark between the two terminals.
87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
11
TESTING THE SETTING OF THE TRAILER BRAKE SYSTEM PRESSURE CONTROL VALVE INCORPORATED IN THE TRAILER BRAKE CONTROL VALVE Proceed as follows:
1
1. Insert union 293190 (1) in the trailer brake coupling and connect to the pressure gauge with scale 0 ÷ 40 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 293190 (1).
26431
12
TROUBLESHOOTING
Problems
Possible causes
Solutions
Pressure above or below prescri- 1. Pressure control valve (6, Replace trailer brake auxiliary conbed range. fig. 10) of trailer brake trol valve. auxiliary control valve faulty. 2. Hydraulic pump (9) faulty.
Replace pump.
TESTING THE HYDRAULIC SYSTEM FOR LEAKAGE Proceed as follows:
1
1. Insert union 293190 (1) in the trailer brake coupling and connect to the pressure gauge with scale 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 and with a pressure of 135 ÷ 145 bar (138 ÷ 148 kg/cm2) check that within 10 seconds the number of pressure peaks is under 10. 3. Apply the parking brake and disconnect the pressure gauge and union 293190 (1).
26431
13
TROUBLESHOOTING Problems On applying the prescribed force on the service brake pedals, p , there are an excessive i number b off pressure peaks over a 10--second period. period
Possible causes
Solutions
1. Oil leaks in the hydraulic Find and eliminate the leaks. system. 2. Excessive leakage from the Replace solenoid valve. solenoid valve (5b, fig. 10). 3. Excessive leakage from Replace trailer brake auxiliary contrailer brake control valve (7). trol valve.
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
12
CHECKING THAT TRAILER BRAKE RELEASE PRESSURE IS NULLIFIED WHEN THE PARKING BRAKE IS APPLIED
Proceed as follows:
1
1. Insert union 293190 (1) in the trailer brake coupling and connect to the pressure gauge with scale 0 ÷ 40 kg/cm2 from kit 380000240. 2. With the engine and the oil in the test conditions described at the beginning of the chapter, fully pull the parking brake lever (1, fig. 10). 3. Check that the pressure is 0 bar and that warning light (22, fig. 10) is ON. 4. With the parking brake applied, disconnect the pressure gauge and union 293190 (1).
26431
14
TROUBLESHOOTING
Problems When the parking brake is applied the trailer brake release pressure is i nott nullified. llifi d
Possible causes
Solutions
1. Parking brake switch (21, Replace switch. fig. 10) 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.
CHECK CALIBRATION ON SWITCHES (8 and 16, fig. 10).
Proceed as follows: 1. Insert union 293190 (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). 4. Apply the parking brake and disconnect the pressure gauge and union 293190 (1).
1
26431
15
TROUBLESHOOTING
Problems
Possible causes
On carrying out the operation de- 1. Trailer brake circuit safety scribed above, the trailer brake switch (8, fig. 10) setting release pressure is nullified perhigher than the nominal manently. pressure (3 ± 0.5 bar). y 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.
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
1
SECTION 35 -- HYDRAULIC SYSTEMS Chapter 5 -- Supplementary cylinder CONTENT Description
Page
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Supplementary cylinder R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Supplementary cylinder D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
single--acting
Amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
n
1 or 2
Rod diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
50
Rod stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
150
1
2
3
4
26521
1 Cross--sectional view of supplementary cylinder 1. 2.
Supplementary cylinder body. Link Rod.
3. 4.
Seal. Dust Seal.
DESCRIPTION AND OPERATION In order to increase the lifting power a supplementary hydraulic cylinder can be connected to the right--hand arm of the lift, pivoting on a support fitted on the right--hand final drive casing.
The single--acting supplementary cylinder is controlled by the oil from the lift control valve, which also acts on the lift internal cylinder.
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
2
SUPPLEMENTARY CYLINDER R.I.
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 supplementary cylinder, proceed as follows. 1. Raise the bonnet. 2. Detach negative lead (1) from battery and insulate. 3. Fully lower the lift arms. 4. Unscrew the three pivot support (5, fig. 3) retaining nuts, secured to the right--hand final drive. 5. Remove the support (5), snap ring (2) and washer (3) from the pin (1) installed on the lift arm. 6. Disconnect the oil delivery line (6) and remove the supplementary cylinder (4).
2
1
7. To refit the supplementary cylinder follow the disassembly operations in reverse order.
2 3
SUPPLEMENTARY CYLINDER D.A.
4
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 disassemble the supplementary cylinder, proceed as follows 1. Extract the rod (2, fig. 1) from the supplementary cylinder and check that it is not deformed or scored. 2. Check the seal (3, fig. 1) and the dust seal (4), and replace if necessary. 3. Lubricate the three parts with the correct oil and insert in the rod (2).
87679925A - 12 - 2007
6
5
26522
3
CONTENTS
1
CONTENTS VOLUME 2 Page
Date
Page
Date
CHAPTER 7 -- Ventral control valves for Walvoil--type open centre system
35 -- HYDRAULIC SYSTEMS CHAPTER 6 -- Electronic Lift Summary . . . . . . . . . . . . . . . 1
11--07
Precautions . . . . . . . . . . . . . 2
11--07
Main Data . . . . . . . . . . . . . . 2÷4
02--10
Torque Specifications . . . . 5
11--07
Special Tools . . . . . . . . . . . 5
11--07
View of electronic lift components . . . . . . . . . . . . . . . . 6
11--07
Electronic lift control layout 7--8
11--07
Description and operation . 9÷11
11--07
Work . . . . . . . . . . . . . . . . . . 12--13
11--07
Hydraulic system lift restoration . . . . . . . . . . . . . . . . . . 14
11--07
Summary . . . . . . . . . . . . . . . 1 Ventral control valve specifications . . . . . . . . . . . . . . . 2 Torque Specifications . . . . 3--4 Ventral control valve version with normal pump . . . 5÷7 Ventral control valve and flow increase control valve version with 80 litre pump . 8÷12 General hydraulic circuit . . 13÷17 Assembly of ventral control valve and flow increase control valve . . . . . . . . . . . . 18 Ventral control valve joystick . . . . . . . . . . . . . . . . . . . . 19--20 2° control valve regenerating function disabling bush 21 Description and operation of ventral control valve . . . 22÷30
Anti--damping device for implements carried on the lift . . . . . . . . . . . . . . . . . . . . . 14
11--07
Description and operation . 15÷17
11--07
Lift fault codes . . . . . . . . . . 18
11--07
CHAPTER 8 -- Front Loader
List of codes . . . . . . . . . . . . 19--20
02--10
Calibrations . . . . . . . . . . . . . 21
11--07
HH MENU access . . . . . . . 21--22
11--07
Lift calibration
23÷26
11--07
Lift electronic control unit . 27÷29
11--07
Removal--Installation -- lift control mouse . . . . . . . . . . . 30--31
11--07
Summary . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . Maximum permissible front axle weights . . . . . . . . . . . . Torque Specifications . . . . Diagrams . . . . . . . . . . . . . . . Ventral control valve specifications . . . . . . . . . . . . . . . . Ventral control valve joystick . . . . . . . . . . . . . . . . . . . . System switching full and dipped beam headlights on lights fitted on handrails . . Ballasting the tractor for front loader operation . . . . Loader general description
Removal--Installation -setting potentiometers panel . . . . . . . . . . . . . . . . . . 32--33
11--07
Lift arm potentiometer replacement . . . . . . . . . . . . . . 34
11--07
Removal --Installation -draft sensor . . . . . . . . . . . . . 35--36
11--07
Removal--Installation -electronic lift . . . . . . . . . . . . 37÷42
11--07
Removal--Installation -- hydraulic control valve . . . . . . 43--44
11--07
(*)Chapters
02--10 02--10 11--07 11--07 11--07 02--10
11--07 11--07 11--07
1 2--3
02--08 02--08
3 4 5÷9
02--10 02--10 02--08
10--11
02--08
12÷14
02--08
15÷16
02--08
17 18÷27
02--08 02--08
prior to section 35 are in volume 1.
87679925A2 --02 --2010
CONTENTS
2 Page
Date
Loader installation -- removal . . . . . . . . . . . . . . . . . . 28÷32
02--08
Implement installation -- removal . . . . . . . . . . . . . . . . . . 33÷36
02--08
Lift arm types and functions 37÷45
02--08
Smooth Ride control . . . . . 46÷48
02--08
Multi Quick coupler connection -- disconnection . . 49÷60
02--08
Hydraulic functions and flow diagram of loaders . . . 61÷71
02--08
Hydraulic Flow Diagrams . 72÷88
02--08
Repair instructions . . . . . . . 89÷94
02--08
Hydraulic components . . . 95÷99
02--08
Fault diagnosis . . . . . . . . . . 100÷105
02--08
Page Disassembly -- Assembly of hydraulic pump to replace seal kit . . . . . . . . . . . . 35 Removal--Installation -steering cylinder . . . . . . . . . 36÷38
Summary . . . . . . . . . . . . . . . 1
11--07
Main Data . . . . . . . . . . . . . . 2÷4
11--07
Torque Specifications . . . . 4
11--07
View of hydraulic pump components . . . . . . . . . . . . 5
11--07
50 -- SUBSIDIARY PARTS
View of hydrostatic steering control valve components . . . . . . . . . . . . . . . . . . 6
11--07
Description and operation . 7÷10
11--07
Fault diagnosis . . . . . . . . . . 11--12
11--07
Special Tools . . . . . . . . . . . 12
11--07
Removal--Installation -- hydrostatic steering control valve . . . . . . . . . . . . . . . . . . 13÷17
11--07
Disassembly--Assembly -hydrostatic control valve . . 18÷31
02--10
Hydrostatic steering control valve bench testing . . . 32--33
11--07
Pressure relief valve testing . . . . . . . . . . . . . . . . . . . . 33
11--07
Power steering pump components . . . . . . . . . . . . . . . . 34--35
11--07
Disassembly -- Assembly of hydraulic pump to replace seal kit . . . . . . . . . . . . 35
87679925A2 --02 --2010
11--07
11--07 11--07
44 -- AXLES AND WHEELS Summary . . . . . . . . . . . . . . . Main Data . . . . . . . . . . . . . . Front wheel track diagram Sections . . . . . . . . . . . . . . . Torque Specifications . . . . Special Tools . . . . . . . . . . . Fault diagnosis . . . . . . . . . . Disassembly--Assembly -wheel axle hub . . . . . . . . . . Removal--Installation -front axle . . . . . . . . . . . . . . . Stub axle hub overhaul . . . Checking leading wheel alignment . . . . . . . . . . . . . .
41 -- STEERING
Date
Summary . . . . . . . . . . . . . . . Safety regulations . . . . . . . Main Data . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . Operating principles . . . . . Conditioning system components . . . . . . . . . . . . . . . . Warnings for air conditioning system repair operations . . . . . . . . . . . . . . . . . . . Cab controls . . . . . . . . . . . . Instructions for use -- air conditioning system . . . . . . Air--conditioning system charging and evacuation recovery/recycling station . Leak detector . . . . . . . . . . . Air conditioning system maintenance . . . . . . . . . . . . Troubleshooting . . . . . . . . . Fault diagnosis . . . . . . . . . . System functional testing .
1 1 2 3 4--5 5 5
11--07 11--07 11--07 11--07 11--07 11--07 11--07
6÷8
11--07
9÷11 12÷14
11--07 11--07
15--16
11--07
1 2 3--4 4 5--6
11--07 11--07 11--07 11--07 11--07
7÷11
11--07
11 12÷14
11--07 11--07
15
11--07
15 16
11--07 11--07
17 18 19÷22 23
11--07 11--07 11--07 11--07
CONTENTS Page
Date
Checking for and eliminating gas leaks . . . . . . . . . . . 24
11--07
Compressor drive belt tension adjustment . . . . . . . . . 25--26
11--07
Removal--Installation -compressor . . . . . . . . . . . . . 27÷30
11--07
Heating systems piping replacement . . . . . . . . . . . . . . 31--32
11--07
Air conditioning piping replacement . . . . . . . . . . . . . . 33÷38
11--07
Condenser replacement
11--07
39
Dryer filter replacement . . 40--41
11--07
Removal--Installation -heater unit . . . . . . . . . . . . . . 42÷44
11--07
Replacing the air--conditioner evaporator . . . . . . . . 45÷47
11--07
Removal--Installation -electric fan . . . . . . . . . . . . . 48--49
11--07
55 -- ELECTRICAL SYSTEM
3 Page
Service . . . . . . . . . . . . . . . . 18--19
Date 11--07
CHAPTER 3 -- Starting system Summary . . . . . . . . . . . . . . . 1
02--10
Technical data . . . . . . . . . . 1
02--10
Torque Specifications . . . . 1
02--10
Description and operation . 2
02--10
Starter and recharging circuit, manual transmissions 3--4
02--08
Fault diagnosis . . . . . . . . . . 5
02--08
Starter and recharging circuit, Power Shuttle transmissions . . . . . . . . . . . . . . . 6--7
02--08
Fault diagnosis . . . . . . . . . . 8
02--08
System testing . . . . . . . . . . 9+11
02--08
Starter motor removal-installation . . . . . . . . . . . . . . 11+13
02--08
CHAPTER 4 -- Charging system
CHAPTER 1 -- Instruments
Summary . . . . . . . . . . . . . . . 1
02--08
Summary . . . . . . . . . . . . . . . 1
11--07
Technical data . . . . . . . . . . 1
02--08
Control panel . . . . . . . . . . . 2--3
11--07
Torque Specifications . . . . 1
02--08
Analog/digital instruments
11--07
Description and operation . 2--3
02--08
11--07
System testing and fault description . . . . . . . . . . . . . . . . 4--5
02--08
Removal and Installation -alternator . . . . . . . . . . . . . . . 6--7
02--08
4
Liquid crystal display . . . . . 5--6 Resetting the hours worked setting . . . . . . . . . . . . . . . . . 6÷8 Access to the setup menu via keypad . . . . . . . . . . . . . . 9÷17
11--07
Calling up functions from keypad . . . . . . . . . . . . . . . . . 18÷21
11--07
Access to the setup menu with the CAL button . . . . . . 21--22
11--07
Calling up functions with the CAL button . . . . . . . . . . 22
11--07
CHAPTER 2 -- Controls
CHAPTER 5 -- Battery Summary . . . . . . . . . . . . . . . 1
02--10
Technical data . . . . . . . . . . 1
02--10
Description and operation . 1
02--10
Removal and Installation -battery . . . . . . . . . . . . . . . . . 2
02--10
Battery testing and charging procedure . . . . . . . . . . . 3+13
02--08
Summary . . . . . . . . . . . . . . . 1
11--07
Introduction . . . . . . . . . . . . . 1
11--07
Dashboard controls . . . . . . 2÷9
11--07
Controls on right--hand mudguard . . . . . . . . . . . . . . 9÷12
Summary . . . . . . . . . . . . . . . 1
02--10
11--07
Maxi power fuses box . . . . 2+4
02--08
In--Cab Controls . . . . . . . . . 12÷14
11--07
Location of fuses and relays . . . . . . . . . . . . . . . . . . . 5+29
02--08
CHAPTER 6 -- Electrical circuits
Controls on right--hand cab upright . . . . . . . . . . . . . . . . . 15--16
11--07
Power sockets . . . . . . . . . . 30--31
02--08
External controls . . . . . . . . 17
11--07
Inlet Grid Heater . . . . . . . . . 31
02--08
87679925A2 --02 --2010
CONTENTS
4 Page
Date
Electronic flasher module . 32
02--08
Ground location points . . . 32--33
11--07
How to use the wiring diagrams . . . . . . . . . . . . . . . . . . 34+36
11--07
Symbols used in electrical circuits . . . . . . . . . . . . . . . . . 37
11--07
Wiring diagram components . . . . . . . . . . . . . . . . . . 38+44
02--10
Version index . . . . . . . . . . . 45
11--07
Version with Power Shuttle and electronic lift . . . . . . . . 47+90
02--10
Standard version (Cab version) . . . . . . . . . . . . . . . . . . . 91+128
02--10
Version with ISO Power Shuttle -- (Deck version) . . 129+158
02--10
Standard ISO version (Deck version) . . . . . . . . . . 159+186
02--10
Version with Power Shuttle for North America -- (Deck version) . . . . . . . . . . . . . . . . 187+216
02--10
Standard version for North America -- (Deck version) 217+243
02--10
Version A -- Front loader circuit TL series . . . . . . . . . . . 244--245 Version B -- Electronic battery cut--off circuit 246--247
02--10
Electronic control unit input/ output wiring diagram . . . . 248+254
02--10
87679925A2 --02 --2010
02--10
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
1
SECTION 35 -- HYDRAULIC SYSTEMS Chapter 6 -- Electronically controlled hydraulic lift CONTENT Description
Page
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Details of electronic lift components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 EDC control mouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Setting potentiometers panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Indicator light panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Position, draft and float mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Lift restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Smooth ride device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Electronically controlled lift functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Lift fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Lift, transmission and services electronic control centre -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 EDC control mouse indicator panel and ceiling light R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Setting potentiometers panel R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Lift arm potentiometer -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Draft sensor R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Electronic draft control R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Hydraulic control valve R. I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
2
ATTENTION Observe the following precautions when carrying out arc welding on a tractor fitted with an electronic lift. •
•
Where possible, remove the part or tool that requires arc welding from the tractor. Disconnect both battery leads. Isolate the cable ends to avoid contact with each other and the tractor.
•
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.
ELECTRONICALLY CONTROLLED HYDRAULIC LIFT DATA
MDM903A
4
1
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
Type . . . . . . . . . . . . . . . . . . . . . . . . Functional check . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . .
Ground position control
3
with controlled position/draft and float setting via the transmission and services electronic control unit located under the panel. 1. Electronic lift mouse, contains: position lever draft ring knurled wheel controlling lever stop in position lift/lower/fast ground entry button (Lift --o--Matic) 2. LED panel, with lifting indicator light lowering indicator light lift disabled / failure warning light slip indicator light 3. Potentiometers panel, with lifting limit down speed sensitivity Slip limit by means of two push--buttons (4) fitted on the rear mudguards
Diameter of arm lifting shaft 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
55.100 ÷ 55.184 (1)
--
left--hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 relative 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.
87679925A2 - 02 - 2010
SEZIONE 35 -- IMPIANTI IDRAULICI -- CAPITOLO 6
4
MAIN SPECIFICATIONS OF IMPLEMENT HITCHING DEVICE
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
three--point linkage 2nd
Category: Draft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of lower arms with draft sensors
Maximum load that can be lifted with vertical rods pivoting in the rear hole of the horizontal arms and three--point linkage connected to upper hole of top link, with working pressure at 90% maximum pressure: -------
at link ends of horizontal arms . . . . . . . . . . . . . . . . . . . . . . . . . . mod. 56/76 and 63/86 KW/HP (with additional jack) . . . . . . . . mod. 71/9, 78/106 and 83/113 KW/HP (with two additional struts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with centre of gravity at 610 mm from link ends: . . . . . . . . . . . mod. 56/76 and 63/86 KW/HP (with additional jack) . . . . . . . . mod. 71/97, 78/106 and 83/113 KW/HP (with two additional struts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
kg kg
2780 3950
kg kg kg
4690 2790 3150
kg
3450
kg kg
3860 4800
kg kg kg
5740 3510 4360
kg
5210
Maximum load that can be lifted with vertical rods pivoting in the rear hole of the horizontal arms and three--point linkage connected to upper hole of top link, with maximum working pressure: -------
at link ends of horizontal arms . . . . . . . . . . . . . . . . . . . . . . . . . . mod. 56/76 and 63/86 KW/HP (with additional jack) . . . . . . . . mod. 71/97, 78/106 and 83/113 KW/HP (with two additional struts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with centre of gravity at 610 mm from link ends: . . . . . . . . . . . mod. 56/76 and 63/86 KW/HP (with additional jack) . . . . . . . . mod. 71/97, 78/106 and 83/113 KW/HP (with two additional struts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87679925A2 - 02 - 2010
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
5
BOLT TORQUES Tightening torque PARTS TO BE TIGHTENED Thread
Nm
kgm
Bolts securing front cover to lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M8x1.25
26
2.7
Cylinder safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M20x1.5
83
8.5
Lift
Lift cylinder retaining bolts: --
front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M14x1.5
157
16
--
upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M16x1.5
260
26.5
Limiter stabiliser strut support retaining bolts . . . . . . . . . . . . . . . . . . . .
M16x1.5
221
22.5
Towing hook support retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M16x1.5
221
22.5
Three point hitch assembly
SPECIAL TOOLS
CAUTION The operations described in this section can only be carried out with the 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.
380000238
Bracket to raise hydraulic lift.
X 380000225
Ring for fitting piston with lift seals.
X 380000262
Punch for fitting lift arm shaft seal.
X 380000230
Wrench for cylinder safety valve setting ring nut.
X 380000231
Wrench for lift pressure relief setting ring nut.
X 380000240
Universal pressure control kit.
X 380000215
Hand pump for valve calibration.
X 380000218
Union for cylinder safety valve calibration.
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
6
25951
2 View of electronic lift components 1. 2. 3. 4. 5.
Hydraulic control valve. Spacer for hydraulic control valve. Right--hand side bushing. Lift body. Left--hand bushings.
87679925A - 12 - 2007
6. 7. 8. 9.
Lift arm position potentiometer. Cylinder safety valve. Lift cylinder control internal line. Cover.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
7
13
MDM911A
3 Electronic lift controls positions 1. 2. 3. 4. 5. 6. 7.
Position control lever. Draft control ring. Lift, lower, fast ground entry button (Lift o Matic). Position lever bottom limit setting wheel. Sensitivity setting potentiometer. Descent speed setting potentiometer. Lifting limit setting potentiometer.
8.
Slip limit setting potentiometer.
9.
Slip lamp.
10. Lift disabled and failure warning light. 11. Arms lifting warning light. 12. Arms lowering warning light. 13. Raise and lower switches on mudguards.
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
8
MDF1521A
MDM884A
4 Location of radar, control valve and draft sensors 1. 2.
Radar. Hydraulic control valve.
87679925A - 12 - 2007
3. 4.
Position reading sensor. Draft sensor (one on each side).
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
9
EDC CONTROL MOUSE -- Position control lever The position control lever (1) is used to determine the position of the lift arms. Move the lever fully forwards for the greatest depth or fully backwards to raise the lift arms completely.
-- Draft control ring The draft control ring (1) is used to set a force of traction. The ring is marked with a scale from 0 to 10. Select 10 for the maximum draft resistance (working in position) and 0 for the minimum draft resistance.
5
6 --
Lift, lower, fast ground entry button (Lift o Matic) The Lift o Matic button (1) is used to raise and lower the lift during headland operations without touching the position lever. The second position at the bottom is used for fast ground entry: keep the button in this position if you want the implement to penetrate into the ground in less space, that is without reading the draft that would normally tend to raise the implement.
-- Position lever adjustment knob Moving the ring (1) sets the position of the limit stop (2). The limit stop determines a maximum depth of the position lever (1, fig. 5).
7
8 87679925A - 12 - 2007
10
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
SETTING POTENTIOMETERS PANEL -- Sensitivity adjustment potentiometer It enables adjusting the sensitivity of the lift, turned fully clockwise there is the greatest sensitivity, the lift reacts by raising the arms with a minimum change in draft. Turned fully clockwise there is the least sensitivity, the lift reacts after a much greater change in draft.
-- Lowering speed adjustment potentiometer There is the greatest speed with the potentiometer turned fully clockwise. Turned fully anticlockwise there is the lowest speed, with the potentiometer in the padlock position there is no lowering. This condition is considered transport safety; with the lift raised during transport, set the potentiometer on the padlock to be certain that it will not accidentally lower.
9
10 -- Height Limit Pot With the potentiometer turned fully clockwise there is no height limit, turned fully anticlockwise the height reached by the lift arms is limited. Use this potentiometer to limit the height when using implements with the PTO shaft, preventing it from getting damaged, or when using implements that, with the lift arms fully up, interfere with the cab windows.
-- Slip limit setting potentiometer With this potentiometer it is possible to set a slip percentage above which the system will raise the lift arms to decrease the draft and thus come back within the set percentage. This potentiometer is associated with the radar.
11
12 87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
11
INDICATOR LIGHT PANEL -- Slip lamp The slip limit lamp is associated with the optional radar and the slip control potentiometer (1, fig. 12). this lamp comes on when the slip percentage is exceeded and the lift raises the arms to decrease the draft, thus coming back within the set percentage.
13 -- Lift disabled / failure warning light When this light comes on it can mean two things: A when the lamp blinks it means that the control unit has detected a fault in the liftâ&#x20AC;&#x2122;s electronic control system and the dot--matrix display shows the fault code. B when it lights up steady, it means that the lift is not enabled, that is the cab controls do not mirror the position of the lift arms and so it is not possible to operate the lift directly with the position lever.
14 -- Arms lifting and lowering warning lights The lifting (2) and lowering (1) warning lights are mounted in parallel with the respective solenoid valves so they signal the actual lifting and lowering of the lift arms.
15
87679925A - 12 - 2007
12
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6 POSITION MODE
When working in position mode the implement keeps the height determined by the position lever and is not affected by the force of traction. Set the draft adjustment ring (1) onto 10 and as a result the system will not read the force of traction. Use the position lever (2) to find the desired height. At the headland, use the Lift o Matic button to raise the implement without using the position lever. After repositioning the tractor, press the Lift o Matic button down to enter the ground.
16
DRAFT MODE When working in draft mode (letâ&#x20AC;&#x2122;s take ploughing as an example), the implement keeps the depth determined by the position lever but the system gives priority to the force of traction; if this, set with the ring (1, fig. 16), exceeds the setting, the system will raise the arms to find a lower draft value, making the value come back within the setting. Initially, set the draft adjustment ring (1, fig. 16) onto 10. Use the position lever (2, fig. 16) to find the working depth. Now set the draft with the ring (1, fig. 16) until the system starts raising the arms, then set the draft on the value immediately lower. When working in draft mode, the central display will show the letters dr (draft). The work will now be done at the depth set with the lever (2, fig. 16) and at the draft set with the ring (1, fig. 16). In the same way, if the draft decreases the system will tend to lower the arms to find a greater draft. This situation of the implement entering the ground will be prevented by the position lever that will not allow a greater working depth than the setting. This mode is usually called mixed.
87679925A - 12 - 2007
17
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
13
If the system calls up the lift too often, it causes too great a change in the soil, making it difficult to drive the tractor because of the jolting with the arms being operated. It is possible to use the sensitivity potentiometer (1, fig. 18) to select a lower sensitivity so as to call up the lift with greater changes in draft. At the headland, use the Lift o Matic button to raise the implement without using the position knob. After repositioning the tractor, press the Lift o Matic button fully down (fast ground entry) to enter the ground without the system, during lowering, failing to read the draft, for ground entry in less space. 18
FLOAT MODE Working in float is done with implements that follow the contours of the ground with wheels, rollers or runners. Set the draft adjustment ring (1, fig. 19) on 10 and as a result the system will not read the force of traction. Move the position lever (2, fig. 19) fully forwards onto position 0 (the lift arms completely lowered). At the headland, use the Lift o Matic button to raise the implement without using the position lever. After repositioning the tractor, press the Lift o Matic button down to lower it. 19 NOTE: In the above--described working modes, the following potentiometers can intervene: descent speed limit (1, fig. 10) during transport, using it for transport safety, lift limit (1, fig. 11) when working with implements at the PTO to avoid damaging the cardan shaft or when working with reversible ploughs to prevent them interfering with the rear cab window, slip percentage (1, fig. 12) when working on slippery ground.
87679925A - 12 - 2007
14
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6 LIFT RESTORATION
Every time: -- you use the external raise lower buttons on the mudguards, -- with the engine switched off, move the lift position control lever the disabled lift warning light (1) will come on.
To put the lift arms back in phase with the position lever it is necessary (clearly with the engine running) to move the lever forwards or backwards until the lift arms move and the related warning light goes out.
20
21
SMOOTH RIDE DEVICE When transporting equipment implement bounce can lead to lack of steering control at speeds. By turning the drop rate control (1) fully anti--clockwise (onto the padlock position) and using the raise lower and fast ground entry button (3, fig. 19) to raise the implement, the smooth ride device comes into operation. The smooth ride device comes into operation above 8 km/h (5 MPH): when the speed is higher than this, the lift lowers by a minimum percentage and the system uses the lifting and lowering solenoid valves to counter the swings. If the speed falls under this value, the lift raises to the maximum height set with the lift limit potentiometer (1, fig. 11).
87679925A - 12 - 2007
22
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
15
1
2
3
4
5
6
7
14
13
12
11
10
9
8
MDE0628A
1. 2. 3. 4. 5. 6. 7.
Electronically controlled lift functional diagram. Neutral phase Lowering solenoid valve. 8. Pressure compensator valve. Lowering control valve fixed seat. 9. Excess pressure discharge chamber. Discharge compartment. 10. Oil coming from the pump. Lowering control valve actuator. 11. Lifting control valve. Lowering control valve. 12. Valve calibration spring (11). Lowering control valve compartment. 13. Non--return valve. To lifting cylinder. 14. Lifting control solenoid valve.
23
Oil at static rest. Pressurised oil. Discharge oil.
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. The cylinder safety valve is on line (7) with the function of absorbing abnormal peaks in pressure.
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
16
1
2
3
4
5
6
7
14
13
12
11
10
9
8
MDE0629A
1. 2. 3. 4. 5. 6. 7.
Electronically controlled lift functional diagram. Lifting phase Lowering solenoid valve. 8. Pressure compensator valve. Lowering control valve fixed seat. 9. Excess pressure discharge chamber. Discharge compartment. 10. Oil coming from the pump. Lowering control valve actuator. 11. Lifting control valve. Lowering control valve. 12. Valve calibration spring (11). Lowering control valve compartment. 13. Non--return valve. To lifting cylinder. 14. Lifting solenoid valve.
24
Pressurised oil. Discharge oil.
DESCRIPTION AND OPERATION Lifting phase The solenoid valve (14) overcomes the resistance of the spring (12) and moves the lifting control valve (11).
87679925A - 12 - 2007
Under these conditions, the oil from pump (10) can flow 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).
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
17
1
2
3
4
5
6
7
14
13
12
11
10
9
8
MDE0630A
25 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, initially, moves the actuator
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.
(4) inside the lowering valve (5). This allows the oil from chamber (6) to discharge through chamber that will open between the lowering valve (5) and the actuator (4). When the actuator reaches the limit stop of the lowering valve, this moves and the oil comes out of the cylinder and discharges through the line (3). The extent of the lowering of the lowering valve is determined by the adjustment of the descent speed potentiometer.
87679925A - 12 - 2007
18
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
LIFT FAULT CODES The fault codes are shown on the dot--matrix display (1) of the analog--digital control panel (ADIC) and on the lower central display (2).
The disabling errors will be shown on the dot--matrix display of the control panel and will be visible for the driver.
26
27 Hidden and saved fault codes can be displayed by using the fault diagnosis mode of the “H” menus and are not visible for the driver. The “H” menu diagnostic mode can be used to access and clear the fault codes which may be stored in the various controllers. The H--menu diagnostic mode also contains many other useful functions which may be used to assist with diagnostics.
Lift arms position display The position of the lift arms is shown on the central display of the analog--digital control panel (ADIC). The position of the arms is given on a scale from 0 to 99, 0 indicates that the arms are completely lowered and 99 that they are completely raised.
28
29 87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
19
LIST OF ELECTRONIC LIFT ERROR CODES FAULT CODE 1002
Description of Fault Radar signal not present
E.C.R. (*) YES
1003
Speed sensor signal not present
YES
1004
Speed sensor signal too High
YES
1006
Slip control potentiometer signal too low
YES
1007
Slip control potentiometer signal too high
YES
1008
Raise / work switch failure
YES
1009
Both ext. sw. operated same time
YES
1010
Height limit pot signal too low
YES
1011
Height limit pot signal too high
YES
1012
Drop rate pot signal too low
YES
1013
Drop rate pot signal too high
YES
1014
R/H load sensing pin signal too low
YES
1015
R/H load sensing pin signal too high
YES
1016
L/H load sensing pin signal too low
YES
1017
L/H load sensing pin signal too high
YES
1018
Both load sensing pin disconnected
YES
1019
Load sensing pin voltage too low
YES
1020
Load sensing pin voltage too high
YES
1021
Sensitivity control potentiometer signal too low
YES
1022
Sensitivity control potentiometer signal too high
YES
1023
Control panel disconnected
YES
1024
Perform the hydraulic lift calibration procedure
NO
1025
Position control potentiometer control voltage too low
YES
1026
Position control potentiometer control voltage too high
YES
1027
Lift arm position sensing control voltage low
YES
1028
Lift arm position sensing control voltage high
YES
1029
Hydraulic control valve disconnected
YES
1030
Break in the ground circuit
YES
1031
Chassis harness disconnected
YES
1032
Draft control potentiometer control voltage high
YES
1033
Draft control potentiometer control voltage low
YES
1049
Wheel speed sensor open or short circuit
YES
1053
Controller 5 Volt reference shorted to positive voltage
YES
1054
Controller 5 Volt reference short to ground
YES
1059
Reference voltage to 8 volt load sensing pins, too high (> +9V), too low (< +7V)
YES
87679925A2 - 02 - 2010
SEZIONE 35 -- IMPIANTI IDRAULICI -- CAPITOLO 6
20
1063
EDC hydraulic valve lower solenoid open circuit
YES
1064
EDC hydraulic valve raise solenoid open circuit
YES
1065
EDC Hydraulic valve lower solenoid short circuit
YES
1066
EDC Hydraulic valve raise solenoid short circuit
YES
1067
EDC control valve supply voltage low
YES
1068
Height limit calibration error
YES
1069
Slip control configuration error
NO
(*) Enter the HH programs of the control panel select the H3 program, enter the ECR, then select the options: E -- show only severe codes, F -- show all codes for 6 minutes of power then pass to â&#x20AC;&#x153;Eâ&#x20AC;?. With option E selected, the word: YES -- means that the code will not be shown on the display but only kept in memory, NO -- means the code will not be shown on the display. NOTE: For resolution of the error codes, refer to Section 55, Chapter 9.
87679925A2 - 02 - 2010
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
21
CALIBRATIONS Fault codes If the Faults Detection Logic reads a fault condition, the code will flash on the information monitor. In this manner, the fault condition can be displayed whilst in HH mode. During calibration, certain faults may be masked.
ATTENTION
1024
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.
30
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. Check that the transmission oil temperature is between 20 á 50 °C. Unless otherwise specified, the levers: - Shuttle control; - gear control; - range gear control; - creeper lever; are in the NEUTRAL position.
HH MENU ACCESS 1. Turn the starter switch (1, fig. 32) to A (OFF) and connect the tool 380000843 (2) to the diagnostics socket (1).
31
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22
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
2. Turn the starter switch (1) to B, the information monitor will show HH MENU plus HO, or HP, or RJ, or JB; two arrows are displayed at the bottom showing the possibility of passing from one option to another. HP = Standard control panel. HO= Advanced control panel. RJ = Transmission, Differential Lock, Four--Wheel Drive, Power Take--Off and Electronic Lift (EDC). JB = Advanced keypad. MDB1669A
32
3. By using the clock adjustment buttons: minutes adjustment (1) and hours adjustment (2) it is possible to pass between the options.
0 x100
1 3
2
33 4. Select the HH menu of the control unit RJ by pressing the push--button (3, fig. 33) and access the sub--system, using the clock adjustment buttons: minutes adjustment (1) or hours adjustment (2) it is possible to access the H1 menu of the control unit RJ of the gearbox, then pressing the push--button (3, fig. 33) to go into calibration.
5. The menu of the selected control unit appears on the information monitor. If the control unit gives a negative response to the ADIC message for menu access the attention sign will appear, in this case you need to turn the switch (1, fig. 32) to A (OFF) and repeat the HH MENU access procedure after checking the supply and connection of the relevant control unit are correct. A. -- Correct access. B. -- Module responds incorrectly.
HHMENU RJ
RJ H1
RJ H1
34
RJ HH
HHMENU
A
B 35
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
23
CALIBRATION H1 MENU LIFT ----
--
--
Pre--Test Procedure. Apply a weight of approx. 200 kg to the lift arms. Lower lift arms and disconnect vertical rods supporting the automatic pick--up hitch (where fitted). Turn all the potentiometers for setting sensitivity, speed, arm height and slip clockwise.
36
Set the draft control ring (1) onto 10 (during the calibrations the system must not read the draft).
37 Arm position control potentiometer calibration. Access the HH MENU RJ as described on page 21 and proceed as follows. -- Select the H1 MENU with buttons (1) and (2), press key (3) to access the above--mentioned H1 MENU. 1. Press the clutch pedal, start up the engine and take it to a speed of 1200 รท 1400 rev/min.
0 x100
1 3
2
38 NOTE: The potentiometer can also be calibrated without the tool 380000843, simply keep the lift, lower, rapid ground entry button (1, fig. 39) pressed on lifting, start the machine and, when the lift status indicator light (1, fig. 40.) blinks, release the push--button.
39 87679925A - 12 - 2007
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
NOTE: There will be no message on the display, the only thing that will occur on entering calibration with the push--button (1, fig. 39) is the blinking of the warning light and....
40
NOTE: ......the performance monitor will show the fault code 1024 (run hydraulic lift auto--calibration). After potentiometer calibration, in this last case it is obviously necessary to calibrate the solenoid valves too.
1024
41 2. Using the position lever, capture the lift arms then move it fully backwards. When the lift arms stop rising (you will hear the pressure relief valve trip for a moment) the value of the potentiometer is taken as the top calibration limit. The arms will lower slightly by approximately 4% to protect the casing from mechanical damage. This position will be 96% of the travel, but it is considered to be 100%.
3. Move the position lever fully forwards, when the arms stop lowering the value of the arms control potentiometer is taken as the lower value.
42
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
25
4. After calibrating turn the switch (1) to A (OFF) to save the calibrations.
MD1669A
44
Solenoid valve calibration Access the HH MENU RJ as described on page 21 and proceed as follows. -- Select the H1 MENU with buttons (1) and (2), press key (3) to access the above--mentioned H1 MENU. -- Press the clutch pedal, start up the engine and take it to a speed of 1200 รท 1400 rev/min;
0 x100
1 3
2
45 NOTE: The solenoid valves can also be calibrated without the tool 380000843, simply keep the lift, lower, rapid ground entry button (1, fig. 46) pressed fully down, and in this condition start the machine and, when the lift status indicator light (1, fig. 40.) blinks, release the push--button.
46
5. The central display will show CAL.
RJ
H1
CAL
47 87679925A - 12 - 2007
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
6. Using the position lever, capture the lift arms then move it fully backwards between 70% and 90% of the travel.
7. On the central display CAL will show 0 to indicate the start of calibration. During calibration the lift is automatically raised and lowered by a small amount 3 times, which takes 2--3 minutes. Each lifting and lowering is counted 0 -- 1 -- 2 on the central display. When the display shows End calibration is over.
80
48
CAL
0 1
2
End 49
8. After calibrating turn the switch (1) to A (OFF) to save the calibrations.
MDB1669A
50 NOTE: For the to calibrations of the lift it is advisable to calibrate the arms position control potentiometer and afterwards, without exiting calibration, calibrate the solenoid valves. Enter calibration either with program H1 of menu HH, or with button (1, fig. 46) pressed on rapid ground entry (fully down), then calibrate the lift by following the operations: -- 5, the one that appears on the central display, -- 1, 2, 3 and 4 to calibrate the arms lift potentiometer, -- 6, 7 and 8 to calibrate the solenoid valves.
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
27
TRANSMISSION, LIFT AND SERVICES ELECTRONIC CONTROL UNIT Renew
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. Disconnect and isolate the battery negative lead. 2. Take off the two knobs and remove the guard mounted under the panel on both sides.
51 3. Pressing upwards from under the panel, remove the keypad on the right--hand side of the steering column, disconnect it from the electrical system.
52 4. Pressing upwards from under the panel, remove the switch assembly (1) on the left--hand side of the steering column, disconnect it from the electrical system.
53
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
5. Take out the panel retaining bolts (1), both on the outside and the bolt inside the two slots housing the keypad and the switch assembly.
6. Take out the bolt on the left--hand side and on the right--hand side retaining the panel (1) under the panel at the front.
54
55 7. Lift the panel without removing the ADIC instrument and disconnect the latterâ&#x20AC;&#x2122;s connections.
8. Take out the two bolts retaining the panel (1) then remove it.
56
57 87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
29
9. Take out the Allen screws retaining the control unit (1) then disconnect it from the electrical system.
58 10. For reassembly, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Connect the electrical connections of the control unit then secure it to the support using the bolts.
--
Mount the front panel with the two bolts on the back.
--
Mount the panel together with the ADIC instrument, connect the latterâ&#x20AC;&#x2122;s connections, screw down all the retaining bolts on the panel and the two side ones on the panel under the panel at the front.
--
Refit the switch assembly on the left--hand side of the steering column and connect the push--button connectors.
--
Refit the keypad on the right--hand side of the steering column and connect it to the electrical system.
--
Refit the two right-- and left--hand panels under the instrument panel and secure it with the relevant knobs.
--
Reconnect the battery negative lead.
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
30
EDC CONTROL MOUSE, INDICATOR LIGHT PANEL AND CEILING LIGHT 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 these assemblies, proceed as follows. 1. Disconnect the battery negative cable. 2. Using a punch, remove the circlip retaining the hand throttle lever (1).
59 3. Using an Allen wrench, remove the controls assembly retaining bolts (1) (two on the front and one on the back).
4. Turn over the controls assembly and disconnect the connectors: 1 -- Lift controls mouse 2 -- Indicator light panel 3 -- Ceiling light
60
61
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
31
5. Using a screwdriver, remove the printed card (2) of the indicator light panel inside the assembly support and, on the outside, remove the panel (1).
62
6. Again inside the support, remove the four bolts retaining the lift controls mouse.
63 7. On the bottom of the assembly support, remove the ceiling light (1) illuminating the adjustment potentiometer unit.
--
64 Remount the printed card and the indicator light panel with the bolts.
ATTENTION
--
Reconnect the three connections.
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
Rest the unit on the mudguard and secure it with the bolts.
--
Remount the hand throttle lever with the pin.
--
Reconnect the battery negative lead.
8. To reassemble the unit, proceed as follows:
--
Refit the ceiling light.
--
Remount the lift control mouse unit with the four screws.
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
32
SETTING POTENTIOMETERS PANEL. 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 these assemblies, proceed as follows. 1. Disconnect the battery negative cable. 2. Remove the two bolts retaining the potentiometer panel (1).
65 3. Disconnect the unit.
4. Remove the knobs (1) of the potentiometers (they are pressed on) then unscrew the hexagonal ring nuts (2) fastening the potentiometers to the support.
66
67
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
33
5. To remove the printed card, with the potentiometers welded, unscrew the four Allen screws fastening to the support.
68 6. To reassemble the unit, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Remount the card on the support.
--
Remount the potentiometer retaining ring nuts and the knobs.
--
Reconnect the support assembly to the system.
--
Remount the support assembly with the two bolts.
--
Reconnect the battery negative lead.
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
34
LIFT ARM POTENTIOMETER Renew
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 and isolate the battery negative lead. 2. Detach and remove the potentiometer--lift arm connection tie--rod (1). 3. Disconnect the potentiometer connection (1).
69
70 4. Take out the retaining bolts and remove the potentiometer (1). 5. To refit the potentiometer, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Assemble the potentiometer.
--
Connect to the connection.
--
Assemble the potentiometer--lift arm connection.
--
Connect the negative cable to the battery.
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
35
DRAFT SENSOR R.I.
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 and isolate the battery negative lead. 2. Disconnect the Lift lower arm anti--swing tie--rod. 3. Disconnect the draft sensor connection (1).
4. Take out the sensor guard retaining bolts (1).
5. Remove the draft sensor support bracket (1).
72
73
74
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
36
6. Slide the guard along the cable and extract the draft sensor (1). 7. To refit the draft sensor, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
Position the draft sensor in its seat, remembering that the spherical part on the end of the pin (1) must be facing towards the rear of the tractor.
--
Fit the guard, sliding it along the cable.
--
Position the draft sensor support bracket.
--
Attach the guard with the relative screws.
--
Connect the electrical connection on the draft sensor.
--
Connect the lift lower arm anti--swing tie--rod.
--
Connect the battery negative lead.
87679925A - 12 - 2007
75
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
37
ELECTRONIC DRAFT CONTROL 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. Disconnect and isolate the battery negative lead. 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 and left--hand wheels (2).
27837
4. Remove the top link of linkage (1).
the three--point
76
77 5. Disconnect the vertical tie--rod (1) from the lift arm (on both sides). 6. Remove the snap ring (2), the union (4), the bracket retaining bolts (5) and remove the extra jack (on both sides).
78
87679925A - 12 - 2007
38
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
7. Take out the cab rear retaining bolts (2) and loosen the two front ones. 8. Insert a wooden strip (50 รท 60 mm) between the upright (1) and relative bracket (3) (on both sides).
9. Loosen the locknuts (1) on the quick--fit couplers support bracket.
79
80 10. Take out the bolts securing both the transmission oil fill pipe (1) and the bracket supporting the top link of the three--point linkage (2).
11. Disconnect the seven--pin socket connection (1).
81
82 87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
39
12. Remove the guard (1), disconnect the single pole connections (2) and the ground cable on the quick--fit couplers support bracket (3). 13. Disconnect the power take--off speed sensor connection (4).
14. Disconnect: the control valve connections (2) and all auxiliary control valve piping (1).
83
15. Remove the auxiliary control valve quick--fit coupler support bracket and piping.
84 16. Disconnect the lift oil discharge line (1) and, if necessary, remove it.
17. Disconnect and remove the lift control valve oil delivery piping (1).
85
86 87679925A - 12 - 2007
40
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
18. If fitted, detach the gear--synchronized PTO transmission lever (1). 19. Disconnect the lift arm position potentiometer connection (2), detach and remove the potentiometer connection tie--rod (3).
20. Disconnect the PTO brake control piping (1).
87
88 21. Unscrew the bolts (1) securing the lift and remove the lift arm position potentiometer.
22. Secure the tool 380000238 (1) to the lift.
89
90 87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
41
23. Connect tool 380000224 (2) to the hoist and to tool 380000238 (3), raise the hydraulic lift unit by a few centimetres, extract from the rear part, tilting the unit to avoid the internal breather pipe. 24. If necessary, detach the gear--synchronized PTO transmission lever (1), this will make the aforementioned operation easier. 25. To refit the hydraulic lift on the transmission casing, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Reconnect the gear--synchronized transmission lever.
--
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 92.
--
Assemble the hydraulic lift 380000238 and 380000224.
--
Secure the lift and potentiometer in position with the relative bolts.
--
Connect the PTO brake piping.
--
Connect the potentiometer connection, the relative tie--rod and the gear--synchronized PTO lever.
--
Assemble the lift oil delivery line.
--
Connect the lift oil discharge line.
using
91
PTO
tools
87679925A - 12 - 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
42 --
Assemble the quick--fit coupler support bracket and connect the relative piping to the auxiliary control valves.
--
Connect the PTO speed sensor connection.
--
Connect the seven--pole and single--pole socket connections.
--
Attach the ground cable to the quick--fit coupler support bracket.
--
Assemble the oil top up pipe and the top link bracket.
--
Fit the quick--fit coupler locknuts.
--
Remove the wooden strip and secure the cab.
--
Assemble and secure the extra jacks.
--
Connect the vertical tie--rods.
--
Fit the third point top link.
--
Fit and secure the rear wheels.
--
Connect the negative cable to the battery.
Diagram showing application of sealing compound when fitting the hydraulic lift on the transmission--gearbox casing. The types of sealing compound are listed in the Repair Manual, section 00.
87679925A - 12 - 2007
27155
92
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
43
HYDRAULIC CONTROL VALVE 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. Disconnect and isolate the battery negative lead.
2. Lock the front wheels using chocks.
3. Using a hoist and sling (1) raise the rear part of the tractor, position a fixed support stand under the final drive, then remove the rear right--hand wheel (2). 4. Make a reference mark on the connections (1 and 2) and detach from the hydraulic control valve.
27837
93
28120
5. Disconnect and remove the hydraulic control valve oil delivery piping (1).
94
95
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
44
6. Disconnect the piping (1 and 2) from the hydraulic control valve.
7. Take out the bolts (1) securing the hydraulic control valve to its spacer.
96
97 8. Remove the hydraulic control valve (1). 9. To refit the hydraulic control valve to the lift, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Assemble and secure the hydraulic control valve.
--
Connect the piping to the control valve.
--
Connect the electrical connections.
--
Fit the rear right--hand wheel and remove the chocks from the front wheels.
--
Connect the battery negative lead.
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98
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
1
SECTION 35 -- HYDRAULIC SYSTEMS Chapter 7 -- Ventral control valves for Walvoil--type open centre system CONTENT Description
Page
Ventral control valve specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ventral control valve diagrams (version with normal pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ventral control valve hydraulic circuit (version with normal pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Ventral control valve diagrams (version with 80 litre pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Ventral control valve hydraulic circuit (version with 80 litre pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Control valve and hydraulic circuit, flow increase mounted on the power steering pump . . . . . . . . . . . . . . . . 11 General hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Assembly of ventral control valve and flow increase control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Ventral control valve joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Control valve circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Description and operation of the ventral control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
87679925A2 -- 02 -- 2010
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
2
VENTRAL CONTROL VALVE SPECIFICATIONS Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
full--flow, with replaceable paper cartridge, (common to the hydraulic lift circuit)
Pump Assembly: -- version with normal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- version with 80 l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
gear pump (common to the hydraulic lift circuit see Chapter 1) as above + 18 l of oil sent by the power steering pump.
Pressure release valve calibration: -- version with normal pump (mounted on the pump) . . . . . . . . . bar -- version with 80 litre pump (mounted on the ventral control valve bar
190 รท 195 (194 รท 199 kg/cm2) 180 รท 185 (183 รท 187 kg/cm2)
VENTRAL CONTROL VALVES Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Walvoil
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right--hand side of tractor near the cab bracket.
Type: -- version with normal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
version with 80 litre pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87679925A2 -- 02 -- 2010
One pack with two control valves. Double acting + floating (with mechanical retainer in float) and double acting + regenerating As above with the solenoid energizing switch on the flow--rate increasing control valve on the power steering pump on the control valve with the regenerative phase. By joystick located on the right--hand side of the operator
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
3
TIGHTENING TORQUE
C6 -- 24 Nm
C5 -- 9.8 Nm
C3 -- 9.8 Nm
C1 -- 24 Nm
C4 -- 42 Nm
C9 -- 6.6 Nm
C7 -- 9.8 Nm C6 -- 42 Nm C8 -- 24 Nm
C10-- 70 Nm
C2 -- 24 Nm
C11 -- 6 Nm
C13-- 15 Nm
C12-- 6 Nm
MDM1542A
1 87679925A -- 12 -- 2007
4
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
Tightening torque PARTS TO BE TIGHTENED
Thread
P1 filler and T1 drain plugs (C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nm
kgm
M22x1.5 M18x1.5
24
2.45
Lever side line cap (C2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3/4”--16UNF (SAE8)
24
2.45
Lever positioner kit stud bolt (C3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M6
9,8
0.99
Supply union to the other circuit services (C4). . . . . . . . . . . . . . . . . . . .
3/4”--16UNF (SAE8)
42
4.28
Pin end cap retaining bolts (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M5
6,6
0,67
Pin supply check valves (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M14x1.5
24
2.45
Switch control kit pin (C7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M6
9,8
0.99
Switch (C8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9/16--18UNF
24
2.45
Switch control kit screw (C9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M5
6,6
0.67
Solenoid valve (*) (C10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7/8 14 UNF
70
7.13
Coil ring nut (C11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M16x1
6
0.6
Plug (C12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12x1.5
25
2.55
Plug (C13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/8 GAS
15
1.53
(*) Apply a few drops of Loctite 542 before screwing on the solenoid valve.
87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
5
VENTRAL CONTROL VALVE VERSION WITH NORMAL PUMP
2
1.
Cap 2nd control valve with additional spring for pin return in regenerating phase.
8.
Plug replacing pressure relief valve (the valve is not used there is the valve of the central system).
2.
Return device 2nd double--acting pin.
9.
Control valve body.
3.
Seal.
4.
Plug (T1) oil drain orifice (not used).
5.
Oil delivery union to other circuit services (supplementary control valves and lift control valve).
6.
Control valve pins.
7.
Oil seal.
10. Plug (P1) of orifice for control valve oil delivery (not used). 11. Control valve pin oil supply check valves. 12. Return device 1st double--acting pin. 13. Cap 1st control valve with mechanical retainer in floating phase. 87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
6
3 A1 1st control valve oil outlet / inlet under pressure / discharge.
1.
Supplementary control valve supply union.
2.
Rod 2nd control valve (double acting + regenerating).
3.
Oil outlet at drain (T).
A2 2nd control valve oil outlet / inlet under pressure / discharge.
4.
2nd control valve oil inlet / outlet under pressure / discharge (B2).
B2 2nd control valve oil outlet / inlet under pressure / discharge.
5.
2nd control valve oil inlet / outlet under pressure / discharge (A2).
Oil inlet from the pump (supply from the trailer brake valve if fitted).
6.
1st control valve oil inlet / outlet under pressure / discharge (A1).
7.
1st control valve oil inlet / outlet under pressure / discharge (B1).
8.
Oil inlet from pump (P).
9.
Rod 1st control valve (double acting + floating -- with mechanical coupling in float).
B1
P
1st
control valve oil outlet / inlet under pressure / discharge.
P1 Oil inlet from pump (not used). T
Oil discharge.
T1 Oil drain (not used).
87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
7
HYDRAULIC DIAGRAM
P A1 B1
T
A2 B2
3
5
4
b b
5 P1
T1
b d
d
c
d
C
c 1
2
a
a
a
MDGM
MDG1655A
MDG1655A A1 Oil delivery for lifting loader. B1 Oil delivery for lowering loader. A2 Oil delivery for lifting loader. B2 Oil delivery for lowering loader. C
Oil delivery to the other system components.
P
Control valve supply.
P1 Control valve supply (not used). T
1. 2. 3. 4. 5.
4
1st control valve pin (double acting + floating -- with mechanical coupling in float). 2nd control valve pin (double acting + regenerating). Return springs for pin in double action and mechanical retainer with pin in float. Return springs for pin in double action and additional spring with pin in regeneration. Pin supply check valves.
Oil discharge from the control valve.
T1 Oil discharge from the control valve (not used). a . Discharge line. b . Supply line. c . Cylinder discharge oil recovery line to flow it into the second control valve supply line. d . Oil flow line, in the neutral phase, reaching the union (C) to pass on to the other circuit services.
Oil at static rest. Pressurised oil. Discharge oil.
87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
8
VENTRAL CONTROL VALVE VERSION WITH 80 LITRE PUMP (with flow increase control valve mounted on the power steering pump)
16
15
14
1
2
3
4 5 11
6
13
12
18
17
10
9
8
7
MDM1543A
5 1.
Cap 2nd control valve with additional spring for pin return in regenerating phase.
10. Plug (P1) of orifice for control valve oil delivery (18 litres from power steering pump).
2.
Return device 2nd double--acting pin.
11. Control valve pin oil supply check valves.
3.
Seal.
12. Return device 1st double--acting pin.
4.
Plug (T1) oil drain orifice (not used).
13. Cap 1st control valve with mechanical retainer in floating phase.
5.
Oil delivery union to other circuit services (supplementary control valves and lift control valve).
14. Switch feeler (16).
6.
Control valve pins.
7.
Oil seal.
16. Flow increase control valve solenoid valve energizing switch mounted on the power steering pump.
8.
Pressure relief valve.
17. Seal.
9.
Control valve body.
18. Feeler screw.
87679925A -- 12 -- 2007
15. Switch support (16).
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
9
12 11
13
12 8
9
11
2
3
10
7
6
5
4
1
MDM1544A
6 1.
Oil delivery union to other circuit services (supplementary control valves and lift control valve).
7.
1nd
2.
2nd control valve (double acting + regenerating).
8.
Oil inlet from pump (P).
3.
Oil outlet at drain (T).
9.
1nd control valve (double acting + floating -- with mechanical coupling in float).
4.
2nd control valve oil inlet / outlet under pressure / discharge (B2).
5.
2nd control valve oil inlet / outlet under pressure / discharge (A2).
6.
1st control valve oil inlet / outlet under pressure / discharge (A1).
control valve oil inlet / outlet under pressure / discharge (B1).
10. Inlet orifice for 18 litres of oil from the power steering pump (P). 11. Flow increase control valve solenoid valve energizing switch mounted on the power steering pump. 12. Switch support (11). 13. System pressure relief valve.
87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
10
HYDRAULIC DIAGRAM
P A1 B1
6
T
A2 B2
5
3
4
b
5 P1
T1
b
b d
d
c
d
C
c
7
1
2
a
a
a
MMM1549A
A1 B1 A2 B2 C P P1 T T1
Oil delivery for lifting loader. Oil delivery for lowering loader. Oil delivery for lifting loader. Oil delivery for lowering loader. Oil delivery to the other system components. Control valve supply. Control valve supply (from the power steering pump). Oil discharge from the control valve. Oil discharge from the control valve (not used).
a b c
Discharge line. Supply line. Cylinder discharge oil recovery line to flow it into the second control valve supply line. Oil flow line, in the neutral phase, reaching the union (C) to pass on to the other circuit services. 1st control valve pin (double acting + floating -- with mechanical coupling in float).
d 1.
87679925A -- 12 -- 2007
2. 3. 4. 5. 6. 7.
7
2nd control valve pin (double acting + regenerating). Return springs for pin in double action and mechanical retainer with pin in float. Return springs for pin in double action and additional spring with pin in regeneration. Pin supply check valves. Solenoid valve energizing switch (no. page). Pressure relief valve.
Oil at static rest. Pressurised oil. Discharge oil.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
9
11
1
2 3 8
4 .
7
6
5
MDM1545A
8 Flow increase control valve mounted on the power steering pump 1.
Solenoid valve coil.
2.
Seal with anti--extrusion ring.
3.
Oil inlet line from pump.
4.
Oil delivery line to the power steering.
5.
Control valve body.
6.
Oil line to lubrication.
7.
Plugs.
8.
Oil supply to the ventral control valve.
9.
Solenoid valve.
87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
12
HYDRAULIC DIAGRAM
2
CF
EF
b 1
a
E P2
M1
MMM1550A 9 CF Oil delivery (20 litres) to the power steering control valve. E
Oil delivery (18 litres) in lubrication.
EF Oil delivery (18 litres) to the ventral control valve.
1.
Priority valve.
2.
Solenoid valve.
M1 Point where it is possible to take the pressure of the power steering pump (closed with a plug). P2 Oil inlet from pump. a
b
Through this line the oil moves the spool of the valve (1), which with the engine off is in the position in the figure, if the quantity of oil for the power steering control valve reaches 20 litres then there will be an increase in pressure due to the restriction in the box. This increase will allow the box to move, compressing the spring, and will send the rest of the oil to the solenoid valve. If for some reason the pump should not be in an optimal condition, the pressure in this circuit will not reach values high enough to compress the spring and the oil will have priority towards the power steering. Through this line the oil will modulate the movement of the box so as to have no water hammering on the steering wheel and for smooth driving.
87679925A -- 12 -- 2007
Pressurised oil. Lubricating oil.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
13
GENERAL HYDRAULIC CIRCUIT Four--wheel drive tractor, with Power Shuttle 12 X 12 transmission, fitted for front loader, flow increase control valve for ventral control valve (80 litre pump version), supplementary control valves with closed centre and electronic lift.
74
71
8
45
47
44
52
49
5 56
75
1
70
55
48 72
MMM1551A 10 Low pressure circuit
NOTE: Key, see page 15.
87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
14
32 10 63
5
1
65 h i
b d
g c
e
f
m
37
l
a
22 25 MMM1552A 11 High pressure circuit
NOTE: Key, see page 15.
87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
15
General hydraulic circuit key. NOTE: Key to figures 10, 11 and 18, see page 13, 14 and 12. 1. 2. 3. 4. 5. 6. 7.
CF E
EF P2 8. 9. L P R T 10. 11. 12. B
N P R Y 13. 14.
15.
16.
Inlet unit composed of: Power steering/low pressure pump. High pressure pump. Filter. Flow increase control valve for ventral control valve. (Figs. 8 and 9) -- composed of: Power steering priority control valve (orbitrol). Solenoid valve (not energized it sends oil, 18 l, to lubrication, energized it sends the oil to the ventral control valves. Oil delivery to orbitrol (20 litres). Oil delivery to lubrication (18 litres), on fully mechanical machines, oil delivery to the discharge in the handbrake compartment. Oil delivery to the ventral control valves (18 litres). Control valve supply (38 litres) from the power steering pump. Power steering control valve, (orbitrol) composed of: Pressure relief valve 170 bar (173.35 kg/cm2) 4 WD, 145 bar (147.86 kg/cm2). Delivery to the cylinder, left--hand side. Supply from the low pressure pump. Delivery to the cylinder, right--hand side. Oil discharge. Trailer brake valve, composed of: Flow regulating valve. Slide piston with pressure limiter. Oil delivery to the trailer brake quick coupler (French valve) or to the control valve for the Italian version. Oil delivery to the ventral control valves (if fitted) or to the supplementary ones. Supply from the high pressure pump. Oil discharge. Oil from the right--hand service brake circuit. Trailer brake control valve Italian version, composed of: Discharge pressure regulating valve 10 ÷ 11 bar (10.20 ÷ 11.22 kg/cm2), keeps pressure in the pipe that goes from the valve to the trailer sufficient to release the safety brake. Trailer brake safety pressure switch 2.5 ÷ 3.5 bar (2.55 ÷ 3.57 kg/cm2), identified with a dab of red paint. Trailer brake indicator pressure switch 9.5 ÷ 10.5 bar (6.69 ÷ 10.71 kg/cm2).
17. Solenoid valve, normally closed, for discharge pressure 10 bar for releasing trailer safety brake. 18. Solenoid valve, normally open, for closing line to trailer brake. 19. Tractor service brakes unit, composed of: 20. Brake pedals / pump. 21. Left service brake. 22. Right service brake. 23. Pilot valve. 24. Front axle braking. 25. Ventral control valves, composed of: 26. Pressure relief valve 180 ÷ 185 bar (183 ÷ 187 kg/cm2). 27. Solenoid valve energizing switch (7). 28. 1st control valve pin (double acting + floating with mechanical catch in float). 29. 2nd control valve (double acting + regenerating). 30. Pressurized oil delivery/return pipes to the loader arm lifting and lowering cylinder. 31. Pressurized oil delivery/return pipes to the bucket loading and unloading cylinder. C Oil delivery to the additional control valves. P Oil supply from the high pressure pump. P1 Oil supply (18 litres) from the power steering pump. T Oil discharge. 32. Closed centre supplementary control valves, composed of: 33. Single/double--acting control valve with float. 34. Single/double--acting control valve with automatic detent release and flow--rate regulator. 35. Flow--rate regulator. 36. Unload valve, sends oil to the control valves only when necessary otherwise it directs it all to the lift. P Oil supply from the ventral control valves (if fitted), from the trailer brake valve (if fitted) or from the high--pressure pump. N Oil delivery to the lift. R Drain. 37. Electronic lift control valve composed of: 38. Raise solenoid valve. 39. Pressure compensator valve. 40. Lower solenoid valve. A Delivery to lift cylinder. P Oil supply from the supplementary lift. R Discharge from the pressure compensating valve. 87679925A2 -- 02 -- 2010
16
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
R1 Discharge from the lift cylinder. 41. Lift box containing: 42 Cylinder safety valve 210 ÷ 215 bar (214.14 ÷ 219.24 kg/cm2). 43. Lift cylinder. 44. Services control valve, composed of: 45. Solenoid valve governing the PTO clutch and clutch brake. 46. Solenoid valve oil discharge control valve pin (45) operated by the synchronized PTO control. 47. Solenoid valve governing the front and rear differential lock. 48. Four--wheel drive solenoid valve. 49. PTO unit: composed of: 50. Clutch pack modulating accumulator. 51. PTO clutch. 52. PTO brake. 53. Lubrication control valve. 54 Lubrication line, with solenoid valve not energized, the control valve (53) controls lubrication of the bearing behind the clutch driving shaft, with solenoid valve energized lubrication is extended to the entire clutch too. 55. Gearbox clutch control valve, composed of: 56. Lubrication pressure regulating valve 2.9 ÷ 3.7 bar (3 ÷ 3.8 kg/cm2) identified by a dab of yellow paint, in the case of mechanical transmissions with hydraulic PTO the valve is fitted on the PTO unit it is set to 4.4 ÷ 5.9 bar (4.5 ÷ 6 kg/cm2) and is identified by a green mark. 57. Reverse drive clutch B solenoid valve. 58. Forward drive clutch A solenoid valve. 59. Dump solenoid valve. 60. Heat exchanger by--pass 3bar (3.06 kg/cm2). 61. Clutches and services working pressure regulating valve 15.7 ÷ 16.7 bar (16 ÷ 17 kg/cm2). 62. Lubrication line for clutches A, B, C, D and gearbox transmission shaft. 63. Non--return valve. 64. Electrical connection between the switch (27) of the ventral control valves and the solenoid valve (7) of the flue increase control valve. 65. Trailer brake quick coupler. 66. Trailer braking device. 67. Lubrication oil cooler.
87679925A2 -- 02 -- 2010
68. 69. 70. 71.
72. 73. 74. 75.
Reverse drive clutch B. Forward drive clutch A. Gearbox oil filter. Gearbox oil pressure switch, 0.8 ÷ 1.2 bar (0.81 ÷ 1.01 kg/cm@) fitted on the oil drain pipe from the orbitrol, on the 2WD with completely mechanical transmission a different pressure switch should be fitted on the oil supply pipe to the orbitrol next to the pump 10 ÷ 12 bar (10.2 ÷ 12.2 kg/cm2). Rear differential lock. 4WD disengaged. Front axle cylinder. Front differential lock.
Discharge oil. Intake oil. Oil at static rest. Oil from the right rear brake for controlling the trailer brake valve. Additional control valve load sensing line. Pressurised oil. Lubricating oil. Oil to the flow control valve.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
69
17
58 59
55
17
18 33
13
57
16 24
61
68
14 56
72
60
51 53
Y 12
N 11
54
21
49
P
50
19
23
10
62 73
R
B
67
52
66
65
15
30
22
28
20 P
74
34
31
32
27
P1 48
L
35
29
C 34
R R
26
35 47
T
8
44
70
P
T
63
45
# 71
CF
37
E
A
7 64
6
Four--wheel drive tractor, with Power Shuttle 12X12 transmission, fitted for front loader, flow increase control valve for ventral control valve (80 litre pump version), supplementary control valves with closed centre and electronic lift. NOTE: Key, see page 15.
41
43
EF
5
GENERAL HYDRAULIC CIRCUIT
N
36
25
9
46
P
38
40 42
3
P2 2 1
4
R2
39
P
R1 12
MDL1547A
87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
18
1
8
9
10
11 12 13
2
3 17
4
16
5 6
15
14
7
MDM1546A
13 Assembly of ventral control valve and flow increase control valve.
--
Ventral control valve.
--
Flow increase control valve.
1. 2.
Pressure/discharge oil delivery to the front loader. 1st control valve (right in the drawing) and 2nd control valve. Oil delivery to the additional control valves. Oil drainage. Solenoid valve energizing switch (11). Oil delivery from the high--pressure pump or from the trailer brake valve (if fitted). Oil delivery from the power steering pump.
42. 43. 44. 45. 46. 47.
Oil delivery to the power steering. Control valve body. Oil to lubrication. Solenoid valve. Delivery to the ventral control valve (see 7). Low (left of the drawing) and high pressure pumps fitted in tandem. Oil delivery from the high pressure pump to the trailer brake valve (if fitted) or to the ventral control valve (see 6) Pumps inlet. Filter support. Power steering oil pressure switch (only on 2WD with completely mechanical transmission, on the other machines it is mounted on the power steering outlet).
3. 4. 5. 6. 7.
48. 49. 50. 51.
87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
19
VENTRAL CONTROL VALVE JOYSTICK
The ventral control valves are governed by a joystick (1) on the operatorâ&#x20AC;&#x2122;s right--hand side.
14
The safety lock on the joystick has three positions: 1.
Fully out. All joystick movements available.
2.
Mid Position. Side movement locked out.
3.
Fully in. All joystick movements locked.
15
ATTENTION To prevent accidental movement of the joystick when travelling on the public highway, or otherwise, put the safety lock into position (3, fig. 15).
87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
20 Joystick Operation
Pull the joystick rearwards (B) to pressurize outlet (A1) of the control valve in the lifting phase. If necessary, moving the joystick fully backwards, to overcome the resistance of the spring, increases the lifting speed. Move the joystick (A) forwards to pressurize outlet (B1) in the lowering phase. Further forward movement (C) of the joystick will select the floating position, connecting both outlets to the drain, which will allow a cylinder connected to the control valve to extend or retract freely. If the cylinder is fitted with an implement for working the land it can follow the surface of the land it is working. NOTE: When using the float position, pushing the joystick fully forward to overcome the resistance exerted by the return spring due to the double action. The lever will stay in that position thanks to a mechanical coupling in the cap of the control valve, to make it go back bring it out of the coupling manually. Moving the joystick to the left (D) to pressurize outlet (A2) in the lowering phase, moving the joystick to the right to pressurize outlet (B2) in the lifting phase. Moving the joystick further to the right (F) takes the pin of the control valve into the regenerating phase, that is the two chambers of the cylinder are pressurized; with different behaviour, depending on the type of cylinder: --
--
with a cylinder with the areas of the piston having the same size there will be no movement of the piston, the pressure sent into the two chambers simultaneously will keep it stationary. with a cylinder where the areas of the piston are different, irrespective of the cylinder’s connection, pressurizing both the stem side and the base side there will be an extension of the cylinder at a higher speed, obtaining a greater lifting speed than the speed obtained in the lifting phase.
IMPORTANT: Do not hold the lever in the extension or retraction positions once the cylinder has reached its limit stop. This will cause the relief valve to ‘blow’ which, if occurring over an extended period, may overheat the oil.
87679925A -- 12 -- 2007
16
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
21
2nd control valve regenerating function disabling bush All machines equipped with a ventral control valve, inside the cap containing the cable junction (1) controlled by the joystick with the pin of the second control valve, are fitted in the factory with a bush (3, fig. 18).
17 The bush (3) is originally fitted inside the cable protection (1) and not on the pin of the control valve. In this way the control valve pin does not get disabled; this can extend, retract the cylinder and regenerate.
If you want to prevent the 2nd control valve from going into the regenerating position you can move the bush into position (2) thereby disabling this condition. In this way the control valve pin can only extend or retract the cylinder and the regenerating condition is disabled, whereas the 1st control valve and its cable (4) are not affected by the bush.
18
87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
22
DESCRIPTION AND OPERATION OF VENTRAL CONTROL VALVE
A
A
B
B
2
a
d
T SECT. A -- A B2 1 3
4 b a
b
a
d
a
SECT. B -- B
A2
2
MDH1681A
19 Oil at static rest. Pressurised oil.
87679925A -- 12 -- 2007
Discharge oil.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
23
Control valve external piping A2 Oil delivery for lowering phase. B2 Oil delivery for lifting phase. T Oil discharge from the control valve.
Control valve internal lines a b d
Discharge line. Supply line. Oil flow line, in the neutral phase, reaching the union (C) to pass on to the other circuit services.
1. 2. 3. 4.
Control valve pin supply check valve. 2° Control valve block pin. Oil seal. Seal.
Operation in the neutral phase With the pin of the 2nd control valve in neutral the one--way valve (1) will stay closed the line (b) will be kept full of oil delivered by the pump that, through the line (d), will reach the oil outlet union from the control valve and then reach the lift. The oil will discharge through the lines (a) into the tank via the union (T). The outlets (A2 and B2) are full of static oil.
87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
24
C
C D
D 2 4
1
b c
c
b
d
a
SECT. C -- C
3 A1
a b
b
d
P SECT. D -- D
B1 MDH1681B
20 Oil at static rest. Pressurised oil.
87679925A -- 12 -- 2007
Discharge oil.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
25
Control valve external piping A1 Oil delivery for lifting phase. B1 Oil delivery for lowering phase. P Control valve supply (from additional control valves).
Control valve internal lines a . Discharge line. b . Supply line. c . Line to recover discharge oil of the 1st control valve from the cylinder to flow it into the 2nd control valve supply line. d . Oil flow line, in the neutral phase, reaching the union (C) to pass on to the other circuit services (lift control valve). 1. 2. 3. 4.
Loader movement control valve pin. Control valve pin supply check valve. Oil seal. Seal.
Operation in the neutral phase With the pin of the 1st control valve in neutral the one--way valve (1) will stay closed the line (b) will be kept full of oil delivered by the pump, via the union (P), that, through the line (d), will reach the control valve outlet union and then reach the lift. The recovery lines (c), being connected to line (d), are kept full of oil by the pump. The oil will discharge into the tank through line (a). The outlets (A1 and B1) are full of static oil.
87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
26
E
E
4 3
5 6
T
P
a
c
b
b a
b b
a
c d
d
d a
a
d C
a
SECT. E -- E 1
2
MDH1681C
21 Oil at static rest. Pressurised oil.
87679925A -- 12 -- 2007
Discharge oil.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
27
Control valve external piping P T C
Oil supply to the control valve (additional control valve). Oil discharge. Oil delivery to the other system components (lift control valve).
Control valve internal lines a b c d
1. 2. 3. 4. 5. 6.
Discharge line. Supply line. Line to recover discharge oil of the 1st control valve from the cylinder to flow it into the 2nd control valve supply line. Oil flow line, in the neutral phase, reaching the union (C) to pass on to the other circuit services. Pin 1stcontrol valve. Pin 2nd control valve. Return springs for pin in double action. Mechanical retainer with pin in floating phase. Additional spring for pin return in regenerating phase. Return springs for pin in double action.
Operation in the neutral phase With the pins of the control valve in neutral the line (b) will be kept full of oil delivered by the pump, via the union (P), that, through the line (d), will reach the oil outlet line from the control valve (C) and then reach the lift. The recovery lines (c) on the 1st control valve, being connected to line (d), are kept full of oil by the pump. The oil will discharge through the lines (a) into the tank via the union (T).
87679925A -- 12 -- 2007
28
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
Operation 1st control valve in lowering phase Move the joystick (A, fig. 16) forwards and the pin will go into the lowering phase, connecting the supply line (b) with the outlet (B1). The outlet (A1) will discharge, through the pin, connecting with the line (c) that will recover the oil and, instead of sending it to the tank, will flow it into the supply line (b) at the 2nd control valve and, if this is not used, through the line (d), it will reach the lift control valve leaving the union (C).
P
A1 B1
b P1
T
A2 B2
b
d
T1
d c
d
C
c
a
a
a
MDH1680F
22 Operation 1st control valve in floating phase Move the joystick further forwards (C fig. 16) and the pin will go into the floating position, connecting the discharge line (a) with the outlet (B1 -- A1) through the hole in the pin. In this way the cylinder is free to extend and retract since the two piston chambers are connected and, through the union (T), connected to the tank. Since the pump is always delivering into union (P), it sends oil through line (d) to the lift control valve, via union (C). The lever remains in this position thanks to the neck (4, fig. 21), to make the pin go back into neutral it is necessary to move the lever out of this position manually.
P
A1 B1
b P1
T
A2 B2
b
d
T1
d c
d
C
c
a
a
a
MDH1680G
23 Operation 1st control valve in lifting phase Move the joystick (B, fig. 16) backwards and the pin will go into the lifting position, connecting the supply line (b) with the outlet (A1). The outlet (B1) will discharge, through the pin, connecting with the line (c) that will recover the oil and, instead of sending it to the tank, will flow it into the inlets to the 2nd control valve (b) and, if this is not used, through the line (d), it will reach the lift control valve leaving the union (C).
P
A1 B1
b P1
b
d
T1
d c
a
T
A2 B2
d
C
c a
a
MDH1680E
24 NOTE: Under this condition the movement of the control valve pin inside the control valve will make the feeler (14, fig. 5) act on the switch (16, fig. 5) that will send the current to the solenoid valve (1, fig. 8) that, energizing, will send no more oil (approximately 18 litres) to lubrication, but will send it to the ventral control valves that will use it for the lifting phase. The solenoid valve (1, fig. 8) is mounted on the power steering pump (see fig. 13, part 11) that, under normal conditions, is equipped with a priority valve (1, page 9) that sends the remainder 20 litres again to the power steering, passing through the solenoid valve, it goes to lubrication, with power shuttle or mechanical transmissions with electrohydraulic PTO, or discharged, in the handbrake casing, with mechanical transmissions. 87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
29
Operation 2nd control valve in lifting phase No matter what position the pin of the 1st control valve has taken, move the joystick (E, fig. 16) to the right and the pin will go into the lifting position, connecting the supply line (b) with the outlet (B2). The outlet (A2) will discharge, through the pin, connecting with the line (a) and, through the union (T), the oil will reach the tank.
P
A1 B1
b P1
T
A2 B2
b
d
T1
d c
d
C
c
a
a
a
MDH1680B
25 Operation 2nd control valve in regenerating phase
Move the joystick (F, fig. 16) further to the right and the pin will go into the regenerating position, connecting the supply line (b) with both outlets (B2 -A2). No matter how the cylinder will be connected, it can behave in one of two ways: --
--
cylinder with the piston surfaces exactly alike, it will neither extend nor retract, so the implement controlled by the cylinder will not move, the pressure acting on both surfaces of the piston will keep the implement stationary. cylinder with different piston surfaces, it will extend faster. The oil coming out of the stem side will re--enter on the base side and it is as if the pump delivery were increasing so the cylinder will extend faster.
P
A1 B1
b P1
T
A2 B2
b
d
T1
d c
d
C
c
a
a
a
MDH1680C
26
Operation 2nd control valve in lowering phase Move the joystick (D, fig. 16) to the left and the pin will go into the lowering position, connecting the supply line (b) with the outlet (A2). The outlet (B2) will discharge, through the pin, connecting with the line (a) and, through the union (T), the oil will reach the tank.
P
A1 B1
b P1
b
d
T1
d c
a
T
A2 B2
d
C
c a
a
MDH1680A
27 87679925A -- 12 -- 2007
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
30
P
A1 B1
b
P1 c
T
A2 B2
P
A1 B1
T1 C
c
1
A2 B2
b
P1 c
T
T1 C
c
2
MDG1655B
28 A1 Oil delivery for lifting. B1 Oil delivery for lowering. A2 Oil delivery for lowering. B2 Oil delivery for lifting. C
Oil delivery to the other system components (lift control valve).
P
Control valve supply (from additional control valves).
P1 Control valve supply (not used). T
Oil discharge from the control valve.
T1 Oil discharge from the control valve (not used). c
Line to recover discharge oil from the cylinder of the 1st control valve to flow it into the 2nd control valve supply line.
b
Supply line 2nd control valve.
1.
Lifting phase 1st control valve.
2.
Lowering phase 1st control valve.
One characteristic of these, open centre, control valves is that the pump delivery is always available on both pins of the control valve even when operated at the same time. On operating the first control valve, the one that would shut off the pump delivery as it is nearest the inlet, there will be: -- oil delivered on the quick coupler A1, oil discharged from the quick coupler B1 (1, fig. 28), lifting phase. The discharge oil enters the line (c) and supplies the second control valve pin line (b), if this is used. -- oil delivered on the quick coupler B2, oil discharged from the quick coupler A1 (1, fig. 28) lowering phase. The discharge oil enters the line (c) and supplies the second control valve pin line (b), if this is used. 87679925A -- 12 -- 2007
Oil at static rest. Pressurised oil. Discharge oil.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
1
SECTION 35 -- HYDRAULIC SYSTEMS Chapter 8 -- Front Loader
CONTENTS Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maximum permissible front axle weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ventral control valve specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Ventral control valve joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 System switching full and dipped beam headlights on lights fitted on handrails . . . . . . . . . . . . . . . . . . . . . . 13 Ballasting the tractor for front loader operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Loader general description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Loader installation -- removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Implement installation -- removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Lift arm types and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Smooth ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Multi Quick coupler connection -- disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Hydraulic functions and flow diagram of loaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
2
LOADER ASSEMBLY KIT FEATURES
56/76 KW/HP
63/86, 71/97 and 78/106 KW/HP
F Foundation d ti
O ti Optional l
Not available
Foundation
Assembly kit comprising: --
radiator grille guard
--
loader supports
--
quick hitches
--
system switching full and dipped beam headlights on lights fitted on handrails
--
sideways sway limiting buffers, fitted on axle support
--
accessory box bracket to be fitted at the rear on the left--hand mudguard
Strengthened assembly kit comprising: --
radiator grille guard
--
loader supports
--
transmission braces
--
Multi Faster quick hitches
--
system switching full and dipped beam headlights on lights fitted on handrails
--
sideways sway limiting buffers, fitted on axle support
--
accessory box bracket to be fitted at the rear on the left--hand mudguard
To mount on tractors fitted with: --
four--wheel drive front axle
--
axle class
--
with cab
87679925A1 - 02 - 2008
Mandatory 1,5 Mandatory
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
3
VENTRAL CONTROL VALVE SPECIFICATIONS Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
full--flow, with replaceable paper cartridge, (common to the hydraulic lift circuit)
Pump: -version with normal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--
as above + 18 l of oil sent by the power steering pump.
version with 80 l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure release valve calibration: -version with normal pump (mounted on the pump) . . . . . . . . . --
gear pump (common to the hydraulic lift circuit see Chapter 1)
bar
version with 80 litre pump (mounted on the ventral control valve bar
190 รท 195 (194 รท 199 kg/cm2) 190 รท 195 (183 รท 187 kg/cm2)
VENTRAL CONTROL VALVES Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Walvoil
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right--hand side of tractor near the cab bracket.
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
One pack with two control valves. Double acting + floating (with mechanical retainer in float) and double acting + regenerating
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
By joystick located on the right--hand side of the operator
MAXIMUM PERMISSIBLE AXLE WEIGHTS WITH LIMITS
Model
km/h max
56/76 KW/HP 63/86 KW/HP 71/97 KW/HP 78/106 KW/HP
8
Maximum weight on road (kg)
Front axle 2WD (A) (kg)
Front axle 4WD (*) (B) (kg)
Rear axle
5700
3500
5000
4600
5700
3500
5000
4600
6200
3500
5000
4600
6200
3500
5000
4600
(*) The permissible static weights given for the front axle are for tractors fitted with a front loader. (A) The maximum permitted weights shown are for wheel tracks less than 1700 mm. (B) The maximum permitted weights shown are for wheel
(o)
(kg)
tracks between 1515 รท 1930 mm. (o) Permissible static weights given for the rear axle are for tractors with ballast, including mounted implements raised off the ground.
87679925A2 - 02 - 2010
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
4
TORQUE WRENCH SETTINGS
MMH1677A
1
PARTS TO BE TIGHTENED
Thread
Tightening torque Nm
kgm
Bolts securing loader support to axle support (C1) . . . . . . . . . . M 20 X 2.5
392 ÷ 431
39.97 ÷ 43.95
Bolts securing loader support to engine spacer (C2). . . . . . . . . M 20 X 2.5
243 ÷ 276
24.78 ÷ 28.14
Bolts securing loader support to engine spacer (C3). . . . . . . . . M 20 X 2.5
392 ÷ 431
39.97 ÷ 43.95
Bolts securing loader support to clutch housing (C4). . . . . . . . . M 16 X 1.5
112 ÷ 125
11.42 ÷ 12.75
Bolts securing loader support to transmission brace (C5). . . . . M 16 X 1.5
112 ÷ 125
11.42 ÷ 12.75
Nuts securing transmission brace to final drive (C6) . . . . . . . . . M 14 X 1.5
176
17.95
87679925A2 - 02 - 2010
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
5
LOADER ASSEMBLY KIT SUPPORTS / BRACES DIAGRAM
MMH1677B
2 1. 2. 3. 4. 5. 6. 7.
Protective guard for radiator grille. Left--hand loader support. Transmission brace (available for strengthened kit mod. 63/86, 71/97 and 78/106 KW/HP). Grille guard retaining holes. Front loader support portion retaining holes. Front loader support portion rear retaining hole. Rear loader support portion to engine spacer retaining holes.
8. 9. 10. 11. 12. 13. 14.
Rear loader support portion to gearbox retaining holes. Rear transmission brace portion retaining holes. Front axle carrier. Engine spacer. Gearbox. Transmission housing. Front transmission brace portion to loader support retaining holes.
87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
6
SIDEWAYS SWAY LIMITING BUFFERS
3 α . Degrees of oscillation 6o (with pads), without pads the oscillation would be 11o. 1. 2.
Sideways anti--sway left--hand buffer. Upper axle sway limiting section.
3. 4.
Lower section on the sway limiting axle support. Front axle pivot.
NOTE: The pads are mounted on all the axles, when there is the front loader.
87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
7
FITTING THE FRONT LOADER VENTRAL CONTROL VALVE
4
3
2
1
4 Assembly of normal type of ventral control valve. 1. 2. 3. 4.
Oil delivery (B2) to the loader bucket operating cylinder for the unloading phase. Oil delivery (A2) to the loader bucket operating cylinder for the loading phase Oil delivery (A1) to the loader operating cylinder for the lifting phase. Oil delivery (B1) to the loader operating cylinder for the lowering phase.
Oil delivery to the other circuit components (additional control valve). 6. Oil outlet (T). 7. Control valve supply (P) (from the trailer brake valve or straight from the pump). 8. Control valve body. 9. Multi Quick coupler handle. 10. Dust cap for quick hitches. 5.
87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
8
Assembly of ventral control valve with supply pipe from the power steering pump, 80 litre pump variant (*). 1. 2. 3. 4. 5.
Oil delivery (B2) to the loader bucket operating cylinder for the unloading phase. Oil delivery (A2) to the loader bucket operating cylinder for the loading phase Oil delivery (A1) to the loader operating cylinder for the lifting phase. Oil delivery (B1) to the loader operating cylinder for the lowering phase. Oil delivery to the other circuit components (additional control valve).
(*) See Section 35 Chapter 7.
87679925A1 - 02 - 2008
Oil outlet (T). Control valve supply (P) (from the trailer brake valve or straight from the pump). 8. Control valve body. 9. Quick--fit connector support. 10. Control valve supply (P1) (from the power steering pump). 11. Solenoid valve energizing switch mounted on control valve supplementing ventral control valves on the power steering pump. 6. 7.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
9
CONTROL VALVE HYDRAULIC DIAGRAM FOR 80 LITRE VARIANT
P A1 B1
6
T
A2 B2
5
3
4
b
5 P1
T1
b
b d
d
c
d
C
c
7
1
2
a
a
a
MMM1549A
A1 B1 A2 B2 C P P1 T T1
Oil delivery for lifting loader Oil delivery for lowering loader Oil delivery for lifting loader Oil delivery for lowering loader Oil delivery to the other system components. Control valve supply. Control valve supply (from the power steering pump). Oil discharge from the control valve. Oil discharge from the control valve (not used).
a b c
Discharge line. Supply line. Cylinder discharge oil recovery line to flow it into the second control valve supply line. Oil flow line, in the neutral phase, reaching the union (C) to pass on to the other circuit services. 1st control valve pin (double acting + floating -- with mechanical coupling in float).
d 1.
2. 3. 4. 5. 6. 7.
5
2nd control valve pin (double acting + regenerating). Return springs for pin in double action and mechanical retainer with pin in float. Return springs for pin in double action and additional spring with pin in regeneration. Pin supply check valves. Solenoid valve energizing switch on the additional control valve mounted on the power steering pump. Overpressure valve (mounted only on this type of control valve, with the other control valve the valve is mounted on the pump..
Oil at static rest. Pressurised oil. Discharge oil.
87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
10
FRONT LOADER VENTRAL CONTROL VALVE SPECIFICATIONS P
A1 B1
b
P1 c
T
A2 B2
P
A1 B1
T1 C
c
b
P1 c
A2 B2
T
T1 C
c
MDG1655B
6 Oil delivery for lifting loader. Oil delivery for lowering loader. Oil delivery for loading bucket. Oil delivery for unloading bucket. Oil delivery to the other system components (lift control valve). P Control valve supply (from additional control valves). P1 Control valve supply (not used). T Oil discharge from the control valve. T1 Oil discharge from the control valve (not used). c Line to recover discharge oil from the cylinder of the 1st control valve to flow it into the 2nd control valve supply line. b Supply line 2nd control valve. 1. Loader lifting phase. 2. Loader lowering phase. A1 B1 A2 B2 C
One characteristic of these, open centre, control valves is that the pump delivery is always available on both pins of the control valve even when operated at the same time. On operating the first control valve, the one that would shut off the pump delivery as it is nearest the inlet, there will be: -- oil delivered on the quick coupler A1, oil discharged from the quick coupler B1 (1, fig. 6), loader lifting phase. The discharge oil enters the line (c) and supplies the second control valve pin line (b), if this is used. -- oil delivered on the quick coupler B2, oil discharged from the quick coupler A1 (1, fig. 6) lowering phase. The discharge oil enters the line (c) and supplies the second control valve pin line (b), if this is used.
87679925A1 - 02 - 2008
Oil at static rest. Pressurised oil. Discharge oil.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8 A second characteristic of this control valve is on the second control valve. This has the double acting + regenerating functions. Operating the pin produces: -- pressurized oil at the union A2 and discharge oil from union B2 (pressure on base side discharge on stem side) for the bucket unloading phase.
P
A1 B1
b P1
11
T
A2 B2
b
d
T1
d c
d
C
c
a
a
a
MDH1680A
--
pressurized oil at the union B2 and discharge oil from union A2 (pressure on stem side discharge on base side) for the bucket loading phase.
7 P
A1 B1
b P1
T
A2 B2
b
d
T1
d c
d
C
c
a
a
a
MDH1680B
8 If the second pin is taken into the regenerating phase, when the limiting bush allows it (see page14 ) there will be pressure on both unions (A2 and B2). -- with a cylinder with mechanical levelling and the areas of the piston of the same size there will be no movement of the bucket, the pressure sent into the two chambers simultaneously will keep the bucket stationary. -- If the loader has hydraulic levelling, where the two surfaces where the pressure acts are different, this situation would make the cylinder extend faster, obtaining faster discharge without energizing the solenoid valve on the loaderâ&#x20AC;&#x2122;s control valve (if the loader is equipped with this variant). This could be useful when working with the bucket and collecting sticky material you want to unload the bucket quickly even though the loader does not have the fast unloading function.
P
A1 B1
b P1
b
d
T1
d c
a
T
A2 B2
d
C
c a
a
MDH1680C
9
87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
12
VENTRAL CONTROL VALVE JOYSTICK
The ventral control valves are governed by a joystick (1) on the operatorâ&#x20AC;&#x2122;s right--hand side. There are two types of joystick: --
a joystick with just one button, for the North America version.
--
a joystick with two buttons, for the ISO version.
NOTE: If you purchase a loader equipped with a fourth external service, the third button on the joystick is not provided in the kit, it will be supplied with the loader.
10
Front loaders should only be attached to agricultural tractors that are equipped with a safety lock for the auxiliary control valve joystick. Tractors without lockable controls should have a shut--off valve installed in the hydraulic line between the auxiliary control valve and loader arm lift cylinders. The safety lock on the joystick has three positions: 1.
Fully out. All joystick movements available.
2.
Mid Position. Side movement (loading, unloading and fast unloading bucket) locked out.
3.
Fully in. All joystick movements locked.
11
ATTENTION To prevent accidental movement of the loader, the control lever or joystick should always be locked in neutral when travelling on the public highway or, alternatively, the shut--off valve should be closed (where fitted).
87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
13
Joystick Operation Pull the joystick backwards to raise the loader. If necessary, moving the joystick fully backwards, to overcome the resistance of the spring, increases the lifting speed. NOTE: With the ventral control valve with the push-button for the 80 litre variant the movement of the control valve pin inside the control valve itself, pulling the joystick back will cause the feeler to press the switch (6, fig. 5) that will send current to the solenoid valve of the supplementary control valve mounted on the power steering pump, on energizing it will not longer deliver oil (approximately 18 litres) for lubrication but will send it to the ventral control valves that will use it for the lifting phase (for further information see sect. 35 Chap. 7).
12
Move the joystick forwards into the lowering position to lower the loader to the ground at controlled speed. Further forward movement of the joystick will select the float position which will allow the loader arms to move up and down freely, enabling the bucket to follow the contours of the land. NOTE: When using the float position to lower the loader, pushing the joystick fully forward to overcome the resistance exerted by the return spring due to the double action, the lever will stay in that position thanks to a mechanical coupling in the cap of the control valve, to make it go back bring it out of the coupling manually. Moving the joystick to the left will cause the bucket to turn backwards (loading), moving the joystick to the right will turn the bucket forwards (dumping). Moving the joystick further to the right takes the pin of the control valve into the regenerating phase, that is the two chambers of the bucket cylinder are pressurized, with different loader behaviour: -- with the other types of loader, pressurizing both the stem and base sides will produce fast bucket dumping, see page11 (caption fig. 9). -- with the other types of loader, pressurizing both the stem and base sides will produce fast bucket dumping, see page11 (caption fig. 9). IMPORTANT: Do not hold the lever in the raise or lower positions once the loader or bucket cylinder has reached the extent of its travel. This will cause the relief valve to â&#x20AC;&#x2DC;blowâ&#x20AC;&#x2122; which, if occurring over an extended period, may overheat the oil.
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
Bucket movement control valve regenerating function disabling bush. All machines equipped with a front loader, inside the cap containing the cable junction (1) controlled by the joystick with the pin of the second control valve, the one for moving the bucket, are fitted in the factory with a bush (3, fig. 14).
13 The bush (3) is originally fitted inside the cable protection (1) and not on the pin of the control valve. In this way the control valve pin does not get disabled; this can extend, retract the cylinder and regenerate.
On fitting the loader with a fork, instead of a bucket, for handling pallets and not wanting to run the risk of regenerating the control valve pin, running the risk of quickly overturning the load (using a loader with hydraulic levelling), the bush can move into position (2) and disable the risk of overturning. In this way the control valve pin can only extend or retract the cylinder and the regenerating condition is disabled. Whereas the 1st control valve and its cable (4) are not affected by the bush.
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
15
SWITCHING FULL / DIPPED BEAM HEADLIGHTS ON LIGHTS FITTED ON HANDRAILS Working in the evening with a front loader, the bucket or attachment fitted on the loader, passing in the range of the lights on the radiator cowling, does not permit projecting the light so that you work in the dark on some sections. On these tractors it is possible to switch the full-dipped beam headlights on additional lights fitted on the handrails of the cab (1).
15 This switch is on the left--hand side of the dashboard on the switch panel. Press the button (1) on the side: A . energizes two relays that cut off power to the
lights on the radiator cowling and pass it to the ones fitted on the cab handrails.
B . de--energizes two relays that cut off power to the
lights on the cab handrails and pass it to the ones fitted on the radiator cowling.
16 The group of relays for the lights with the relays energized by the joystick buttons are located under the dashboard on the left--hand side straight above the clutch pedal switch.
17 87679925A1 - 02 - 2008
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
The switch connection, relay wires and wiring carrying the current to the lights on the handrails are part of the wiring connected to the main cab wiring. Under the dashboard on the left--hand side near the back of the fuse box there is a 6--pin connection where, when there is no loader, there is a connection with a 2--wire jumper (to bridge the full and dipped beam headlight wires); on the contrary, with the loader, the lights switch wiring must be connected.
18 The end of this wiring must be connected to a connection inside the Multi Quick coupler and is used to carry current to the solenoid valves of the loader (1). The opposite side is connected to the joystick buttons. Pressing these buttons energizes two relays (one for the nose joystick) that take the current from the fuse to the solenoid valves passing through the connection fitted alongside the Multi Quick coupler.
19
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
17
BALLASTING THE TRACTOR FOR FRONT LOADER OPERATION To ensure safe operation both in the field and on the public highway, it will be necessary to equip the tractor with some form of rear counterweight. This may take the form of liquid in the rear tyres, weights fitted to the rear wheels (1, Fig. 20 or a weight on the 3--point hitch (Fig. 21).
NOTE: Do not overload the tractor by selecting too heavy a ballast weight. See the tractor Operators Manual for maximum ballast recommendations. NOTE: Remove all front ballast weights from the tractor before attaching the front loader boom.
Tractor steering and braking should be taken into consideration when fitting additional weight. Adding too much or too little weight may have a serious effect on tractor control, stability and overall braking distances. NOTE: Never exceed the maximum permissible front axle loads, see page 3. Rear wheels ballast BALLAST
REAR TYRE SIZE All available rear tire sizes
Maximum of 3 weights per wheel (1) of 50 kg each Total weight per wheel -- 150 kg
Liquid tyre ballasting See tractor â&#x20AC;&#x153;Operators Manualâ&#x20AC;? for liquid tyre ballasting recommendations.
20
Rear counter weights Tractor hp (kW)
Loader model
Ballast weight*
60 -- 95 (44-- 70)
90 FL
650 kg
70 -- 95 (52 -- 70)
100 FL
650 kg
80 -- 120 (59 -- 89)
120 FL
650 kg
* Rear ballast weight attached to the 3--point hitch. The weights shown above are recommended for general purpose applications.
21
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
18
LOADER GENERAL DESCRIPTION Loader types -- tractor powers Type
Tractor power
KW/HP 56/76
63/86
71/97
78/106
X
X
X
X
X
X
X
X
90FLHS
NA
NA
NA
NA
100FLNS
X
X
X
X
X
X
X
X
120FLHS
X
X
X
X
120FLNS
X
X
X
X
X
X
X
X
X
X
X
X
90FLNS 90FLMS
Tractors from 44--70 kW (60--95 ( HP))
120FLMS
Tractors from 52--70 kW (70--95 ( HP))
120FLMS
Tractors from 60--89 kW (80--120 ( HP))
120FLHS NA = not available. Loader Description The FL range of loaders are available in three configurations. FLNS Hydraulically operated loader with Easylock mounting system, double acting cylinders for lift and bucket operation. Protective guard for radiator grille. Without self--levelling. FLMS Hydraulically operated loader with Easylock mounting system and double acting cylinders for lift and bucket operation. Hydraulic self levelling bucket control. Protective guard for radiator grille. FLHS Hydraulically operated loader with Easylock mounting system and double acting cylinders for lift and bucket operation. Hydraulic self levelling. Protective guard for radiator grille.
ATTENTION The mentioned technical data are theoretical values which apply only for liftarm pivot of the liftarm shown on the picture. In practice the actual values can differ from the mentioned values due to tractor geometry and tire equipment.
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
19
90FLNS
22 HYDRAULIC PUMP: 185 bar (18.5 MPA) EFFICIENCY: 0,85
NS
Q1
Breakout force
At pivot pin, at ground level
kg
2050
Q2
Lifting capacity
At pivot pin, max lift height
kg
1474
N1
Load
Centre of gravity of bucket at X = Max
kg
1551
N2
Load
Less bucket weight -- 200 kg
kg
1034
N1
Load
900 mm forward of pivot pin
kg
1234
N2
Load
Less Pallet Fork weight -- 120 kg
kg
810
R
Tearout force
At ground level
kg
1677
H
Max. height of lifting
At attachment pivot pin
mm
3755
L V
Lift--over height Tip angle
Bucket level With lift arm fully lowered
mm °
3545 155
Z
Dump angle
At maximum lift height
°
58
Y
Dump angle
At 3.5 m lift height
°
67
X
Roll--back angle
At ground level
°
47
A W
Dump height Dump height
At “Z” At “Z”
mm mm
2860 628
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
20 90FLMS
23 HYDRAULIC PUMP: 185 bar (18.5 MPA) EFFICIENCY: 0,85
MS
Q1
Breakout force
At pivot pin, at ground level
kg
2050
Q2
Lifting capacity
At pivot pin, max lift height
kg
1474
N1
Load
Centre of gravity of bucket at X = Max
kg
1850
N2
Load
Less bucket weight -- 200 kg
kg
1274
N1
Load
900 mm forward of pivot pin
kg
1930
N2
Load
Less Pallet Fork weight -- 120 kg
kg
1354
R
Tearout force
At ground level
kg
2288
H
Max. height of lifting
At attachment pivot pin
mm
3755
L V
Lift--over height Tip angle
Bucket level With lift arm fully lowered
mm °
3545 81
Z
Dump angle
At maximum lift height
°
58
Y
Dump angle
At 3.5 m lift height
°
67
X
Roll--back angle
At ground level
°
47
A W
Dump height Dump height
At “Z” At “Z”
mm mm
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
21
100FLNS, 100FLHS
24 HYDRAULIC PUMP: 185 bar (18.5 MPA) EFFICIENCY: 0,85
NS/HS
Q1
Breakout force
At pivot pin, at ground level
kg
2532
Q2
Lifting capacity
At pivot pin, max lift height
kg
1821 / 1761
N1
Load
Centre of gravity of bucket at X = Max
kg
1962 / 1902
N2
Load
Less bucket weight -- 200 kg
kg
1324 / 1264
N1
Load
900 mm forward of pivot pin
kg
1552 / 1492
N2
Load
Less Pallet Fork weight -- 120 kg
kg
1029 / 969
R
Tearout force
At ground level
kg
2070
H
Max. height of lifting
At attachment pivot pin
mm
3755
L V
Lift--over height Tip angle
Bucket level With lift arm fully lowered
mm °
3545 155
Z
Dump angle
At maximum lift height
°
58
Y
Dump angle
At 3.5 m lift height
°
67
X
Roll--back angle
At ground level
°
47
A W
Dump height Dump height
At “Z” At “Z”
mm mm
2860 628
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
22 100FLMS
25 HYDRAULIC PUMP: 185 bar (18.5 MPA) EFFICIENCY: 0,85
MS
Q1
Breakout force
At pivot pin, at ground level
kg
2532
Q2
Lifting capacity
At pivot pin, max lift height
kg
1821
N1
Load
Centre of gravity of bucket at X = Max
kg
2332
N2
Load
Less bucket weight -- 200 kg
kg
1621
N1
Load
900 mm forward of pivot pin
kg
2412
N2
Load
Less Pallet Fork weight -- 120 kg
kg
1701
R
Tearout force
At ground level
kg
2780
H
Max. height of lifting
At attachment pivot pin
mm
3755
L V
Lift--over height Tip angle
Bucket level With lift arm fully lowered
mm °
3545 81
Z
Dump angle
At maximum lift height
°
58
Y
Dump angle
At 3.5 m lift height
°
67
X
Roll--back angle
At ground level
°
47
A W
Dump height Dump height
At “Z” At “Z”
mm mm
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2860 628
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
23
120FLNS, 120FLHS
26 HYDRAULIC PUMP: 185 bar (18.5 MPA) EFFICIENCY: 0,85
NS/HS
Q1
Breakout force
At pivot pin, at ground level
kg
2310 / 2592
Q2
Lifting capacity
At pivot pin, max lift height
kg
1688 / 1878
N1
Load
Centre of gravity of bucket at X = Max
kg
1798 / 2034
N2
Load
Less bucket weight -- 200 kg
kg
1229 / 1381
N1
Load
900 mm forward of pivot pin
kg
1453 / 1625
N2
Load
Less Pallet Fork weight -- 120 kg
kg
974 / 1076
R
Tearout force
At ground level
kg
2036 / 2351
H
Max. height of lifting
At attachment pivot pin
mm
4084
L V
Lift--over height Tip angle
Bucket level With lift arm fully lowered
mm °
3874 155
Z
Dump angle
At maximum lift height
°
58
Y
Dump angle
At 3.5 m lift height
°
76
X
Roll--back angle
At ground level
°
47
A W
Dump height Dump height
At “Z” At “Z”
mm mm
3192 785
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
24 120FLMS
27 HYDRAULIC PUMP: 185 bar (18.5 MPA) EFFICIENCY: 0,85
MS
Q1
Breakout force
At pivot pin, at ground level
kg
2310
Q2
Lifting capacity
At pivot pin, max lift height
kg
1688
N1
Load
Centre of gravity of bucket at X = Max
kg
2110
N2
Load
Less bucket weight -- 200 kg
kg
1488
N1
Load
900 mm forward of pivot pin
kg
2190
N2
Load
Less Pallet Fork weight -- 120 kg
kg
1568
R
Tearout force
At ground level
kg
2281
H
Max. height of lifting
At attachment pivot pin
mm
4084
L V
Lift--over height Tip angle
Bucket level With lift arm fully lowered
mm °
3874 86
Z
Dump angle
At maximum lift height
°
58
Y
Dump angle
At 3.5 m lift height
°
76
X
Roll--back angle
At ground level
°
47
A W
Dump height Dump height
At ”Z” At ”Z”
mm mm
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3192 785
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
25
Lift arm main dimensions
28
Type 90FL 100FL 120FL
L
B
H
Ã&#x2DC; Cylinder
mm
mm
mm
mm
2500
95
3750
2720
115
4080
63 / 40 70 / 45 70 / 45
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26
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
Reference dimension for drive--in support bracket
29
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
27
Reference dimensions for hook attachments
30
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
28
LOADER INSTALLATION -- REMOVAL Installation of loader unit Unhook the Easylock lever (1) on the loader parked on the ground, climbing onto the tractor, drive it forwards until the pins (2) enter the bottom of the respective shoes. Brake the tractor in this position by applying the handbrake.
Connect the hydraulic line by means of the respective Multi Quick couplers and electrical connections, where applicable, see page 49. Move the control valve lever into the lifting position, until the pins (2, fig. 31) contact their seats completely on both sides. Lift the loader arms until the bucket is clear off the ground and move the Easylock lever (1, fig. 31) fully down to the locked position.
31
32 Fold the support stands against the lift arm, see page 31.
ATTENTION When handling the parking stand there is a danger of injury by pinching. Keep hands clear of the area between support stand and loader arm. Operate the loader lift and bucket cylinders several times to circulate the hydraulic oil. Check to ensure hydraulic hoses and electrical cables are not chafing or trapped. Ensure the Multi Quick coupler is securely clamped and there are no visible signs of oil leaks.
ATTENTION Do not operate the bucket or attachment cylinders until the loader arms are securely locked in the support pillars. Operating the bucket or attachment cylinders may result in injury or damage to the parking stands.
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29
Adjusting the Easylock system. The Easylock system comprises of an adjustable wedge that is inserted between the glide rail and the rear support pin when the locking lever is in the fully down position. After initial installation or a period of work, it may be necessary to re--set the tension on the locking wedge. Access to the locknut (4) may be gained by moving the locking lever into the release position and inserting a 24 mm open ended spanner through the vertical locking lever slot. Loosen the locknut and, using a 24 mm socket and bar, rotate the tensioning bolt (5) anti--clockwise to tighten the wedge. Adjust in small increments until the tensioning process commences in position (b) of the gripping lever, which should be noticeably preloaded in position (c). Re--tighten the locknut (4) after adjustment. When correctly set, the tensioning wedge will prevent the loader pins from moving in the locating hooks when the locking lever is moved fully down to position (c). The tensioning mechanism should be checked for play each time the loader is re--attached to the support pillar. If the loader remains mounted on the tractor for long period, it is recommended the tensioning adjustment be checked on a regular basis. Re--adjust if necessary.
33
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30
Removal of the front loader
ATTENTION The loader arms or attachments should only be installed and removed by the operator. Do not park the front loader on the ground without the bucket or another implement attached, otherwise there is the danger of the loader tipping over! Select a flat, level surface and lower the loader to the ground. With the bucket or attachment resting on firm level ground, move the locking lever (1) to the release position (a). Continue to lower the arms until the pins (2) come into contact with the runner. Using the joystick, slowly retract the lift cylinders until both upper pins (2) are fully free of the locking hook, but remain supported by the runner; then switch off the tractor engine and apply the handbrake.
MMG1643A
34 NOTE: Slightly raising the front loader attachment as well as thoroughly lubricating the glide path will assist in loosening the tensioning wedge. Release the parking stands from the retaining catches and lower them to the ground. The stands will remain fixed in the lowered position when the support struts are positioned, see page 31. Ensure the ground is firm enough to support the loader.
MMG1643B
Disconnect the loaderâ&#x20AC;&#x2122;s hydraulic Multi Quick coupler from the tractor and place in a safe position, see page 50. Disconnect any electrical connectors and place them in a safe position.
35
With the parking stands down and the loader safely supported, start the tractor engine and carefully reverse away from the loader ensuring disconnected hoses and electrical cables do not get crushed by the tractor or loader support pillars.
36
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
31
Unfolding Varipark system stands. To unfold the parking stands (2), move them sideways towards the tractor, against spring pressure, while simultaneously pressing down. The stand will then release from the locking catch (1) and can be lowered to the ground. The parking stands will remain fixed in the open position once the support strut locks have been positioned (3, fig. 38), held by the preload of the spring (4).
ATTENTION Ensure the ground is firm enough to support the loader.
Folding up Varipark system stands. To fold up the Varipark stands, use one hand to pull up the support strut (3) against the resistance of the torsion spring (4) in the direction of arrow (A) and at the same time push the Varipark stand in the direction of arrow (D). Keep on holding the strut to prevent it locking and quickly move the stand upwards until it goes into the catch of the spring (1, fig. 37). To facilitate easy operation, keep the spring catches lubricated.
37
ATTENTION When handling the Varipark stand there is a danger of injury by pinching. Keep hands clear of the area between Varipark stand and loader arm.
38
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
32
Loader installation/removal decal NOTE: to ensure complete safety when removing or installing the loader boom, follow the instructions of the decal placed on the loader pillar.
A B
C
D
B
LOADER INSTALLATION AND REMOVAL DECAL
39
Connection
Removal
1. Unlock the hand lever, detail (1, fig. 39). 2. Drive the tractor forward until the pins (B) come into contact with the stop shoe (A) of the runner (D). Stop the tractor and apply the parking brake. 3. Relieve hydraulic system pressure (see tractor operatorsâ&#x20AC;&#x2122; manual) and connect the Multi Quick coupler and electrics. 4. Raise the loader until the loader arm retaining pins (B) are fully resting in the shoe.
Do not remove the loader unless a bucket or attachment is fitted.
ATTENTION
ATTENTION Do not operate the bucket or attachment cylinders until the loader arms are securely locked. 5. Raise the loader and move the lever downwards so that the locking wedges (C) go into position on the bottom pin, (B) detail (2, fig. 39).
87679925A1 - 02 - 2008
1. Apply the tractor parking brake and lower the loader until it is resting on the ground. 2. Lower the parking stands and unlock the hand lever, detail (1, fig. 39). 3. Continue to lower the loader until the rear pins are resting on the glide rails. 4. Disconnect the Multi Quick coupler and electrical connections. Reverse the tractor away from the loader assembly.
ATTENTION
Check the tightness of the locking mechanism at regular intervals, adjust if required.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
33
ATTACHMENT INSTALLATION -- REMOVAL
WARNING
The loader arms or attachments should only be installed and removed by the operator.
Installing attachments using Quick Attach
1. Using the joystick, tilt the quick attach frame approximately 15 degrees forward and drive up to the attachment. 2. Pull out the release handle (1) for the locking bar on the left hand side of the quick attach frame. Turn the release handle clockwise until the locking bar rests against the lower end of the slotted hole. The stop (2) on the locking bar will prevent the bar from springing back to the lock position. 3. Position the top shaft of the quick attach frame below the hooks on the attachment and raise the loader arms. To ensure the shaft is correctly seated in the hooks, visually check that the top of the attachment is parallel with the quick coupler frame on both sides; then raise the attachment clear off the ground.
40
4. Continue to tilt the quick attach frame rearwards until the locking bar is released and spring pressure automatically engages it in the two lugs on the rear of the attachment. The attachment is now securely mounted on the Quick Attach frame. 41 IMPORTANT: To allow correct operation of the self locking system, do not raise the attachment more than 50 cm above the ground before tilting the frame rearwards. Removing the bucket or attachment is the reversal of the mounting procedure.
N.B.: Before using the front loader, visually check that the pins of the locking bar are fully engaged and the attachment is safely secured to the quick attach frame. Lubricate the contact areas of the locking bar frequently to assist easy operation.
42 87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
34
Setting Bucket Level Indicator. After changing a bucket or attachment, it may be necessary to adjust the level indicator so that the top ends of guide tube (2) and indicator rod (1) are aligned when the attachment is horizontal.
To adjust the level indicator, ensure the attachment is horizontal and loosen the locknut (3) on the retaining bolt (4). Unscrew the pinch bolt approximately two turns until the guide tube can be moved in the support collar. Align the end of the indicator rod with the guide tube then re--tighten the pinch bolt and locknut. The bucket level indicator will provide a visual indication of the bucket angle when backfilling, levelling, scraping, digging, raising or when transporting loads.
43
ATTENTION When using a loader equipped with self--levelling, be aware of bucket position at all times. A loader in the raised position with the bucket fully rolled back may dump material onto the tractor causing damage or injury to tractor and/or operator.
87679925A1 - 02 - 2008
44
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
35
Installing Attachments Using Hydro Quick Attach (where fitted) The optional Hydro Quick Attach (HQA) facility allows the operator to change buckets or attachments without leaving the seat. Hydro Quick Attach is operated by using the selector switch (1), in combination with the loader joystick.
NOTE: The Hydro Quick attachment enabling -- disabling button (1) is not in the loader assembly kit for T5000 series machines, so it will be supplied with the loader. NOTE: The selector switch must always be returned to the ’off’ position (light extinguished) after removing or changing the attachment. Leaving the switch in the ’on’ position may reduce battery power if the tractor is not used for a period of time.
45
Installing Attachments 1. Depress the release side of the selector switch (the warning light will illuminate). Move the joystick operating the bucket crowd circuit. Hold the joystick in this position until the hydraulic locking pins (1) are fully retracted. 2. Move the tractor forward until the top shaft on the quick attach frame is positioned below the hooks on the rear of the attachment. Slowly raise the loader until the shaft is fully seated in the hooks. Visually check that the top of the attachment is parallel with the quick attach frame then raise the attachment until it is just clear of the ground.
3. Press the lock side of the selector switch (the warning light will extinguish) and, moving the joystick, roll the attachment rearwards until the crowd cylinders are fully withdrawn. Continue to hold the joystick in this position for a few seconds until the locking pins (1) are fully extended and the attachment is secured to the frame.
46
IMPORTANT: To maintain attachment lock, the HQA selector switch must be left in the lock (off) position. N.B.: Before using the front loader, visually check that the pins of the locking bar are fully engaged and the attachment is safely secured to the quick attach frame. Lubricate the contact areas of the locking bar frequently to assist easy operation.
47
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
Removing Attachments 1. To remove the attachment, depress the release side of the selector switch (warning light on). Using the joystick, fully roll back the attachment and hold in this position for a few seconds to release the locking pins. 2. Rotate the attachment forward until it is level and then lower to the ground. With the attachment on the ground continue to rotate the quick attach frame forwards simultaneously lowering the loader arms. When the top shaft is clear of the hooks slowly reverse the tractor away from the attachment.
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37
LIFT ARM TYPES AND FUNCTIONS FL front loaders are offered not only in the NS version without levelling, but also with the multi functional hydraulic self levelling motion type HS or with mechanical self levelling motion type MS. Mechanical self levelling Loaders with mechanical self--levelling lift and lower the attachments keeping the angle between the attachment and the ground constant, set by the attachment cylinder. This is thanks to a bar fitted parallel to the first section of the supporting arms of the loader. Bar on the one side secured to the front portion of the loader and on the other to a bracket joining the attachment cylinder and the centreline of the loaderâ&#x20AC;&#x2122;s supporting arms.
48 1. 2. 3. 4.
Mechanical levelling bar pivot. Attachment cylinder (loading/unloading bucket), Attachment cylinder pivot. Attachment cylinder pivot on attachment side.
5. 6.
Bracket joining the attachment cylinder, mechanical levelling bar and centreline of the loader. First section of the loaderâ&#x20AC;&#x2122;s supporting arms.
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38
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
Advantages of Hydraulic self levelling Hydraulic self levelling can be switched off by the push on a button When a loader is lifted with the Hydraulic self levelling switched off, the load falls down into the bucket -- because the angle of the attachment increased while rising the liftarm. There are no losses because of pouring. Mechanically controlled front loaders do not possess this â&#x20AC;&#x153;scooping effectâ&#x20AC;?.
Rapid discharge Fast Tip Besides discharge with normal speed you can, on your HS--loader, press a button to activate the integrated rapid discharge valve in order to get a rapid discharge. This optional function not only saves time and increases the loading performance, but it also improves the discharge properties when handling sticky goods because of the jolting action of the bucket -even the corners of the bucket are cleared.
Adjustable lowering speed There are loading jobs where a sensitive control operation is required, such as the loading of pallets. One turn on the adjustment valve, and the HS--loader can be operated sensitively. When loading ground or manure, time is often restricted. No problem with the HS--loader -- one turn of the valve and you are on rapid operation.
49
50
NOTE: When rapid--discharging operate control unit and push--button always combined!
51
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
39
Operation of Hydraulic self levelling In order to work with the hydraulic self--levelling function, the adjusting toggle SK of the control unit must be turned and locked in the direction of “Float Disengagement” (Z). Pressing the off button (S2) at the liftarm actuation control lever will result in the short term de--activation of the Hydraulic self levelling. The loader liftarm is locked hydraulically while it is being raised or lowered with a tipped bucket. Pressing the off button (S2) deactivates the locking effect. If Hydraulic self levelling is disengaged the Lift capacity of the loader liftarm will increase.
52
Turn adjusting toggle SK of the control unit to “floating position” (A) if: -- More lowering speed of the loader arm is required (without accurate parallel motion). -- The loader arm has to be lowered when the tractor engine is stopped. -- The front loader has to be removed. In this case pressure is released from the hydraulic rams and operation of the screw couplings will be easier. -- When the loader arm must be set in the floating position, for example for levelling work such as snow--ploughing, etc. In this case set the control unit to the floating position and operate the off button (S2 Hydraulic self levelling “off”).
Closed
53
fast movement in parallel extension ”QUICK OUT” maximum lift capacity
Open
work in position of float function
Parallel movement: LIFT/LOWER. Attachment completely unloaded or tilted -- Loader not working
Parallel movement: LIFTING Maximum lowering speed (parallel movement less precise in the LOWERING function)
LOWERING the liftarm with the engine switched off
Removing the front loader (hydraulic system depressurized)
54
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40
Function of Hydraulic self levelling The oil will be diverted during raising of the loader liftarm from the piston rod area of the liftarm rams into the piston chamber of the attachment rams. The oil from the piston rod chamber of the attachment rams flows via a load retaining valve back into the oil reservoir of the tractor. This process will result in a following control function which ensures (in conjunction with the preceding control lever system) that the bucket, with is horizontally adjusted base, assumes in every attitude of the liftarm an attachment angle parallel to the starting position. The oil supplied by the tractor pump flows during lowering of the loader liftarm into the piston rod chamber of the attachment rams, at the same time there is a transfer of oil from the piston chamber of attachment rams into the piston ring chambers of the liftarm rams which are thereby retracted. The oil from the piston chamber of the liftarm rams returns via a load retaining valve to the oil reservoir to the tractor. The oil from the piston chamber of the liftarm rams returns via a load retaining valve to the oil reservoir to the tractor. The oil supplied by the hydraulic pump of the tractor flows during tilting (charging) of the bucket into the piston rod chambers of the attachment rams and the oil from the piston chamber of the attachment rams then flows pressure--free back into the oil reservoir of the tractor. The oil supplied by the hydraulic pump of the tractor flows during tipping (discharging) of the bucket into the piston chambers of the attachment rams and the oil returning from the piston rod chambers of the attachment rams is at the same time conducted via a load retaining valve into the oil reservoir of the tractor. This process prevents also rapid dropping of the bucket.
ATTENTION When lowering the loader arm with Hydraulic self levelling switched on, avoid too high an engine speed otherwise the pressure relief valve of the tractor hydraulics would respond causing the hydraulic pump to steadily feed oil against high pressure.
55 1. 2. 3.
Attachment cylinder pivot. Attachment cylinder. Pivot on attachment side.
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4. 5. 6.
Hydraulic levelling control valve. First section of the loaderâ&#x20AC;&#x2122;s supporting arms. Flow of oil in the self--levelling phase.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
41
Float mode for FLHS models Turn the selector control (SK) two turns anti--clockwise (direction A) to engage float facility. This setting provides a good balance between the accuracy of the self levelling function and speed of loader operation. Turning the selector control further anti--clockwise will have no noticeable effect on loader performance. With the joystick in the float position, the loader arms are free to move up or down following the ground contours. This is very useful for grading topsoil or other fine materials where the tractor moves in reverse with the underside of the bucket â&#x20AC;&#x2122;floatingâ&#x20AC;&#x2122; on the surface of the ground. Using this technique, tractor wheel marks are removed from the finished work. IMPORTANT: Do not carry out grading operations with fully extended attachment cylinders. The bucket should not be tilted down by more than 45 degrees. A greater tilt angle may result in serious damage to both front loader and tractor.
MMG1645A
56
In loading applications, the float facility can be used to automatically lower the loader when reversing away from the hopper or trailer being filled. When using the loader for clearing snow it is recommended the selector valve be set to the float position. NOTE: To lower the loader boom with the engine switched off, always select float mode. If the front loader is to be removed from the tractor, selecting float will make it easier to relieve oil pressure in the hydraulic lines. NOTE: Refer to the tractor Operators Manual for correct procedure to release system pressure when operating a loader using electronic remote control valves.
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42
Bucket rapid discharge function (FLNS and FLHS models) By engaging the Fast Tip function, the operator can generate a higher oil flow to provide rapid tipping of the loader bucket. Sticky materials can be easily discharged by using the momentum generated by Fast Tip to ’jerk’ material free from the bucket. FLNS and FLHS loaders with the 3rd auxiliary hydraulic valve and Fast Tip, have a two position selector switch mounted on the left side of the cross beam. This switch, operating in conjunction with the button on the joystick, selects either third service operation, position I, or the Fast Tip function, position O. With Fast Tip selected, the 3rd service is non functional, likewise, with 3rd service activated, Fast Tip will not operate. With Fast Tip activated, the hydraulic oil in the rod end of the bucket cylinder is quickly transferred to the piston end of the cylinder as the bucket is tipped. Additional oil from the tractor hydraulic system is used to ’top up’ the piston end of the bucket cylinder preventing cavitation during the next loading cycle.
57
The Fast Tip function is activated by depressing button 1 (NS) or button 2 (HS) on the joystick.
ATTENTION Engage the Fast Tip function only when tipping the bucket. If Fast Tip is activated during bucket or attachment roll--back, the control valve will immediately reverse bucket rotation causing it to tip.
58
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43
Lowering speed adjustment FLHS models (if installed) For normal operation, the speed adjustment screw (S) is set to provide rapid lowering of the loader arms. However, when operating with pallet forks or similar, improved control during the lowering cycle will be of great benefit. To reduce the lowering speed and improve control sensitivity, turn the adjusting screw (S) clockwise (screw inwards) until it stops. Do not overtighten the screw. For general applications, set the screw (S) to provide rapid lowering by turning fully anti--clockwise (screw outwards). Do not overtighten the screw as this may result in damage to the oil seals. 59
ATTENTION With hydraulic self levelling activated, avoid using high engine speeds when lowering the loader as this may cause the main pressure relief valve in the tractor hydraulic system to operate. This may cause the hydraulic oil to overheat resulting in possible damage some internal components.
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44
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
Third and Forth auxiliary hydraulic service (where fitted). Attachments with additional hydraulic services, such as a silage forks or bale grab, may be operated through an electronically controlled auxiliary hydraulic circuit. The additional hydraulic valve, or valves, are located on the loader arm cross beam and are controlled by push button(s) on the loader joystick. When viewed from the tractor seat the third auxiliary control valve connectors are on the right side of the cross beam and the fourth auxiliary control valve connectors on the left side. Switching from the bucket cylinder circuit to the auxiliary circuit is achieved by depressing and holding the push button on the joystick which corresponds to the hydraulic function required. With the button depressed, move the joystick to the left or right to operate the auxiliary circuits. Releasing the button returns control to the bucket tip circuit. NOTE: The system for the fourth service is not supplied in the loader assembly kit for T5000 series tractors. The button for the fourth service control valve is supplied with the loader. Joystick Button Functions With FLMS loader Push--button 1. Third auxiliary service circuit. Push--button 2. Fourth auxiliary service circuit. With FLNS loader Push--button 1. Third auxiliary service circuit / fast tip function. Push--button 2. Fourth auxiliary service circuit. With FLHS loader Push--button 1. Suspend attachment self--levelling action. Push--button 2. Third auxiliary service circuit / fast tip function. Push--button 3. Fourth auxiliary service circuit (if fitted). N.B.: When operating the loader, ensure that the tractor engine speed setting is high enough to generate sufficient oil flow to allow full control of all loader functions. N.B.: When using a four--position remote valve with Float facility, do not use float position to tip a loaded bucket. NOTE: If the above recommendations are not observed, a vacuum may be created in the hydraulic cylinders which may cause the hydraulics to perform erratically during the next operating cycle.
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60
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
45
Connecting the third and fourth hydraulic service
-- with Quick Couplers Before connecting the couplers, ensure both male and female connectors have been thoroughly cleaned. Relieve any pressure in the tractor hydraulic system before attempting to couple the connectors. (See the tractor Operators Manual). Remove the protective covers from the connectors and, gripping the hose tightly close to the male connector, push firmly into the female connector until it â&#x20AC;&#x2122;clicksâ&#x20AC;&#x2122; into position. Pull lightly on the hose to ensure it is fully engaged in the coupler.
61
For the attachment to work properly, a grapple bucket for instance, the grapple must open when the joystick is moved to the left (bucket crowd) and close when the joystick is moved to the right (bucket unloading). For the attachment hydraulic function to operate, the corresponding button on the joystick must be kept depressed. To disconnect the Quick Coupler, grip the hydraulic hose close to the male connector and push inwards. Move the collar on the female connector upwards against spring pressure to release the locking mechanism. Pull the attachment hose out of the coupler. Release the collar, clean any oil from the connectors and replace the protective covers. -- with Multi Quick Couplers Operation of the Multi Quick coupler for attachments is similar to connecting the loader arm hydraulic hoses. See text on Multi Quick Coupler operation, pages 49 and 50.
62
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46
SMOOTH RIDE CONTROL
Description of operation Longer transport travels at high speed on bumpy lanes can heavily stress the tractor and the driver especially if a front loader is installed. This situation is largely improved by the SMOOTH RIDE CONTROL system available as an option for the front loader (retrofit is also possible). The operating principle is simple but highly effective: opening of a shut--off tap will lead the oil inside the service for the loader arm cylinders to be deviated towards two diaphragm--type pressure accumulators. The oil can expand against the pressure of the rubber diaphragms. Violent shocks transmitted from the road to the front loader are effectively damped and eliminated by the pressure accumulators.
63 1. 2. 3.
Gas pressure cylinder Diaphragm Stop valve, open
To suppress the SMOOTH RIDE CONTROL effect for the loading operation, it suffices to close the shut-off tap again.
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4. 5.
Pressure variations Line leading to tractor control valve
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
47
SMOOTH RIDE CONTROL protects your tractor and increases the driving comfort. Without SMOOTH RIDE CONTROL
With SMOOTH RIDE CONTROL
64 When a tractor is fitted with a conventional front loader, i.e. without SMOOTH RIDE CONTROL, the jolting that occurs when travelling at high speed over rough terrain is further accentuated by the front loader. This effect can only be reduced by the flexing action of the tires if the tractor is fitted with rigid axles. Both tractor and driver are heavily stressed as a result of the poor travelling characteristics.
65 If fitted with the SMOOTH RIDE CONTROL system, the front loader effectively cushions the movement of the tractor under the same conditions. Sitting relaxed in his cab, the driver securely steers the tractor along the road. Shocks acting on the front loader are smoothly compensated by the two pneumatic pressure accumulators -- the connection between tractor and front loader is no longer rigid but flexible.
General instructions When the loader unit is fitted with SMOOTH RIDE CONTROL please notice the following instructions: • It is preferable to use SMOOTH RIDE CONTROL when operating in long term road driving and bad road conditions (cock valve open). As shown in principal on the picture right the impact load of the liftarm will be damped through the accumulator. • When loading with short distances to drive, such as earthwork, the SMOOTH RIDE CONTROL cock valve should be closed between the lift side of the liftarm ram and the accumulator. At maximum load of front loader the permanently changing use are disadvantages for the membrane of the accumulator. Further wise, a certain “swinging effect” can occur through the accumulator. The cock valve should be also closed when working with palette forks to refuse any “swinging effects” when lifting or lowering of palette.
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48
Please observe the following instructions when your front loader is fitted with Smooth Ride Control. 1. It is recommended that Smooth Ride Control is switched to the ON position (1) when travelling on the highway or during long journeys on bumpy surfaces.
1
ATTENTION Before carrying out any operations with a heavy load, earth moving for instance, close the shut--off valve between the lifting side of the loader arm cylinders and the pressure accumulator of the smooth ride system, position (2).
N.B.: If the front loader is used with a heavily laden bucket and the shut--off valve open, peak pressures developed by load â&#x20AC;&#x2122;bounceâ&#x20AC;&#x2122; may lead to failure of the diaphragm in the accumulator. If the loader is operated with Smooth Ride Control activated, the pressure accumulator may produce a surge effect causing the loader arms to raise unexpectedly.
WARNING When operating with pallet forks the shut--off valve for ride control must be closed, position (2) (system de-activated).
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2 66
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
49
MULTI QUICK COUPLER CONNECTION -- DISCONNECTION Multi Quick coupler connection. All for hydraulic hoses can be connected and disconnected in no time. This is a very good solution that pays as connection times significantly reduce. It is possible to unbolt with maximum hydraulic pressure. This is an environmentally friendly solution as significant leakages will not occur.
ATTENTION It is essential that the male and female connectors of the Multi Quick Coupler are clean when the hoses are coupled. Relieve all pressure from the hydraulic system before coupling the hoses. Damage to the seals could result if the hoses are coupled under pressure. To couple with the Multi Quick coupler, depress the button (2) and lift the clamp lever (3). Raise the hinged guard (1) protecting the female connector until it locks in the vertical position as shown. Using the two pins on the male connector as a guide, place it onto the female connector and pull down the clamp lever until the button (2) is seen to spring out, locking the lever.
Guidelines for connecting hydraulic hoses:
67
1. Loader arm lower 2. Loader arm raise 3. Bucket roll back 4. Bucket tip Where fitted, connect the loader electrical services after first removing their protective dust covers. IMPORTANT: Whenever the loader is removed from the tractor, always ensure the cover (1) for the manifold is fully closed to prevent dust and debris getting inside.
68
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50
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
Multi Quick coupler disconnection. N.B.: It is essential to make sure the male and female couplings on the Multi Quick Coupler are clean before attempting to couple or uncouple the hoses. Relieve all pressure from the hydraulic system (see the tractor Operators Manual) before coupling the hoses. With the loader resting on the ground, relieve all pressure in the hydraulic system. Press the button (2) and lift the clamp lever (3) until the upper part of the Multi Quick Coupler can be removed from the female connector. Lower the hinged cover (1) to protect the female connector block. Return the clamp lever to the locked position. NOTE: With the loader uncoupled. To prevent unnecessary strain on the hoses and couplings, attach the male coupler and electrical connector to the Easylock connector control lever, (1 Fig. 34). Where fitted, disconnect the loader electrical connections and fit on their protective dust covers.
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
51
Connecting the third and fourth hydraulic service
For the attachment hydraulic function to operate, the corresponding button on the joystick must be kept depressed.
-- systems with Quick Couplers (1, fig. 70) Before connecting the couplers, ensure both male and female connectors have been thoroughly cleaned. Relieve any pressure in the tractor hydraulic system before attempting to couple the connectors. (See the tractor Operators Manual). Remove the protective covers from the connectors and, gripping the hose tightly close to the male connector, push firmly into the female connector until it â&#x20AC;&#x2122;clicksâ&#x20AC;&#x2122; into position. Pull lightly on the hose to ensure it is fully engaged in the coupler. For the attachment to work properly, a grapple bucket for instance, the grapple must open when the joystick is moved to the left (bucket crowd) and close when the joystick is moved to the right (bucket unloading).
To disconnect the Quick Coupler, grip the hydraulic hose close to the male connector and push inwards. Move the collar on the female connector upwards against spring pressure to release the locking mechanism. Pull the attachment hose out of the coupler. Release the collar, clean any oil from the connectors and replace the protective covers. -- with Multi Quick Couplers (2, fig. 70) Operation of the Multi Quick coupler for attachments is similar to connecting the loader arm hydraulic hoses. See text on Multi Quick Coupler operation, pages 49 and 50.
70
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52
Multi Quick coupler Tractor -- liftarm
71 1. 2. 3. 4. 5.
Multi Quick Coupler upper part. Multi Quick Coupler lower part. Male seal coupling. Female seal coupling. Lever locking knob.
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6. 7. 8. 9. 10.
Cover. Male/female terminal ends. Lever retaining screw. Handle. Multi Quick lower assembly retaining bolts.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
53
Liftarm -- attachment.
72 1. 2. 3. 4.
Multi Quick Coupler upper part. Multi Quick Coupler lower part. Male coupling. Female coupling
5. 6. 7. 8.
Lever locking knob. Cover. Coupling guide grub screw. Handle.
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
54 Coupling outfit Tractor -- liftarm Male coupling:
Female coupling: 1. 2. 3. 4.
73
Tappet Anti Extrusion Ring O--Ring Circlip
74 Liftarm -- attachment Male coupling:
Female coupling: 1. 2. 3. 4.
75
Tappet Anti Extrusion Ring O--Ring Circlip
76 87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
55
Multi Quick Coupler troubleshooting Fault Description
Corrective action
Leakage with Multi Quick Coupler connected.
Locate the leaking line by means of draining holes on the sides of fixed part. Replace the damaged seal (N, fig. 77) of the male coupling that leaks. If the leak continues, replace the female coupling too. If the leakage goes on again verify if the levers are deformed. Deformed levers provoke a misalignment and cause the seals breakage.
Leakage resulting from a connection under pressure.
Locate the leaking line by means of draining holes on the sides of fixed part. Replace the damaged seal (N, fig. 77) of the male coupling that leaks. If the leak continues, replace both male and female couplings of the relevant line. If the leakage goes on again verify if the levers are deformed. Deformed levers provoke a misalignment and cause the seals breakage.
Leakage from the male part in disconnected position.
Locate the leaking line. Replace the damaged seal (N, fig. 77) of the male coupling that leaks . If the leak continues, replace the male coupling of the relevant line. If, after testing the line, the leakage continues then replace the female coupling and the seal (N, fig. 77) of the male coupling . If the leakage goes on again verify if the levers are deformed. Deformed levers provoke a misalignment and cause the seals breakage.
Leakage from the female part in disconnected position.
Locate the leaking line. Replace the female coupling of the relevant line.
Multi Quick Coupler does not connect.
Verify if the lines are under pressure. With lines under pressure it is necessary an higher force on the lever. If you are not able to get a manual connection do not use extensions or other attachments, you could damage the levers and the internal components of couplings. Decrease the pressure by unscrewing the fittings. If the lines are not under pressure verify that the levers or the reference pins are not damaged. If they are, replace them.
Multi Quick Coupler does not disconnect.
Verify if the levers are not damaged. If they are, replace them.
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56
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
77 Diagram of the coupling between the male and female unions with the aid of the Multi Quick coupler.
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
57
Replacement of female part coupling 1. Unscrew the damaged internal body (1).
2. Reassemble the new internal body as shown in the drawing.
78
79 3. Re--position the coupling and tighten to 70 Nm.
80
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58
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
Replacement of male part coupling 1. Unscrew the lock nut (1) by using the socket wrench (2).
2. Remove the damaged male part.
81
82 3. Insert the new male part on shoulder.
4. Re--position the coupling and tighten the lock nut to 50 Nm.
83
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
59
Replacement of seals to male section of Multi Quick Coupler 1. Tighten the manifold block in a vice.
2. Pull back the valve with a screw driver.
85
86 3. Keep the valve open by utilising a suitable tool.
87
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
4. Remove the damaged seal.
5. Clean the seal seat carefully. 6. Lubricate the seal before inserting in the groove. 7. Insert the seal in the position as shown in the figure.
88
89 8. Ensure that the seal is well arranged in its groove. 9. Release the valve carefully.
Lever Replacement 1. Take out the screws (1 and 2). 2. Remove the damaged lever. 3. Insert the new lever. 4. Grease the holes (3). 5. Insert the screws (1 and 2). 6. Tighten screws to 40 Nm.
90
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61
HYDRAULIC FUNCTIONS AND OIL FLOW FOR HS LIFTARM Liftarm lowering without Hydraulic self levelling
8
7
6
4
5
2
3
1
12 13 11 9
10
92 1. 2. 3. 4. 5. 6. 7.
Hydraulic self levelling Lowering brake valve Load check valve Lowering brake valve -- attachment Load check valve Pressure relief valve A Pressure relief valve B
Operating:
8. 9. 10. 11. 12. 13.
Fast Tip valve Adjusting toggle Pressure relief valve C Driving direction Liftarm cylinder Attachment cylinder
-- Press button S2 -- Move Joystick to lower position
Valve functions: Pressurized oil (red):
-- Hydraulic self levelling valve (1) switched â&#x20AC;&#x153;onâ&#x20AC;? -- Lowering brake valve (2) active
Return flow (green):
-- Load check valve (3) in neutral -- Adjusting toggle (9) in closed position
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62
HYDRAULIC FUNCTIONS AND OIL FLOW FOR HS LIFTARM Liftarm raising without Hydraulic self levelling
8
5
7
3
4
1
2
6
12
13 11 9
10
93 1. 2. 3. 4. 5. 6. 7.
Hydraulic self levelling Lowering brake valve Load check valve Lowering brake valve -- attachment Load check valve Pressure relief valve A Pressure relief valve B
Operating:
8. 9. 10. 11. 12. 13.
Fast Tip valve Adjusting toggle Pressure relief valve C Driving direction Liftarm cylinder Attachment cylinder
-- Press button S2 -- Move Joystick to lift position
Valve functions: Pressurized oil (red):
-- Load check valve (3) in open position -- Lowering brake valve (2) in neutral position -- Adjusting toggle (9) in closed position
Return flow (green):
-- Hydraulic self levelling valve (1) switched â&#x20AC;&#x153;onâ&#x20AC;?
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63
Liftarm lowering with Hydraulic self levelling
8
7
6
5
4
2
3
1
12
13 11 9
10
1. 2. 3. 4. 5. 6. 7.
Hydraulic self levelling Lowering brake valve Load check valve Lowering brake valve -- attachment Load check valve Pressure relief valve A Pressure relief valve B
Operating: Valve functions: Pressurized oil (red):
Pilot oil (orange):
Return flow (green):
8. 9. 10. 11. 12. 13.
Fast Tip valve Adjusting toggle Pressure relief valve C Driving direction Liftarm cylinder Attachment cylinder
94
-- Move Joystick to lower position
------------
Hydraulic self--levelling valve (1) in neutral position Load check valve (5) in open position Lowering brake valve (4) neutral position Pressure relief valve A/B/C (6/7/10) in neutral position Fast Tip valve (8) in neutral position Attachment cylinder (13) in retracted position The hydraulic oil on the piston side of the attachment cylinders (13) is sent onto the lift arm cylinder stem side (12) Lift arm cylinder (12) in retracted position Load check valve (3) in neutral position Lowering brake valve (2) in on position Adjusting toggle (9) in closed position 87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
64
Liftarm raising with Hydraulic self levelling
6
7
5
4
3
2
1
8
12
13 11 9
10
95 1. 2. 3. 4. 5. 6. 7.
Hydraulic self levelling Lowering brake valve Load check valve Lowering brake valve -- attachment Load check valve Pressure relief valve A Pressure relief valve B
Operating: Valve functions: Pressurized oil (red):
Pilot oil (orange): Return flow (green):
87679925A1 - 02 - 2008
8. 9. 10. 11. 12. 13.
Fast Tip valve Adjusting toggle Pressure relief valve C Driving direction Liftarm cylinder Attachment cylinder
-- Move Joystick to lift position
------------
Hydraulic self levelling valve (1) in neutral position Load check valve (3) in open position Lowering brake valve (2) in open position Adjusting toggle (9) in closed position The hydraulic oil on the lift arm cylinder stem side (12) is sent onto the piston side of the attachment cylinders (13) Attachment cylinder (13) in extended position Fast Tip valve (8) in neutral position Pressure relief valve A/B/C (6/7/10) in neutral position Load check valve (5) in neutral position Attachment lowering brake valve (4) in on position
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
65
Attachment bucket crowding 7
6
5
4
2
3
1
8
12
11
13 9
10
96 1. 2. 3. 4. 5. 6. 7.
Hydraulic self levelling Lowering brake valve Load check valve Lowering brake valve -- attachment Load check valve Pressure relief valve A Pressure relief valve B
Operating:
8. 9. 10. 11. 12. 13.
Fast Tip valve Adjusting toggle Pressure relief valve C Driving direction Liftarm cylinder Attachment cylinder
-- Move Joystick to crowd position
Valve functions: Pressurized oil (red):
-----
Load check valve (5) open position Attachment lowering brake valve (4) neutral position Pressure relief valve A/B/C (6/7/10) neutral position Attachment cylinder (13) in retracted position
Return flow (green):
-- Fast Tip valve (8) in neutral position
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66
Attachment bucket tipping
6
7
8
5
4
2
3
1
12
13 11 9
10
97 1. 2. 3. 4. 5. 6. 7.
Hydraulic self levelling Lowering brake valve Load check valve Lowering brake valve -- attachment Load check valve Pressure relief valve A Pressure relief valve B
Operating:
8.
Fast Tip valve
9.
Adjusting toggle
10. Pressure relief valve C 11. Driving direction 12. Liftarm cylinder 13. Attachment cylinder
-- Move Joystick to tip
Valve functions: Pressurized oil (red):
-- Pressure relief valve A/B/C (6/7/10) neutral position -- Fast Tip valve (8) in neutral position -- Attachment cylinder (13) extended position
Return flow (green):
-- Load check valve (5) in neutral position -- Attachment lowering brake valve (4) in neutral position
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67
Attachment bucket tipping with Fast Tip
8
6
7
5
4
2
3
1
12
11
13 9 10 98
1. 2. 3. 4. 5. 6. 7.
Hydraulic self levelling Lowering brake valve Load check valve Lowering brake valve -- attachment Load check valve Pressure relief valve A Pressure relief valve B
Operating:
8. 9. 10. 11. 12. 13.
Fast Tip valve Adjusting toggle Pressure relief valve C Driving direction Liftarm cylinder Attachment cylinder
-- Move Joystick to tip -- Press button S1
Valve functions: Pressurized oil (red):
-- Pressure relief valve A/B/C (6/7/10) neutral position -- Fast Tip valve (8) switched “on” ⇒ Attachment cylinder (13) extend position ⇒ The hydraulic oil on the stem side of the attachment cylinders (13) is sent ⇒ onto the piston side of the attachment cylinders (13)
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68
Hydraulic Quick Attach: locked position
8
11
7
6
5
4
3
2
1
14 13
15 10
12
9
99 1. 2. 3. 4. 5. 6. 7. 8.
Hydraulic self levelling Lowering brake valve Load check valve Lowering brake valve -- attachment Load check valve Pressure relief valve A Pressure relief valve B Fast Tip valve
Operating:
9. 10. 11. 12. 13. 14. 15.
Adjusting toggle Pressure relief valve C Hydraulic attachment lock valve Driving direction Attachment cylinder Liftarm cylinder Hydraulic Quick Attach cylinder
-- Button SW in off position -- Move Joystick to crowd position
Valve functions: Pressurized oil (red):
-- Load check valve (5) open position -- Attachment lowering brake valve (4) neutral position -- Pressure relief valve A/B/C (6/7/10) neutral position -- Hydraulic attachment lock valve (11) neutral position -- Fast Tip valve (8) neutral position ⇒ Attachment cylinder (13) retract position ⇒ Hydraulic Quick Attach cylinder (15) extend position ⇒ (FPiston side > FStem side)
Return flow (green):
-- Fast Tip valve (8) in neutral position
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
69
Hydraulic Quick Attach: in release position
8
7
11
6
5
4
2
3
1
14 13 15
10
12
9
100 1. 2. 3. 4. 5. 6. 7. 8.
Hydraulic self levelling Lowering brake valve Load check valve Lowering brake valve -- attachment Load check valve Pressure relief valve A Pressure relief valve B Fast Tip valve
Operating:
9. 10. 11. 12. 13. 14. 15.
Adjusting toggle Pressure relief valve C Hydraulic attachment lock valve Driving direction Attachment cylinder Liftarm cylinder Hydraulic Quick Attach cylinder
-- Button SW in on position -- Move Joystick to crowd position
Valve functions: Pressurized oil (red):
-- Load check valve (5) open position -- Attachment lowering brake valve (4) neutral position -- Pressure relief valve A/B/C (6/7/10) neutral position -- Hydraulic attachment lock valve (11) in “on” position ⇒ Attachment cylinder (13) retract position ⇒ Hydraulic Quick Attach cylinder (15) retract position ⇒ Attachment unlocked
Return flow (green):
-- Fast Tip valve (8) in neutral position 87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
70
Third auxiliary service: cylinder extension
12
8
7
6
5
4
3
1
2
15 14 16 9
10
13
101 1. 2. 3. 4. 5. 6. 7. 8. 9.
Hydraulic self levelling Lowering brake valve Load check valve Lowering brake valve -- attachment Load check valve Pressure relief valve A Pressure relief valve B Fast Tip valve Adjusting toggle
Operating:
10. 11. 12. 13. 14. 15. 16.
Pressure relief valve C No reference Third auxiliary control valve Driving direction Attachment cylinder Liftarm cylinder Third auxiliary service cylinder
-- Press button S3 -- Move Joystick to tip
Valve functions: Pressurized oil (red):
-- Third auxiliary control valve (12) in “on” position -- Pressure relief valve A/B/C (6/7/10) neutral position ⇒ Third auxiliary service cylinder (16) in extended position
Return flow (green):
-- Load check valve (5) in closed position -- Attachment lowering brake valve (4) in on position
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
71
Third auxiliary service: cylinder retraction
12
8
7
6
5
3
4
2
1
15 14 16 10
13
9
102 1. 2. 3. 4. 5. 6. 7. 8. 9.
Hydraulic self levelling Lowering brake valve Load check valve Lowering brake valve -- attachment Load check valve Pressure relief valve A Pressure relief valve B Fast Tip valve Adjusting toggle
Operating:
10. 11. 12. 13. 14. 15. 16.
Pressure relief valve C No reference Third auxiliary control valve Driving direction Attachment cylinder Liftarm cylinder Third auxiliary service cylinder
-- Press button S3 -- Move Joystick to crowd position
Valve functions: Pressurized oil (red):
-- Third auxiliary control valve (12) in “on” position -- Load check valve (5) open position -- Attachment lowering brake valve (4) neutral position -- Pressure relief valve A/B/C (6/7/10) neutral position ⇒ Third auxiliary service cylinder (16) in retracted position
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
72
HYDRAULIC DIAGRAMS Abbreviations used in hydraulic diagrams A
Liftarm
B
Attachment
C
Third auxiliary service
D
Fourth auxiliary service (if fitted)
K
Adjustment control switch, fitted next to the control valve on the loaderâ&#x20AC;&#x2122;s arms, see page 42. Makes it possible to use one button for two functions.
W
Quick Attach hydraulic coupling cylinder
Z
Ignition
S1
Fast Tip . . . . . on
S2
Hydraulic self levelling off
S3
Third auxiliary service on
S4
Fourth auxiliary service on (joystick button not supplied in kit) see 1st note page 44.
SW
Hydraulic Quick Attach on--off switch
1
Lowering
2
Raising
3
Tipping
4
Crowding
NOTE: Buttons S1 and S3 on the joystick are shown with a single button, the switch W will switch between fast tipping (S1) and the third external service, see page 42.
NOTE: ATTENTION The electric systems described in this paragraph do not exactly mirror the system fitted on the tractors, they are merely a guide.
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
73
NS (standard -- basic version)
NOTE: Refer to the key on page 72.
103
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74
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
NS with third auxiliary service
NOTE: Refer to the key on page 72.
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104
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
75
NS with third auxiliary service and Hydraulic Quick Attach
NOTE: Refer to the key on page 72.
105
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76
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
NS with third and fourth auxiliary service
NOTE: Refer to the key on page 72.
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106
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
77
NS with third and fourth auxiliary service and Hydraulic Quick Attach
NOTE: Refer to the key on page 72.
107
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78
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
HS (standard -- basic version)
NOTE: Refer to the key on page 72.
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108
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
79
HS with Hydraulic Quick Attach
NOTE: Refer to the key on page 72.
109
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80
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
HS with third auxiliary service
NOTE: Refer to the key on page 72.
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110
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
81
HS with third auxiliary service and Hydraulic Quick Attach
NOTE: Refer to the key on page 72.
111
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82
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
HS with third and fourth auxiliary service
NOTE: Refer to the key on page 72.
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112
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
83
HS with third and fourth auxiliary service and Hydraulic Quick Attach
NOTE: Refer to the key on page 72.
113
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84
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
MS (standard -- basic version)
NOTE: Refer to the key on page 72.
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114
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
85
MS with third auxiliary service
NOTE: Refer to the key on page 72.
115
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86
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
MS with third auxiliary service and Hydraulic Quick Attach
NOTE: Refer to the key on page 72.
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116
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
87
MS with third and fourth auxiliary service
NOTE: Refer to the key on page 72.
117
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88
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
MS with third and fourth auxiliary service and Hydraulic Quick Attach
NOTE: Refer to the key on page 72.
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118
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8 REPAIR INSTRUCTIONS Mechanical components ATTENTION: Fit the pins instructions.
(1)
89
following the
At (high stress) pivot points on the loaders, special high--grade pivot bolts are used. â&#x20AC;˘ MS (1, fig. 119) 6 positions â&#x20AC;˘ NS/HS (1, fig. 120) 2 positions
119
120 So take care on repairs that these pins are inserted again to the points marked with (1, fig. 119 and 120). The high--grade pins can be recognized by the ring groove mark (2, fig. 121) on the inside end face.
Replacing pins 1. Knock out hollow tension pin (1). 2. Knock out pin (2) with a suitable extractor. 3. Carry out assembly in reserve order.
121
122 87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
90
Replacement of drive--in triangles of NS and HS liftarms
ATTENTION For this operation the liftarm has to be disassembled from tractor!
1. Remove the pins (1 and 2) as per the instructions on page 89. 2. Take off drive--in triangle (3). 3. Carry out assembly in reserve order. Replacement of drive--in triangles of MS
123
ATTENTION For this operation the liftarm has to be disassembled from tractor!
1. Remove the pins (1, 2 and 3) as per the instructions on page 89. 2. Take off drive--in triangle (4). 3. Carry out assembly in reserve order.
Replacement of control rods (MS liftarms only) 1. Remove the pins (1 and 2) as per the instructions on page 89. 2. Take off control bar (3). 3. Carry out assembly in reserve order.
124
125 Replacement of linkage plates (MS liftarms only) 1. Remove the three pins (1) as per the instructions on page 89. 2. Take off the two deflection plates. 3. Carry out assembly in reserve order.
126 87679925A1 - 02 - 2008
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91
Replacement of relay arm 1. Remove the pin (1) as per the instructions on page 89. 2. Take off relay arm. 3. Carry out assembly in reserve order.
Replacement of double lever handle 1. Remove the pin (1) as per the instructions on page 89. 2. Take off double lever handle. 3. Carry out assembly in reserve order.
127
128 Replacement of Quick Attach frame
ATTENTION For this operation the liftarm has to be disassembled from tractor!
1. Remove the pin (1) as per the instructions on page 89. 2. Take off frame. 3. Carry out assembly in reserve order.
Replacement of Varipark stands
129
ATTENTION For this operation the liftarm has to be disassembled from tractor!
1. Detach tension spring (1). 2. Remove the pin (2) as per the instructions on page 89. 3. Take off support stand (3). 4. Carry out assembly in reserve order.
130 87679925A1 - 02 - 2008
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92
Replacement of spring for Varipark lock
ATTENTION For this operation the liftarm has to be disassembled from tractor!
1. Remove screw (1). 2. Take out spring (2). 3. Carry out assembly in reserve order.
Replacement of lock for Varipark
131
ATTENTION For this operation the liftarm has to be disassembled from tractor!
1. Detach tension spring (1). 2. Remove screw (2). 3. Take off locking (3). 4. Carry out assembly in reserve order. Replacement of visual metering unit 1. Remove screw (1). 2. Pull off tube (2) with sleeve (3) and yoke (4) from visual display in direction A.
132
133 3. Remove screw (1). 4. Take off visual display (2). 5. Carry out assembly in reserve order.
134 87679925A1 - 02 - 2008
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93
Replacement of Quick Attach 1. Knock out medium hollow tension pin (1) -- Attention, due to the spring tension the bar (4) bounces to the left. 2. Take off spring. 3. Knock out left hollow tension pin (2). 4. Knock out right hollow tension pin (3). 5. Take off bar (4) to the left from the change frame. 6. Take off plug (5) from the change frame. 7. Carry out assembly in reserve order. Bushing replacement 1. Remove the pin (1) as per the instructions on page 89. 2. Knock out worn bushes. 3. Carry out assembly in reserve order. Please note that the bushes are to be of a flush fit.
Replacement of locking of drive--in triangles
135
136
ATTENTION For this operation the liftarm has to be disassembled from tractor! 1. Remove drive--in triangle. 2. Release locknut (1, fig. 137). 3. Knock out the two split pins. 4. Unscrew stud bolt (2) from the key. 5. Screw down locknut from stud bolt. 6. Screw down castle nut from stud bolt. 7. Remove cup spring packages (1) from stud bolt (2, Fig. 138). 8. Screw down ball handle (3) from the retaining bolt (4). 9. Pull out stud bolt from the drive--in triangle. 10. Take off grip bolt from the drive--in triangle. 11. When assembling -- in reverse order -- tighten the castle nut lightly against the cup spring packages and lock with a split pin. The position of the key has to be considered as well (see figure).
137
138 87679925A1 - 02 - 2008
94
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
Replacement plug for Hydraulic Quick Attach 1. Disassemble cylinder (1) as to the instruction on page 95 (fig. 143), headed, “Replacement hydraulic cylinder for Hydraulic Quick Attach” 2. Take off plug (2). 3. Carry out assembly in reserve order.
139
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95
HYDRAULIC COMPONENTS Replacing cylinder of “Lifting -- lowering” functions 1. Disassemble lines (1). 2. Remove the pins (2) as per the instructions on page 89. 3. Remove cylinder. 4. Carry out assembly in reserve order.
Replacing cylinder for “Tipping -- Crowding” functions 1. Disassemble lines (1) (with MS liftarm additionally the bleed valve). 2. The visual display unit of the left cylinder, as seen from the driving direction, has to be assembled according to the instructions given on page, headed, 92 ”Replacement of visual metering unit” to remove the cylinder. 3. Remove the pins (2) as per the instructions on page 89. 4. Remove cylinder. 5. Carry out assembly in reserve order.
140
141 Replacement diaphragm accumulators for Smooth Ride Control 1. Disassemble line of corresponding diaphragm accumulator. 2. Disassemble locknut (1) at the bulkhead connection. 3. Take out the diaphragm accumulator. 4. Carry out assembly in reserve order.
Replacing hydraulic cylinder for Hydraulic Quick Attach 1. Set attachment lock on “Unlock”. 2. Knock out tension pins (1) through fitting opening. 3. Remove hydraulic cylinder. 4. Take out lines (2).
142
ATTENTION A residual pressure will remain in the lines. 5. Carry out assembly in reserve order.
143 87679925A1 - 02 - 2008
96
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
Replacement of pressure relief valve for MS liftarms 1. Disassemble base plate (1) by removing the screws (2). 2. Disassemble hydraulic lines. 3. Remove fixing bolts (3) of valve. 4. Take off relief valve. 5. Carry out assembly in reverse order whereby the position of the valve has to be considered.
Replacement valve for Hydraulic Quick Attach and 3rd or 4th control service of MS liftarms Replacement of valves for Hydraulic Quick Attach (1), third auxiliary service (3) and fourth auxiliary service (4) is to be carried out in the same way as the replacement of pressure control valve, above.
144
145 Replacement Fast Tip valve for NS liftarms 1. Disassemble base plate (1) by removing the screws (2). 2. Take off cap (3) on the solenoid coil. 3. Disassemble hydraulic tubes. 4. Remove the four fixing bolts (4) of valve. 5. Take out the valve. 6. Carry out assembly in reverse order whereby the position of the valve has to be considered.
Replacement of valve for Hydraulic Quick Attach and third and fourth auxiliary services of NS liftarms The valves for Hydraulic Quick Attach (2), third auxiliary service (3) and fourth auxiliary service (4) are flanged between Fast Tip valve (1) and base plate with the pressure control valve (5). Therefore the replacement of these valves is carried out in the same way as the replacement of the Fast Tip valve in the instruction above for NS liftarms.
146
147 87679925A1 - 02 - 2008
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97
Replacement of Hydraulic self levelling control block for HS liftarms 1. Disassemble base plate (1) by removing the two screws (2). 2. Take off the cap on the solenoid coil. 3. Disassemble hydraulic lines. 4. Remove the four fixing screws (3) of valve. 5. Take out the valve. 6. Carry out assembly in reserve order.
Replacement of Fast Tip valve for HS Liftarms 1. Disassemble base plate (1) by removing the two screws (2). 2. Take off cap (3) on the solenoid coil. 3. Disassemble hydraulic lines (4). 4. Take off fixing screws (5) of valve. 5. Take out the valve. 6. Carry out assembly in reverse order whereby the position of o--rings has to be considered.
148
149 Replacement of “Hydraulic self levelling off” valve for HS liftarms The replacement of the “Hydraulic self levelling off” valve (1) is carried out the same way as the replacement of the Fast Tip valve, above.
Replacement valve for Hydraulic Quick Attach and third and fourth auxiliary services of HS liftarms The valves for Hydraulic Quick Attach (2), third auxiliary service (3) and fourth auxiliary service (4) are flanged between Fast Tip valve (1) and the parallel control block (5). The replacement of these valves is carried out in the same way as the replacement of the Fast Tip valve (6) for the HS Liftarms, above.
150
151 87679925A1 - 02 - 2008
98
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
Replacement of the spool for the Fast Tip valve 1. Disassemble base plate as to the instruction on page 79, “Replacement Fast Tip valve of HS Liftarms” (fig. 121). 2. Remove the connector (1) from the solenoid coil. 3. Take off milled nut (2). 4. Extract the solenoid coil (3) from valve. 5. Unscrew valve (4) from block. 6. Carry out assembly in reserve order.
152
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
99
CONTROL VALVE HS (VS 140) Replacement of compression spring and cup spring packs for Fast Tip valve 1. Disassemble base plate as to the instruction on page 97 “Replacement of Fast Tip valve of HS Liftarms”. 2. Unscrew the cap (K) from the block. 3. Take off cup spring pack (60) with the compression spring. 4. Carry out assembly in reverse order, whereby it has to be considered that the piston end is lubricated.
153
Replacement of compression spring and cup spring packs for Hydraulic self levelling valve 1. Disassemble base plate as to the instruction on page 97 “Replacement of Fast Tip valve of HS Liftarms”. 2. Unscrew the three fixing screws and take off adjusting screw (S). 3. Take off cup spring pack (59) with the compression spring. 4. Carry out assembly in reverse order, whereby it has to be considered that the piston end is lubricated.
154
Measurements of cup spring pack 59: 30 layers with 3 units, first cup spring adjacent outside 60: 31 layers with 3 units, first cup spring adjacent outside.
155
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100
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
TROUBLESHOOTING General analysis Fault Description Small lift and tearout force.
Corrective action Check the tractor hydraulic system. Joystick difficult to operate. Bowden cables hard to operate. Check routing and movability of the bowden cables. If necessary oil or replace bowden cables. Loader and attachment move 2. Insufficient oil in hydraulic sys- Check Oil level and refill oil if slowlyy or not at all. tem. necessary. 3. Hydraulic coupler connection Check and correct couplers. incorrect. 4. Defective Multi Quick Coupler. Check coupler and replace if necessary. 5. Insufficient oil flow. Check the tractor hydraulic system. 6. Loader pressure relief valve Check system pressure. stuck in the open position. Loader and/or attachment operate 1. Couplers connected incorrect- Check and correct couplers. in wrong ly. g direction relative to J Joystick. ti k 2. Bowden cables connected in- Check and correct bowden cables correctly. connection. Slow speed or sticking lift function 1. Insufficient oil in hydraulic sys- Check Oil level and refill oil if of the loader. tem. necessary. 2. Engine RPM too low. Increase engine speed. 3. Cold hydraulic fluid. Allow hydraulic system to warm up to operating temperature. 4. Load too high. Reduce load. 5. Defective hydraulic coupler. Check coupler and replace if necessary. 6. Internal leakage in hydraulic Check cylinder, replace defective cylinder. cylinder if necessary. 7. Pressure relief valve incorrect Check setting of the pressure adjusted. relief valve. 8. Internal leakage of control Check control valve, replace if valve. necessary. Insufficient lift power. 1. Internal leakage in hydraulic Check cylinder, replace defective cylinder. cylinder if necessary. 2. Load too high. Reduce load. 3. Pressure relief valve incorrect Check setting of the pressure adjusted. relief valve. 4. Internal leakage of control Check control valve, replace if valve. necessary. Air in the hydraulic system 1. Hydraulic pump sucks air. Check hydraulic lines between (indicated by foamy fluid). pump and reservoir for loose or defective connections. 2. Hydraulic filters are dirty Check hydraulic filters and replace if necessary.
87679925A1 - 02 - 2008
Cause Low Oil Pressure.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
Fault Description Leaking couplers of the third or fourth service of the loader auxiliary circuit.
Cause Leakage by penetrated dirt.
Loader arm or attachment is locking g after a certain lifting g movement.
1.
Attachment is tilting to the rear. Onlyy MS loaders.
2. 1. 2.
101
Corrective action Clean the coupler and replace as required. When not using the loader and/or the third and fourth auxiliary circuit lock the couplers with protective caps and keep the cover of the Multi Quick Coupler closed. The coupling is not completely Check the Multi Quick Coupler. closed. Coupling defective. Replace defective coupler. Relief valves maladjusted or Examine relief valves, if defective. necessary exchange. Manoeuvring error: Engine Increase engine speed. RPM too low.
Hydraulic liftarm variants NS/HS Fault Description The liftarm is locking at lowering when the “Hydraulic self levelling” is switched off by means of the push button. Liftarm or attachment is locking after a certain lifting g movement. The valve for “switched off Hydraulic self levelling” or “switched on Fast Tip” cannot be actuated.
The liftarm begins to swing when lowering loads.
Attachments of NS loader arms are tilting to the rear.
Cause Connections of the plug couplings have been confused.
Corrective action Pipes 1 and 2 for the loader arm have to be connected to the same control unit.
1. The coupling is not completely Check the coupler. closed. 2. The coupling is defective. Replace defective coupler. Check current supply to the bush buttons of the control lever and check the further flow of the circuit when one of the push buttons is actuated. If switching should not be possible although current is fed to the solenoid, check the earth lead. The solenoids are connected to earth via the valve and the loader arm. For this reason the surface between solenoid and valve must be free from paintwork. Reduce lowering speed. In case of loading operations which do not require an accurate parallel motion at lowering the adjusting toggle should be unlocked about 2 turns. Fast Tip must only be switched on if the control is set to “Tipping” and the engine speed is high enough so as to allow oil circulate from the tractor pump to the ram. Otherwise a vacuum would result which would be compressed at the next phase thus allowing the scoop to swing back. 87679925A1 - 02 - 2008
102
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
Fault Description The attachment actuating rams extend, but do not retract.
Leakages g in the control unit for “H d li selflf levelling”. “Hydraulic l lli ”
Attachment opens and liftarm lowers.
Attachments of NS loader arms are tilting to the rear.
The attachment actuating rams extend, but do not retract.
Leakages g in the control unit for “H d li selflf levelling”. “Hydraulic l lli ”
87679925A1 - 02 - 2008
Cause Corrective action 1. The piston seal of the attach- Check all rams separately for ment actuating ram is leaking. internal/external leakage; replace defective cylinders if necessary. 2. The seat valve does not return Remove the seat valve and check to its initial position when rapid it for contamination; replace it if motion is actuated. necessary. Retighten screw connections. In case of leakage between the solenoid and the valve: undo the knurled nut, remove the solenoid and retighten the core with a suitable socket wrench. In case of leakage between the base and flange of the valves: tighten the screws or renew O--ring seals. This trouble is caused by the con- At liftarm lifted, extend the tool trol unit of the hydraulic self--level- actuating ram up to the limit stop ling function: the Fast Tip valve by actuating the hydraulic system produces an oil switchover in the (without rapid motion). Now the oil attachment actuating ram betwe- can no longer circulate from the en ring and piston surface, cauloader arm ram to the attachment sing g the attachment to tilt. The re- actuating ram. sultlt is i a vacuum att the th piston i t sur- At liftarm lifted, fully retract the face which is compensated by the attachment actuating ram so that liftarm ram connected to the atthe centre of gravity of the tachment actuating ram. attachment is situated behind the pivot point. Fast Tip must only be switched on if the control is set to “Tipping” and the engine speed is high enough so as to allow oil circulate from the tractor pump to the ram. Otherwise a vacuum would result which would be compressed at the next phase thus allowing the scoop to swing back. 1. The pistons seal of the attach- Check the seal of all the cylinders ment actuating ram is defective separately; replace defective so that the surface of the pis- cylinders if necessary. tons and that of the seal are joined to each other. 2. The seat valve does not return Remove the seat valve and check to its initial position when rapid it for contamination; replace it if motion is actuated. necessary. Retighten screw connections. In case of leakage between the solenoid and the valve: undo the knurled nut, remove the solenoid and retighten the core with a suitable socket wrench. In case of leakage between the base and flange of the valves: tighten the screws or renew O--ring seals.
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
Fault Description Attachment opens and liftarm lowers.
Cause This trouble is caused by the control unit of the hydraulic self--levelling function: the Fast Tip valve produces an oil switchover in the attachment actuating ram between ring and piston surface, causing the attachment to tilt. The result is a vacuum att the th piston i t surface f which is compensated by the liftarm ram connected to the attachment actuating ram.
103
Corrective action At loader arm lifted, extend the attachment actuating ram up to the limit stop by actuating the hydraulic system (without Fast Tip). Now the oil can no longer circulate from the loader arm ram to the attachment actuating ram. At liftarm lifted, fully retract the attachment actuating ram so that the centre of gravity of the attachment is situated behind the pivot point.
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104
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
Valve control block HS (VS 140)
156 A: B: S: SK: V: 3: 43: 58: 59: 60:
Valve governing Fast Tip function Valve governing hydraulic self--levelling function Adjusting screw Adjusting toggle Sealing screw Piston Seal Obturator Cup spring package (hydraulic self levelling) Cup spring package (Fast Tip)
157
158 87679925A1 - 02 - 2008
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
Fault Description Liftarm crowds up at lowering.
Cause
105
Corrective action
1. Adjusting screw (S) unscrewed Reduce lowering speed by in too far. screwing g of the adjusting j g screw. 2. Lowering speed too high. 3. Specific cup spring pack (59) Replace cup spring package, broken due to too high loading remove rests, lubricate piston end of liftarm. well.
Liftarm lowers self--acting.
1. Adjusting toggle (SK) open.
Shut adjusting toggle (SK).
2. Adjusting toggle (SK) leaky due Clean adjusting toggle (SK). to dirt. 3. Check valve leaky due to wear- Renew it. ing / dirt. 4. Specific piston (3) clamps due Renew it. to corrosion or foreign matter. 5. Specific piston (3) clamps due Tightening torque 20--22 Nm. to sealing screw (V) screwed too tightly. 6. Leakage at piston due to wear- Renew it. ing. Attachment itself does not tip. H d li selflf levelling Hydraulic l lli / Liftarm Lift does not lift.
1. Specific shutter (58) stuck.
No operating function ( l t i operation). (electric ti )
1. Cable defect / loose contact
Clean it.
2. Piston clamps due to foreign Renew it. matter or oxidation. Repair the electric components.
2. Solenoid cable or connector Replace solenoid connector. loose inside. 3. Ground screw of spool con- Tighten / replace. nector loose / missing.
Hydraulic self levelling does not shut down or Fast Tip p without f function. ti
1. Piston clamps due to dirt or Clean piston and control drilling. foreign matter.
Attachment crowd self--acting.
Air in the system by tipping via pressing Fast Tip.
De--aerate system.
Liftarms lowers too slowly.
Adjusting screw (S) is screwed in too far.
Basic adjustment: unscrew adjustment screw up to stop, then screw in for 1.5 turns
2. Torque of fixing screws too Tighten the screws properly high. (20--22 Nm); if the problem persists, renew them.
Oil leakage at the cap or adjusting Specific seal (43) defect due to wearing, foreign matter, oxidized screw (S). piston.
Renew it.
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106
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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
SECTION 41 -- STEERING -- CHAPTER 1
1
SECTION 41 -- STEERING Chapter 1 -- Steering CONTENT
Description
Page
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Components and operating diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Power steering control valve R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Power steering control valve D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Power steering control valve bench testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Power steering oil pump D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Front axle steering cylinder R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Front axle steering cylinder R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
2
SPECIFICATIONS POWER STEERING Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
hydrostatic control
Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
independent, fed by hydraulic pump
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
paper cartridge on pump intake side
Control valve, manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DANFOSS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORBITROL, with the rotating valve controlled directly by the steering column; the steering continues to function even if the pump is damaged
Outfit code: --
all models two--wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . .
OSPC 100 OR -- 150 N
--
4WD models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OSPC 125 OR -- 150 N
Pressure relief valve calibration (22, fig. 2) --
2WD models (OSPC 100 OR -- 150 N) . . . . . . . . . . . . . . . . . bar
140 รท 145 (143 รท 148 kg/cm2)
--
4WD models (OSPC 125 OR -- 150 N) . . . . . . . . . . . . . . . . . bar
165 รท 170 (168 รท 173.4 kg/cm2)
87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
3
LIFT HYDRAULIC PUMP DATA 41L/MIN (*)
Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
paper cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
fixed to the pump housing on suction side
Pump Assembly Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
gear type with oil suction from transmission casing
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flanged on the rear left--hand side of the engine
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bosch--Rexroth
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of the engine gears
Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . .
left--hand side
Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . .
1 : 1.088
Maximum speed of pump rotation (with engine at maximum power equivalent to 2300 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm
2502
Rated output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/turn
0.01462
Corresponding rated output for new pump . . . . . . . . . . . dm3/min (l/min)
41.08
(*) Standard equipment for all models with 4WD, compulsory for 2WD with power steering pump with supplementary control valve for ventral control valves (see section 35 chapter 7).
87679925A - 12 - 2007
4
SECTION 41 -- STEERING -- CHAPTER 1 LIFT HYDRAULIC PUMP DATA 28 L/MIN (**)
Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
paper cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
fixed to the pump housing on suction side
Pump Assembly Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
gear type with oil suction from transmission casing
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flanged on the rear left--hand side of the engine
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bosch--Rexroth
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of the engine gears
Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . .
left--hand side
Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . .
1 : 1.088
Maximum speed of pump rotation (with engine at maximum power equivalent to 2300 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm
2502
Rated output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/turn
0.01147
Corresponding rated output for new pump . . . . . . . . . . . . dm3/min (l/min)
28.69
(**) For all 2WD models, not available for power steering pump with supplementary control valve for ventral control valve (see section 35 chapter 7).
BOLT TORQUES PARTS TO BE TIGHTENED
Thread
Bolt securing power steering unit to tractor (2, fig. 77) . . . . . . . . . . . . .
Tightening torque Nm
kgm
--
47 รท 55
4.8 รท 5.6
Bolt securing cover to power steering housing (13, fig. 2) . . . . . . . . . .
M8x1
34
3,5
Hydrostatic steering control pump retaining bolt . . . . . . . . . . . . . . . . . .
M6x1
8
0,8
87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
5
MDF1823A
1 Power steering pump components 1. 2. 3. 4. 5. 6.
Thrust sleeve. Front cover. Seals. Centring pins. Seals. Seals.
7. 8. 9. 10. 11. 12.
Centring pins. Driven and driving gears. Gear support bushings. Pump body. Protective cap. Rear cover.
87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
6
24725
2 Hydrostatic steering control valve components Dust ring Backflow valve balls Backflow valve pins Control valve body, rotating valve and rotating valve seat sleeve 5. Check valve ball 6. Non--return valve threaded plug 7. O--ring 8. Seal ring support ring (7) 9. Thrust bearing components 10. Spring retaining ring (11) 11. Springs for returning sleeve to neutral position 1. 2. 3. 4.
87679925A - 12 - 2007
12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Sleeve--rotor drive shaft trim pin Cover retaining screws Non--return valve seat screw Washers Cover O--rings Rotor and fixed ring for rotor Shim ring O--ring Rotor drive shaft Damping valve
SECTION 41 -- STEERING -- CHAPTER 1
2
1
5
7
3
4
MDF1824A
3 General hydraulic diagram 1. 2. 3. 4. 5. 6.
Steering cylinders Power steering control valve Steering wheel Pressure switches Filter Flow divider
Intake oil Pump delivery oil Static rest oil Oil at lubrication pressure
87679925A1 - 02 - 2008
SECTION 41 -- STEERING -- CHAPTER 1
8
Balancing valve components (2WD) 1. 2. 3. 4.
Orbitrol side Internal one--way valve (lets oil flow from orbitrol to cylinder) External one--way valve (lets oil flow from cylinder to orbitrol) Cylinder side
4
Two--wheel drive tractors are fitted with a single conventional steering cylinder, the balancing valve (1, fig.5) keeps the oil pressure in the two chambers (stem side and piston side) slightly different to compensate for the difference in the surfaces on which the two pressures act. On four--wheel drive tractors, the balancing valve is not necessary since a steering cylinder is fitted with the stem on both sides, so the surface on which the pressure acts in the two chambers is identical. Operation of this device is described below.
1
3
2 4
1
Static rest oil Pump delivery oil Oil return to tank Intake oil Oil in balancing pressure
2
13
12
3
11 4
10
5
9
8
7
6
MDE0716A
Diagram showing 2WD power steering operation 1.
Balancing valve
2.
Steering cylinder assembly
3.
Steering motor
4.
Kick back check valve
5.
Non--return valve
6.
Power steering lines
87679925A1 - 02 - 2008
7. 8. 9. 10. 11. 12. 13.
Pump Filter Return to rear transmission Pressure relief valve Valve seat sleeve (12) Rotating valve Backflow valves
5
SECTION 41 -- STEERING -- CHAPTER 1 OPERATION The oil intake is from the rear transmission casing by means of the gear pump (7), passing through a filter (8) and directed to the power steering control valve (3). Turning the steering wheel clockwise (or anticlockwise) causes the steering column to act on the valve (12) that, turning clockwise (or anticlockwise) to the sleeve (11), will send oil through the internal ducts to the hydraulic cylinder (2, fig. 5), or hydraulic cylinders (2, fig. 6) for steering on the right or left of the tractor.
9
Neutral position (fig. 5 and 6) With the wheels parallel to the direction of tractor travel, as indicated in the drawing, the rotating valve (12) connected to the steering wheel is in the neutral position on the sleeve (11). In this position, which is maintained and guaranteed by the springs (11, fig. 2) the internal passages on parts (11 and 12, figs. 5 and 6) are aligned and direct the oil from the pump (7) to the discharge line (9). Static rest oil Pump delivery oil Oil return to tank
The system is totally hydrostatic without any mechanical connection between the steering wheel and the wheels.
Intake oil
1 13
2
12 3
11 4
10
5
9
8
7
6
MDE0717A
6 Diagram showing 4WD power steering operation 1. 2. 3. 4. 5. 6. 7.
Power steering lines Steering cylinder assembly Steering motor Kick back check valve Non--return valve Anticavitation storage tank Pump
8.
Filter
9.
Return to rear transmission
10. Pressure relief valve 11. Valve seat sleeve (12) 12. Rotating valve 13. Backflow valves 87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
10
Steering to right* (fig. 7) When the steering wheel is turned in a clockwise direction, the springs (11, fig. 2) deform, allowing the valve (12, fig. 6) to rotate in relation to the sleeve (11). Under these conditions the following occurs: -- The internal passages on parts (11 and 12, fig. 6), which were previously communicating in the neutral phase, become misaligned and the oil outflow is interrupted. -- The alignment with the same number of ducts, that are connected with the compartments on the rotor in the pump suction phase (7, fig. 6) and in the delivery phase of the steering cylinders (2), allow turning to the right to be carried out. Steering to the left* When the steering wheel is turned in a counter--clockwise direction, the internal grooves on parts (11 and 12, fig. 6) and the delivery to the steering cylinder are inverted, allowing turning to the left to be carried out.
Manual turning to the right* In the event of power steering pump failure or insufficient oil pressure, turning is possible manually. When the steering wheel is turned in a clockwise direction, the power steering control valve (3, fig. 6) internal rotor operates as a hand pump, directing the oil to the rod side of the cylinders (2), allowing manual turning to the right. Manual turning to the left * When the steering wheel is turned in a counter--clockwise direction, the internal power steering control valve rotor operates as a hand pump (as previously described, directing the oil to the cylinder piston side, allowing manual turning to the left. NOTE: * This description holds also for the 2WD model shown in fig. 5
A
B
MDE0718A
Diagram showing 4WD power steering operation A. Right hand turn B. Steering to the left
Oil in delivery line to hydraulic cylinder 87679925A - 12 - 2007
Pump delivery oil Intake oil Oil return to tank
7
SECTION 41 -- STEERING -- CHAPTER 1
11
HYDROSTATIC STEERING TROUBLESHOOTING Problems
Possible causes
Solutions
Oil leaking from the hydrostatic 1. Seal (7--8, fig. 2) faulty. steering unit: a. Control side. b. Cover side.
Replace the seal (7) and relative antiextrusion ring (8) using tool 380000281 or 380000305.
2. Bolts insufficiently tightened Tighten the bolts to the prescribed (13). torque (24 รท 36 Nm -- 2.5 รท 3.7 kgm). 3. Sealing washers (15) O--rings (17) faulty. Hard steering.
or Replace the washers and seals.
1. Hydraulic pump faulty.
Repair the pump.
2. Non--return valve (5) held Eliminate foreign bodies and clean open by foreign bodies or due filter; put a new ball into the seat (if to absence of ball. missing). 3. Pressure relief valve (22) in- Calibrate the valve correctly. correctly set. 4. Pressure relief valve (22) Eliminate foreign bodies and clean jammed or held open by fo- the filter. reign bodies. 5. Steering column has become Eliminate the causes. stiff on its bushing due to rusting, seizing, etc. Excessive steering wheel play.
1. Excessive play between the Replace the worn parts. steering column and the coupling with the rotating valve (12, fig. 6). 2. Excessive play in the coupling Replace the worn parts. between the shaft (21, fig. 2) and the trim pin (12). 3. Excessive play in the splined Replace the worn parts. coupling between the shaft (21) and the rotor (18). 4. Combination of excessive Replace the excessively worn parts. play as described in the previous points. 5. Leaf springs (11) damaged or Replace springs. fatigued.
The steering wheel turns normally, 1. Inadequate control cylinder Replace seal. but the steering is: seal. a. Low.
2. Cylinder rod broken.
Replace the damaged part.
b. Null.
3. Rotor drive shaft (21) or Replace the damaged part. pin (12) broken.
With the engine stopped, the stee- 1. Excessive wear between ro- Replace the worn parts. ring wheel can be turned without tor and fixed ring (18). turning the wheels. 2. Non--return valve damaged.
Replace control valve assy. (overleaf)
87679925A - 12 - 2007
12
SECTION 41 -- STEERING -- CHAPTER 1 HYDROSTATIC STEERING TROUBLESHOOTING
Possible causes Problems Steering wheel jolts, uncontrolla- 1. Incorrect synchronisation of ble steering, g, wheels turning g in the hydrostatic steering. opposite it di direction ti to t th thatt d desired. i d 2. Pipes to cylinder inverted. The wheels do not maintain the 1. Hydraulic cylinder piston seal desired alignment and steering g g worn. mustt b be continually ti ll corrected t d with ith 2. Backflow valve (2, fig. 2) held the steering wheel. open by foreign bodies or damaged.
(overleaf) Solutions
Synchronise correctly. Correct the connections. Replace seal. Eliminate foreign bodies and clean filter or replace the control valve.
3. Mechanical wear of control Replace control valve assy valve. Neutral phase of power steering 1. Leaf springs (11), for sleeve unobtainable. During manual con(4) return to neutral position, trol, operation is normal; when damaged or fatigued. stopping manual man al control the steestee ring wheel tends to move on its 2. Sleeve and rotating valve (4) locked in delivery position beown, or remain stationary, but cause of the presence of fosteering continues slowly in the direign bodies. rection that was initially selected (â&#x20AC;&#x153;mopedâ&#x20AC;? effect), therefore stee- 3. Sleeve (4) crushed on the rotating valve due to excessive ring must be continually corrected with the steering wheel. pressure.
Replace the leaf springs assembly.
Eliminate foreign bodies and clean the filter.
Check the pressure relief valve calibration (22, fig. 2).
Vibrations on front wheels (shim- 1. Air pockets in the hydraulic cy- Bleed the air and eliminate the causes my). y) linder. of possible infiltration. 2. Wear on mechanical joints on Replace the worn parts. steering rods. 3. Backflow valve (2) held open Eliminate foreign bodies and clean filby foreign bodies or dama- ter or replace the control valve. ged. Difficulty in steering in general, or 1. Insufficient pressure. only in one direction.
Check the hydraulic pump and the pressure relief valve calibration (22, fig. 2).
2. Excessive leakage inside the Replace control valve assy. control valve. SPECIAL TOOLS
CAUTION The operations described in this section can only be carried out with the 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.
87679925A - 12 - 2007
X 380000210 Tool for fitting dust ring on control valve body. X 380000281 Tool for fitting ROTOGLYD seal on rotating valve. X 380000305 Tool for fitting KIN--RING seal on rotating valve. 380000306 Plug for fitting the hydrostatic steering rotating valve return springs. X 380000307 Hydrostatic steering rotor retaining lever. X 380000223 Steering wheel extractor. X 380000240 Universal pressure control kit.
SECTION 41 -- STEERING -- CHAPTER 1
13
HYDROSTATIC STEERING CONTROL VALVE R.I.
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. Remove the bonnet assembly (1) as directed in section 90 and disconnect the negative cable of the battery.
8
2. Remove the catch (2) and detach the toolbox (1).
9 3. Remove the right and left--hand panels (1) on the instrument panel.
1
24865
10
87679925A - 12 - 2007
14
SECTION 41 -- STEERING -- CHAPTER 1
4. Take out the three exhaust silencer rear retaining bolts (1).
5. Remove the clamp (1), the air filter dust ejector pipe (2) and the four nuts (3) securing the silencer to the exhaust manifold.
11
12 6. Remove the silencer (2) together with the exhaust pipe (1).
7. Remove the two retaining screws (1) and the silencer heat guard (2).
13
14 87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
15
8. Remove the four fittings (1) and the front wheel hydraulic cylinder and power steering oil return and delivery pipes.
9. Remove the four dashboard retaining bolts (1).
15
16 10. Disconnect the electrical connections (1) of the hazard lights.
11. Disconnect the main electrical connections (2) connected to the dashboard (1), and then remove the dashboard.
17
18 87679925A - 12 - 2007
16
SECTION 41 -- STEERING -- CHAPTER 1
12. Using the wrench (2), remove the two upper retaining bolts (1) of the power steering device between the free gaps of the steering column as shown in the figure.
13. Using the wrench (2), remove the two lower retaining bolts of the power steering device in the gap at the base of the steering column (1) as shown in the figure.
19
20 14. Using the punch (2), remove the pin fixing the power steering / steering column shaft in the gap at the base of the steering column (1) as shown in the figure.
15. Remove the power steering control valve assembly (1) from the front on the engine side.
21
22 87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
17
16. To fit the power steering control valve, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Reassemble the power steering control valve and secure inside the cab with the four bolts.
--
Fit the pin fixing the power steering / steering column shaft.
--
Using the wrench, fit the two lower retaining bolts of the power steering device in the gap at the base of the steering column.
--
Using the wrench, fit the two upper retaining bolts of the power steering device between the free gaps of the steering column.
--
Reconnect the electrical connections of the hazard lights.
--
Reconnect the main electrical connections to the dashboard.
--
Refit the dashboard and tighten the four retaining bolts.
--
Fit the four fittings and the front wheel hydraulic cylinder and power steering oil return/delivery pipes.
--
Fit the silencer heat guard and tighten the two retaining screws.
--
Fit the silencer and exhaust pipe.
--
Fit the four nuts retaining the silencer to the exhaust manifold and the air filter dust ejector pipe with its retaining clamp.
--
Fit the three rear retaining bolts of the exhaust silencer.
--
Fit the right-- and left--hand panels on the instrument panel.
--
Fit the toolbox, inserting the retaining clamp.
--
Fit the bonnet assembly as directed in section 90 and reconnect the negative cable of the battery.
--
Close the bonnet.
87679925A - 12 - 2007
18
SECTION 41 -- STEERING -- CHAPTER 1
HYDROSTATIC STEERING CONTROL VALVE D.A. with control valve removed To disassemble the power steering control valve, proceed as follows: 1. Remove the cover retaining bolts.
24701
23
2. Remove the cover by sliding to the side.
24702
24 3. Remove the rotor fixed ring, the rotor and the inner spacer. 4. Remove the two O--rings on the rotor fixed ring.
24703
25
5. Extract the rotor drive shaft.
24704
26 87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
19
6. Extract the thrust washer.
24705
27
7. Remove the threaded plug on the non--return valve seat.
24706
28 8. Extract the O--ring seal from the control valve body.
24707
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.
29
30 87679925A2 - 02 - 2010
SECTION 41 -- STEERING -- CHAPTER 1
20
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
31
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
32 13. Extract the valve--sleeve trim pin.
24711
33
CAUTION 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
34 87679925A2 - 02 - 2010
SECTION 41 -- STEERING -- CHAPTER 1
21
14. Extract the rotating valve from the valve seat sleeve.
24713
35
15. Remove the springs from the neutral position, extracting them from their seats.
24714
36 16. Remove the dust seal and the O--ring seal from their seats in the control valve body.
24715
37
17. Using a 6 mm Allen wrench, remove the threaded plug on the pressure relief valve and extract the seal washer.
24721
38 87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
22
18. Remove the pressure relief valve adjuster screw.
24722
39
19. Turn the control valve body over and complete disassembly by extracting the spring and the pressure relief valve piston.
24723
40 Pressure relief valve components disassembly--assembly).
(order
of
24724
20. Thoroughly clean all control valve component parts. 21. Replace the washers and seals. 22. Carefully check all mechanical parts, replacing components that show signs of wear. 23. Before re--fitting, lubricate the components with hydraulic oil.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
87679925A - 12 - 2007
41
SECTION 41 -- STEERING -- CHAPTER 1
23
24. Re--fit the rotating valve on the sleeve, checking that the reference marks indicated in the drawing coincide.
24726
42
25. Use tool 380000306 to insert the flat and curved springs (11, fig. 2). Diagram for fitting springs (11, fig. 2) neutral position for OSPC 100 ON--150N power steering.
24728
43 26. After inserting the springs in the seat, align and centre (as shown in the drawing).
24729
44 27. 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
45 87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
24
28. Insert the sleeve--rotor drive shaft trim pin.
24731
46
29. Fit the thrust bearing, following the order and indications shown in the drawing below.
24732
47 1.
Bearing external ring.
2.
Thrust bearing.
1
3.
Bearing internal ring with bevel facing the shim on part (5).
2
4.
Rotating valve.
5.
Rotating valve seat sleeve.
3 4 5 24733
48
30. Position the control valve body so that the housing seat on the rotating valve sleeve is positioned horizontally, then insert the bush on guide (1) of tool: 380000305 (for KIN--RING seal) OR 380000281 (for ROTOGLYD seal)
24734
1 49
87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
25
31. Lubricate the support rings (1), and seal rings (2) with hydraulic oil and assemble, as shown in the drawing, on the head (3) of tool: 380000305 (for KIN--RING seals) OR 380000281 (for ROTOGLYD seals)
1
2
3
Example of support head for fitting KIN--RING support and seal rings " (part of tool 380000305) 32. Insert the punch assembly in the previously installed guide bushing.
24735
50
24736
51 33. Whilst holding the external bushing with the hands, press fully down and simultaneously rotate the punch in order to facilitate the entry of the O Ring seal in the control valve body seat.
24737
52 87679925A - 12 - 2007
26
SECTION 41 -- STEERING -- CHAPTER 1
34. Extract the parts on tool 380000305, or 380000281 (external bushing and punch). NOTE: The support and seal ring support head remains on the control valve body (see fig. 50).
24738
53
35. Insert the parts that were previously fitted in operations 24 รท 29, 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
54 36. 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 380000305 or 380000281 (see fig. 50) and insert the rings (1) and (2) on the control valve body seat (see operation 31).
24740
1 55
37. Rotate the control valve body and insert the non--return valve ball into the seat indicated by the arrow.
24741
56 87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
27
38. 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
57
39. Insert the non--return valve balls into the two seats indicated by the arrows.
24743
58 40. Position the pins, complete with springs, in the backflow valve seats indicated by the arrows (see fig. 58).
24745
59
41. Lubricate the O--ring seal and insert into the seat on the control valve body.
24746
60 87679925A - 12 - 2007
28
SECTION 41 -- STEERING -- CHAPTER 1
42. Fit the thrust washer, so that the holes coincide with the holes on the control valve body.
24747
61
43. 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
62 44. 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. 62) and the trim pin installed on the sleeve.
24749
63
87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
29
45. 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 62 with the centre line of one compartment on the rotor.
1
24750
64 46. 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
65
47. Fit the cover, aligning the retaining holes with those on the rotor fixed ring.
24753
66
87679925A - 12 - 2007
30
SECTION 41 -- STEERING -- CHAPTER 1
48. Remove retaining tool 380000307 and fit the special screw and washer in the non--return valve seat, shown in the drawing.
24754
67
49. 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 4.
24755
68 50. Turn over the control valve body and insert (see component details in fig. 41) the pressure relief valve piston in the seat indicated in the drawing.
24756
69
51. Insert the pressure relief valve spring.
24757
70 87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
31
52. 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
71
53. Tighten the plug (1) with the relative seal, using an 8 mm Allen wrench, and tighten to the prescribed torque value of 40 รท 60 Nm (4.1 รท 6.1 kgm).
1
24763
72 54. When the unit has been assembled, insert the dust ring seal (2) in the seat on the control valve body, using tool 380000210 (1).
73
87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
32
HYDROSTATIC STEERING CONTROL VALVE Bench test Test Conditions Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with ISO VG 68, DIN 51524 / 51525 specifications (for outside temperatures of 0 °C to 50 °C) Oil viscosity . . . . . . . . . . . . . . . . . . . . . . . SAE 20 W Oil temperature . . . . . . . . . . . . . . . . . . . . . . . . 60 _C Hydraulic pump capacity . . . . . dm3/min (l/min) 12 Electric motor speed . . . . . . . . . . . . . . . . . 1450 rpm
1
2
3
5 4 24912
74 1. 2. 3.
Diagram showing the installation of the tools and equipment required for the rotating valve, seals and pressure relief valve calibration test Splined drive shaft. 4. Restriction Torque wrench 5. Pressure adjustment handwheel Delivery
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. A -- CHECKING ROTATING VALVE WEAR 1. Make the connections shown fig. 74 and complete the circuit as in fig. 75. Using the splined drive shaft (1), hold the hydrostatic steering control valve in the steering position (right or left).
87679925A - 12 - 2007
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, replace the rotating valve (12, fig. 6) and relative sleeve (11).
SECTION 41 -- STEERING -- CHAPTER 1
33
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), is released after each simulated steering movement.
1
C -- SEAL CHECK
7
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.
6
2
D -- PRESSURE RELIEF VALVE CALIBRATION 1. Make the connections as shown in the diagram in fig. 74 and complete the circuit as in the drawing 75. 2. Using the drive shaft (1) simulate a turn (to the left or to the right) so as to interrupt the oil flow to the discharge.
5
3. Gradually increase the in the circuit by turning the handwheel (5, fig. 74), and check on the pressure gauge that the pressure relief valve (22, fig. 2) 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.
3
4 24911
CHECKING THE HYDROSTATIC STEERING PRESSURE RELIEF VALVE WITH CONTROL VALVE INSTALLED ON TRACTOR
75 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”.
Proceed as follows: 1. Start the engine and perform a few steering movements with the tractor, until the oil reaches a temperature of approx. 50 °C.
1
2
3
4
5
2. Switch off the engine and detach the oil delivery pipe union (4) on the hydraulic cylinder (5). 3. Replace the original union with unions (2 and 3), and connect the pressure gauge (1) with a scale of 0 ÷ 150 kg/cm2 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 (22, fig. 2) should intervene, with the pressure gauge showing the value prescribed on page 2. 5. If the pressure is different, the valve (22) can be calibrated by means of the adjuster screw.
24915
76 1. Pressure gauge of kit 380000240 -- 2. Union 293874 (of kit 380000240) to be fitted in the place of the original union -- 3. Union 291318 (of kit 380000240) to be connected to the pressure gauge (1) -- 4. Oil delivery pipe to the hydraulic cylinder -- 5. Hydraulic cylinder. 87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
34
MDF1821A
77 Power steering and hydraulic lift pump components 1. 2.
Lift pump body. Pump retaining bolts.
3. 4.
Seal. Power steering pump body.
NOTE: The power steering and lift hydraulic pumps are mounted in tandem. They are maintenance free. If even just one pump works badly, it is necessary to replace the complete tandem. If there is any oil leakage, replace the kit of seals as described in the following operation.
87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
35
MDF1823A
78 Power steering pump components 1. 2. 3. 4. 5. 6.
Thrust sleeve. Front cover. Seals. Centring pins. Seals. Seals.
7. 8. 9. 10. 11. 12.
POWER STEERING OIL PUMP Disassembly -- Assembly with pump removed to replace the seal kit
Centring pins. Driven and driving gears. Gear support bushings. Pump body. Protective cap. Rear cover.
Once the parts are removed, proceed as follows:
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
3. Always ensure maximum cleanliness to prevent foreign matter from entering and damaging the pump and clean all the component parts thoroughly.
Proceed as follows:
4. Replace the old seals with those of the new kit.
1. Remove the retaining tie--rods (2, fig. 77), seal (3) and remove the pumps (1) and (4).
5. Lubricate the parts with the oil used in the system and refit the lift pump, referring to the above figure.
ATTENTION
2. Remove the thrust sleeve (1, fig. 78) and dismantle the hydraulic lift pump, as directed in the above figure.
6. Fit the pumps (1) and (4, fig. 77), inserting the seal (3) and the retaining tie--rods (2).
87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
36
FRONT AXLE STEERING CYLINDER R.I.
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 steering cylinder from the front axle, proceed as follows: 1. Remove the nuts (1) locking steering heads on stub axles.
79 2. Using an extractor, extract the steering heads from the seats on the stub axle housings.
3. Extract the steering heads (1) governing the stub axles, on both sides. On the left--hand side, loosen the locknut (2) for adjusting toe--in, then fully unscrew the head.
80
81
87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
37
4. Take out the power steering pipe bracket retaining bolt (1), remove the related unions and extract them.
5. Unscrew the ring nut retaining the steering cylinder on the support.
82
83 6. Loosen the right--hand steering union (1) then extract it. Then extract the cylinder assembly, taking it out from the left--hand side of the support.
7. To assemble, proceed as follows:
84
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 8. Perform the above--described operations in reverse order.
87679925A - 12 - 2007
SECTION 41 -- STEERING -- CHAPTER 1
38
FRONT AXLE STEERING CYLINDER R.I.
1
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.
To remove the axle steering cylinder, proceed as follows: 1. Remove the exhaust pipe, raise the bonnet.
24768
85
2. Unscrew the pipe unions (1, fig. 85) for the cylinder oil delivery and return line (2). 3. Unscrew the nut securing the cylinder rod articulated head to the lever (1, fig. 86).
24858
86 4. Using the extractor (1) separate the articulated head from the cylinder rod.
1
24859
87
5. Remove the pin securing the cylinder to the axle body and remove the cylinder (1). 6. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
7. Perform the above--described operations in reverse order. 87679925A - 12 - 2007
24860
88
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
1
SECTION 44 -- AXLES AND WHEELS Chapter 1 -- Axles and wheels CONTENT Description
Page
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fault diagnosis and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Front axle hub D. A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Front axle R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Stub axle Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Checking 2 WD front wheel camber and toe--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Checking 4 WD front wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPECIFICATIONS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
inverted U--section, U section, telescopic and oscillating at centre
Camber angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
°C
2°, corresponding to approx. 15 mm for 16” rims
Toe--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
±3
Diameter of stub axle pin (7, fig. 2) at bushings (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 articulation pivot (1, fig. 2) . . . . . . . . . . . . . . . . . . . . . .
mm
37.961 ÷ 38.000
Internal diameter of fitted bushings (2) . . . . . . . . . . . . . . . . . . . . . .
”
38.050 ÷ 38.140 (*)
Clearance between stub axle pin and bushings . . . . . . . . . . . . . . .
”
0.050 ÷ 0.179
Stub axle articulation
Axle articulation
(*) Value to be obtained without refacing.
87679925A - 12 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
2
2WD FRONT WHEEL TRACK DIAGRAM
23928
1
Wheel tracks M d l Models
56/76 63/86 71/97 78/106 KW/HP
t tyres A
B
C
D
E
F
G
7.50--16
1450
1550
1650
1750
1850
1950
2050
9.00--16
1494
1594
1594
1794
1894
10.00--16
1494
1594
1594
1794
1994(2) 2094(2)
1994(2) 1994(2) 2094(2)
(2) Wheel tracks requiring full extension of the lights when travelling by road to signal clearance, only for models with roll bars.
87679925A - 12 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
3
26155
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 Steel thrust ring Grub screw for cap (11) and thrust washer (12) Tapered roller bearings for wheel Cover for greasing and adjusting the bearings Cylinder fulcrum pin (18) Power steering cylinder installation position 87679925A - 12 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
4
C1 --49 Nm
C2 --314 Nm
C6 -- 186 รท 206 Nm
C5 -- 186 รท 206 Nm
C3 -- (*) C4 -- 186 รท 257,7 Nm
26157
3 Front axle torque settings C1
Axle pivot pin retaining bolt
C4
Axle end retaining nut
C2
Disk to hub retaining bolt
C5
Stub axle pin control lever retaining bolt nut
C3
Bearings adjuster nut
C6
Nut securing cylinder to fulcrum pin
*
See operations 13. and 14., page 8
87679925A - 12 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
5
BOLT TORQUES PARTS TO BE TIGHTENED
Thread
Front axle Bolt retaining axle support to engine . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torque Nm
kgm
M18x1.5
353
36
Stub head locknut for steering transverse tie--rod . . . . . . . . . . . . . .
M16x1.5
102 ÷ 123.5
10.4 ÷ 12.6
Locknut for steering transverse tie--rod . . . . . . . . . . . . . . . . . . . . . . .
M20x1
176
18
Axle articulation pin retaining bolt (C1, fig. 3) . . . . . . . . . . . . . . . . . .
M10x1.25
49
5
Nut (C2) securing leading wheel to hub . . . . . . . . . . . . . . . . . . . . . .
M18x1.5
314
32
Nut (C3) for bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M20x1.5
(*)
(*)
Nut (C4) for pin securing end of axle . . . . . . . . . . . . . . . . . . . . . . . . .
M20x1.5
186 ÷ 257.7
19 ÷ 26.3
Nut (C5) for stub axles left and right--hand levers retaining bolt . . .
M14x1.5
186 ÷ 206
19 ÷ 21
Nut (C6) securing cylinder to fulcrum pin . . . . . . . . . . . . . . . . . . . . .
M18x1.5
186 ÷ 206
19 ÷ 21
(*) See operations 13. and 14., page 8
SPECIAL TOOLS
CAUTION The operations described in this section can only be carried out with the 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.
380000237
Wheel lifting hook.
TROUBLESHOOTING Problems Abnormal tyre wear.
Poor tractor stability.
Possible causes
Solutions
1. Wrong inflation pressure.
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.
2. Wrong front wheel toe--in.
Correct the toe--in.
1. Wrong inflation pressure.
Inflate the tyres to the correct pressure, following the instructions given above.
87679925A - 12 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
6
FRONT AXLE HUB 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. The wheel hubs can be removed without removing the axle from the tractor, proceeding as follows for each wheel: 1. Lock the front wheels using chocks. 2. Lift the front of the tractor.
24765
4
3. Place a mechanical stand (1) under the engine sump and insert a wooden block between the engine sump and the stand.
1 24766
5 4. Remove the front wheel retaining bolts (1).
24767
6
87679925A - 12 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
7
5. Remove the cover (1) for wheel hub bearing greasing.
24775
1 7
6. Remove the wheel hub bearing adjuster nut securing ring (1).
24776
8 7. Using a socket wrench, unscrew the wheel hub bearing adjuster nut.
24777
9
8. Remove the wheel hub (2) and recover the bearings (1 and 3).
1
2
3
24778
10 87679925A - 12 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
8
9. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 10. Check and replace any worn bearings or faulty seals, using suitable pullers and punches. 11. Fill the wheel hub with AMBRA GR9 GREASE. 12. Refit the wheel hub, complete with bearings. 24780
11
13. 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. 14. 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.
24779
12 15. Check the rolling torque R, bearing in mind that: R โ ค 0.8 kgm 16. Secure the nut (1) by notching. 17. Refit the cover for wheel hub bearing greasing.
24776
13
87679925A - 12 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
9
FRONT AXLE 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. To remove the front axle assembly from the tractor, proceed as follows: 1. Lock the front wheels using chocks. 2. Lift the front of the tractor.
24765
14 3. Place a mechanical stand (1) under the engine sump and insert a wooden block between the engine sump and the stand.
1 24766
15
4. Remove the front wheel retaining bolts (1).
24767
16
87679925A - 12 - 2007
10
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
5. Disconnect the pipes (1) of the power steering cylinder (2).
1
2
24768
17
6. Remove the axle articulation pin retaining bolt (1).
24769
18 7. Secure the axle by means of a sling (1).
1
24770
19
8. Extract the axle articulation pin (1) using an extractor tool fitted with adapter and extension.
24771
20 87679925A - 12 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1 9. Remove the complete axle (1).
11
1
10. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Refit the axle assembly on the tractor with the sling and, using a bronze striker, fit the axle articulation pin.
--
Fit the axle articulation pin retaining bolt (1).
--
Connect the hoses of the power steering cylinder.
--
Fit on the front wheels and their retaining bolts.
--
Remove the mechanical stand beforehand under the engine sump.
--
Remove the chocks on the rear wheels.
24772
21
installed
87679925A - 12 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
12 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. The stub axles can be removed without removing the axle from the tractor, proceeding as follows for each individual wheel: 1. Lock the front wheels using chocks. 2. Lift the front of the tractor.
24765
22 3. Place a mechanical stand (1) under the engine sump and insert a wooden block between the engine sump and the stand.
1 24766
23
4. Remove the front wheel retaining bolts (1).
24767
24
87679925A - 12 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
13
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
25
6. Extract the control lever (1) from the stub axle pin (2).
24783
26 7. Lower the hydraulic jack and remove the stub axle (1).
1 24784
27
8. Take out the bolts securing the end of the axle (1).
24785
28 87679925A - 12 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
14
9. Remove the axle end (1).
24786
29
10. Clamp the end of the axle in a vice and, using an extractor tool, extract the stub axle pin articulation bushings (1).
24787
30 11. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
Refit the stub axle, using a striker to fit the new bushings on the axle ends.
--
Fit the axle end.
---
Unscrew the bolts securing the axle end. Refit the cup (9, fig. 2) at the base of the stub axle, then the bronze thrust rings (1) inserting them on the stop grub screws (8 and 14, as shown in fig. 2).
--
Fit the stub axle on the axle end, using the hydraulic jack.
--
Insert the control lever on the stub axle pin and tighten the retaining bolt.
--
Fit on the front wheels and their retaining bolts.
--
Remove the mechanical stand beforehand under the engine sump.
--
Remove the chocks on the rear wheels.
87679925A - 12 - 2007
24788
31
inserted 24789
32
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1 CHECKING 2 WD FRONT WHEEL CAMBER AND TOE--IN
15
A
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).
A+X C
When driving in a straight line, the wheels must also be parallel to longitudinal axis with a tolerance of ± 3 mm. C = B ± 3 mm 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.
B 8821
33
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 3 mm. 6. If necessary, correct the toe--in by adjusting the end of the transverse steering tie--rod.
87679925A - 12 - 2007
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
16
CHECKING 4 WD FRONT WHEEL ALIGNMENT When travelling forward in a straight path, the wheels of four--wheel drive tractors must be parallel to the longitudinal axis of the tractor, alternatively a slight tolerance of ±3 mm is permissible. A = B ± 3 mm 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. On the horizontal plane passing between the centres of the wheels, measure the distance (A) between the front inside edges of the rims.
A
180o
then, at the 5. Turn both front wheels through height of the wheel hub centres, measure the distance (B) between the rear inside edges of the wheel rims, checking that the new measurement is equal to or greater than distance (A) by a maximum of 3 mm. The rotation of the wheels through 180° is required in order to eliminate the effect on the measurement of any wear on the rims.
B
24666
34 6. If wheel toe--in needs to be adjusted, remove nut (2) and extract the track rod end (1) from its housing. 7. Loosen lock nut (3) and screw the track rod end (1) in or out to decrease or increase the distance (2, fig. 34). 8. Reposition the track rod end (1) in the housing and check the toe--in as described in points 4 and 5. 9. After having adjusted the toe--in to within the prescribed limits, tighten lock nut (3) to a torque value of 180 Nm (18.3 kgm) and nut (2) to 100 Nm (10.2 kgm). NOTE: Self--locking nut (2) must be replaced each time it is removed or unscrewed.
87679925A - 12 - 2007
1
3
2
24667
35
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
1
SECTION 50 -- AUXILIARY UNITS Chapter 1 -- Auxiliary units
CONTENT Description
Page
Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operating principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Main components of the cab air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Warnings for air conditioning system repair operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Instructions for use -- air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Refrigerant recovery -- recycling and evacuation -- charging stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Electronic leak detector 380000314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Air conditioning system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Air conditioning system troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Air conditioning system troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Air conditioning system functional testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Checking for gas leaks with leak detector 380000314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Compressor drive belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Compressor drive belts. Tension adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Air conditioner compressor. R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Heating pipes. Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Air conditioning pipes. Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Air conditioner condenser. Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Filter/dryer. Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Cab heater unit. R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Air conditioner evaporator. Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Electric cab fan. R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
2
CAB AIR CONDITIONING SYSTEM --
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 drained the system.
--
do not loosen or remove the compressor oil level check cap with the system pressurised.
--
do not heat the refrigerant container. If the temperature exceeds 50 °C the pressure will increase very rapidly.
-In order to avoid accidents follow the simple precautions described below.
keep the air conditioning system away from heat sources to prevent explosions as a result of an increase in pressure in the system piping.
The operation of emptying and charging the system must be carried out in a well--ventilated area, well away from any naked flames.
When transferring refrigerant from one container to another, only use homologated liquid refrigerant containers equipped with safety valves.
During the charging and emptying operations, take the necessary precautions to protect the face and above all the eyes from accidental contact with refrigerant.
Never fill liquid refrigerant containers over 80% of their maximum capacity.
SAFETY REGULATIONS
The refrigerant must be handled with great care in order to avoid personal injury; always use safety goggles and gloves.
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, which is dangerous if inhaled.
In the event of an accident, proceed as follows:
--
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.
87679925A - 12 - 2007
Do not modify the settings of safety valves and the control devices.
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 -- AUXILIARY UNITS -- CHAPTER 1
3
CAB AIR CONDITIONING SYSTEM CHARACTERISTICS SANDEN SD 7H15 Compressor Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm3
155
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 HFC134a
Quantity of HFC--134a refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . g
1600
System delivery side pressure . . . . . . . . . . . . . . . . . . . . . bar (kg/cm2)
16 ÷ 24 (16.3 ÷ 24.5)
System suction side pressure bar . . . . . . . . . . . . . . . . . . . bar (kg/cm2)
0.5 ÷ 3 (0.5 ÷ 3)
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 . . . . . . . . . . °C
60 ÷ 120
Temperature of refrigerant fluid at condenser outlet . . . . . . . . . . . °C
40 ÷ 60
Temperature of refrigerant fluid at evaporator outlet . . . . . . . . . . . °C
0 ÷ 15
Maximum capacity of electric centrifugal fan I, II, III speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . m3/min
3.5 ÷ 8.5
VARIATIONS IN WORKING TEMPERATURES OF THE CAB AIR CONDITIONING SYSTEM External ambient temperature Temperature of air at vent outlets (inside cab)
20 °C
27 °C
4 ÷ 8 °C
28 °C
35 °C
6 ÷ 12 °C
36 °C
43 °C
12 ÷ 20 °C
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SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
4
It should be remembered that altitude affects pressure, as indicated in the table.
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.
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
TOOLS REQUIRED FOR SERVICING THE CAB AIR CONDITIONING SYSTEM
CAUTION The operations described in this section can only be carried out with the 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
Recovery, recycling, evacuation and charging station. Acoustic gas leak detector.
X 380000312
Combs for cleaning and straightening the fins on the condenser and evaporator.
X 380200011
Compressor belt assembly tool.
87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- 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. Simplified psychometric diagram 1. Sensation of unbearable coldness. 2. Sensation of coldness. 3. Comfort zone. 4. Sensation of heat. 5. Sensation of unbearable heat.
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 %
25372
Temperature oC
1
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SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
6
The air conditioning system comprises five main components: 1. compressor; 2. condenser; 3. filter/dryer;
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).
4. 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 0.5 ÷ 3 compressing it to a pressure of 16 ÷ 24 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.
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. Compressor. 2. Condenser. 3. Filter/dryer. 87679925A - 12 - 2007
4. Expansion valve with thermostatic sensor. 5. Evaporator.
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 MAIN COMPONENTS OF THE AIR CONDITIONING SYSTEM
1
2
3
4
7
5
Axial flow reciprocating piston compressor SANDEN SD 7H15 1. Combined inlet and discharge valve. 2. Piston with seal ring. 3. Driving gear. 4. Connecting rod disk. 5. Cam rotor.
25375
3
Compressor The compressor serves to pressurise the refrigerant and force it through the system. SANDEN SD 7H15 MODEL Axial reciprocating piston type, driven by the engine crankshaft via a vee belt. 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). Driven by the compressor pulley, as the cam rotor (5) rotates it exerts a continuous thrust on the swashplate (4), which is prevented from rotating by the coupling with the fixed gear (3). The angle of the rotor cam (5), in relation to the axis of rotation, causes the reciprocating movement of the pistons (2). The piston head (2) is fitted with a reed valve (1) with seven lobes (one for each piston), and controls the inlet and discharge stages of the cylinders (2). 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.
87679925A - 12 - 2007
8
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
Condenser The condenser 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. 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 is fitted opposite the engine radiator, in the best position for the air flow necessary for heat exchange. Filter/dryer The filter/dryer, fitted near the compressor and 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.
1
The filter therefore contains substances capable of absorbing humidity. Solid particles, such as grit, oxides, metal particles produced by the mechanical wear of the compressor, etc., can also damage the system and so the filter incorporates screens to retain them.
2 3
Filter/dryer
4
1. Sight glass.
5
2. Upper screen. 3. Disk. 4. Drying unit. 5. Lower screen.
87679925A - 12 - 2007
25376
4
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
9
Thermostatic expansion valve 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. The expansion valve has two main functions: --
metering: the calibrated bore (6, fig. 5) 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.
If the thermostatic sensor (2, fig. 5) 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 3. NOTE: In the event of malfunction, replace the valve.
2
1
3
Expansion valve block 1. From the evaporator outlet. 2. Thermostatic sensor.
4
3. To compressor suction inlet. 4. From filter/dryer.
7 6
5. Spring. 6. Calibrated bore and ball. 7. To evaporator inlet.
5
25389
5
87679925A - 12 - 2007
10
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
Adjustable electronic thermostatic switch (ANTIFROST)
1
2
The adjustable electronic thermostat, or thermostat for brevity, is a safety device fitted with a sensor (1) that, inserted between the evaporator fins (2), constantly monitors the temperature. The sensor head (1), contains a gas which is sensitive to evaporator temperature variations, varying the volume inside the sensor. The variation of the volume inside the sensor head (1), acting on a membrane connected to a complex mechanism, opens or closes the electric circuit connected to the compressor electromagnetic clutch. The opening or closing of the compressor electromagnetic clutch electric circuit causes the compressor to engage or disengage. The electronic thermostatic switch (1, fig. 6) is adjustable from inside the cab with the knob (2, fig. 12) installed on the case of the control panel. It acts on a potentiometer designed to adjust the thermostat temperature range. For this reason it is important that the electronic thermostatic switch (1) is always checked and inserted between the evaporator fins (2, fig. 6), in order that the system can function correctly.
NOTE: In the event of malfunction, check the electric circuit of the electronic thermostatic switch and the control installed on the control panel case.
87679925A - 12 - 2007
25377
6
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 Evaporator
11
WARNINGS FOR AIR CONDITIONING SYSTEM REPAIR OPERATIONS
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.
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.
As it passes through the evaporator radiator the refrigerant absorbs heat from the cab air, evaporates, and is then taken in by the compressor as vapour.
When disconnecting the hoses, close the ends with plastic caps to prevent foreign matter and humidity from getting inside the hoses.
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.
Handle the thermostatic sensor carefully to avoid damage that may prevent efficient system operation.
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.
Always use two spanners to unscrew the hose fittings to avoid twisting the fitting.
Do not use any type of engine oil to lubricate the compressor and the system.
The evaporator also dehumidifies the air.
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.
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.
The centrifugal fan draws the ambient air through the fins of the evaporator (where it is cooled and dehumidified) and into the cab.
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.
The housing around the evaporator is equipped with a condensate trap from which the condensate is carried outside the vehicle through discharge tubes.
Check that the thermostatic sensor is correctly inserted in the fins on the evaporator to ensure efficient system operation.
87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
12
CAB HEATING AND VENTILATION CONTROLS Ventilation
1
2
Turn on the cab ventilation by means of the switch (1, fig. 7) 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 recirculation vents (1, fig. 8) which can be placed in two positions. ---
vents closed: air is drawn from outside the cab through the lateral filters. vents open: a larger quantity of air comes from inside, via the vents.
Fresh air drawn into the cab from outside is always filtered.
24023
7
1
When the electric fan is operating and with the doors, re--circulation vents and windows closed, the pressure inside the cab is higher than the pressure outside, and consequently air can only enter the cab via the side filters. NOTE: To increase the air pressure inside the cab, use only external air (air recirculation vents 1, fig. 8 closed).
24024
8
Electric Fan
1
A
B
C
The fan control switch (1, fig. 7 and 9) is powered up when the ignition switch (1, fig. 11) is in position B. A. Low speed. B. Medium speed. C. High speed. 24025
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.
87679925A - 12 - 2007
9
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
13
HEATING
1
2
3
The heating control knob (1, fig. 10) 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 vents (3, fig. 10) and (1, fig. 8). 24026
10
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 (including the cab heating system) is 16 litres for all the models in the TLA series.
IGNITION SWITCH To operate the four switch functions, turn the key (1) through the following positions:
A
B C
A. No power supply to any of the circuits (key can be removed). Engine stopped: automatic activation of fuel injection cut--off.
p
B. Standby for engine start up. Operation of panel lights and instruments, various circuits powered up.
1 25235
C. Engine start: if released, the key returns automatically to position (B).
11
p. Sidelights ON, control panel illuminated, auxiliary lights powered up (the key can be removed).
87679925A - 12 - 2007
14
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
MDF1826A
12 CAB AIR CONDITIONING CONTROLS Air conditioning and temperature control knobs
A
Functions when the ignition switch (1, fig. 13) is in the starting position (B).
B C
With the electric fan knob (1, fig. 12) in positions A--B or C, turn the knob (2) to switch on the air conditioning.
p
1 25235
13 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 This switch operates with the starter key (1, fig. 13). is in the starting position (B). D. Low speed. E. Medium speed. F. High speed. NOTE: To pressurise the cab, see the Ventilation chapter on page 12 in this Section.
87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 AIR CONDITIONING SYSTEM -- INSTRUCTIONS FOR USE The air conditioning system provides dehumidified air or warm dehumidified air.
15
SWITCHING OFF cool,
NOTE: When the engine is not running, the air conditioner will not work because the compressor is driven by the engine. To operate the system, proceed as follows:
Before stopping the engine, always turn off the air conditioning unit with the knob (2, fig. 12) and move the electric fan knob (1) to the OFF position.
AIR--CONDITIONING SYSTEM RECOVERY-RECYCLING--EVACUATION--CHARGING STATION (380000315)
START UP
CAUTION
Before starting the engine, turn the knob (2, fig. 12) so as to switch off the air conditioning unit. Start the engine and proceed as follows.
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.
CAUTION
Before switching on the conditioner, always switch on the electric fan. When the fan is switched off the air conditioning will not function.
ADJUSTMENT
Meaning The station is designed to initially recover and recycle the refrigerant used in air conditioning system.
For a correctly air conditioned cab, open the re--circulation vents when the air conditioning is running, and keep the doors, roof and rear window closed.
Recovered refrigerant is first subjected to an evaporation process in a special chamber to remove any oil.
To lower the temperature in the cab and, at the same time, reduce the air humidity, turn the knob (3, fig. 12), counter--clockwise until the desired temperature is obtained.
In the filter section, the acidity is neutralised, moisture is absorbed and solid particles are screened out.
NOTE: When working in very dusty environments, the cab pressure may have to be increased to prevent dust from entering the cab; you are also advised to close the re--circulation vents. If only the dehumidification function on the air conditioning system is required, without lowering the air temperature, turn the knob (3, fig. 12) clockwise until the desired temperature is obtained. To restore the temperature in the cab after a prolonged halt in the sun, start the tractor, switch on the air conditioning and after about a minute open the rear fanlight or the roof to let the hot air escape.
The decontaminated refrigerant is then stored in the metering cylinder. The station then drains and recharges conditioning system with refrigerant.
the
The emptying stage is necessary to remove any moisture and impurities from the system. As regards system recovery--recycling and evacuation--charging, refer to the Operatorâ&#x20AC;&#x2122;s manual provided with control unit 380000315.
87679925A - 12 - 2007
16
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
LEAK DETECTOR (380000314) 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. 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. 25387
Mounted on the front of the instrument are the on/off switch, the red on/off LED and the acoustic gas detection indicator. 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. Use Set the switch to ON: start looking for leaks; the frequency and the amplitude of the audible signal will increase if gas is detected.
14 Service 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. 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.
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.
1
2
3
4
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. Refrigerant gas leak test 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. 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. 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.
87679925A - 12 - 2007
25388
15 Leak detector probe 1. Flexible probe 2. Sensing tip 3. Felt pad 4. Guard
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 MAINTENANCE OF THE AIR CONDITIONING SYSTEM
NOTE: Carry out the same checks on the EVAPORATOR (9) and the CONDENSER (5).
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.
3) FILTER/DRYER: Replace the filter/dryer after the system has been repaired on two occasions. 4) EXPANSION VALVE: this valve does not require maintenance; in the event of malfunction, check the valve and thermostatic expansion valve as indicated on page 9 and the thermostatic sensor as indicated on page 10 or contact specialised personnel of the CNH service network.
For this purpose, start the engine and run at 1500 rpm for around 10 minutes. Set the cab ventilation fan to maximum speed. Turn the knob (2, fig. 12) to switch on the air conditioning. 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 23.
If the temperature of the air at the vent outlets does not conform to the indications given in the table on page 23 proceed with the system troubleshooting operations described on page 18.
If the temperature values are correct, the system is perfectly efficient and only requires a visual inspection of the main components:
ATTENTION
1) COMPRESSOR: check the mountings, the tension of the drive belt and the oil level.
Caution -- If any of the system components need to be replaced, follow the recovery, recycling and charging operations, using control unit 380000315.
2) CONDENSER: check mounting and that the fins are free of excessive deposits. Straighten any bent fins using the comb tool 380000312.
2
1
17
3
4
10
9
8
7
6
5
25374
16 Schematic diagram of the air conditioning system 1. 2. 3. 4. 5.
Compressor. Inlet pipe (low pressure). Outlet pipe (high pressure). Warm air. Condenser.
6. 7. 8. 9. 10.
Filter/dryer. Sight glass. Expansion valve with thermostatic sensor. Evaporator. Cool, dehumidified air.
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SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
18
CAB AIR CONDITIONING SYSTEM TROUBLESHOOTING 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. 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 compressor and support are correctly secured, and check the pulley alignment and tension of the compressor drive belt.
--
Look for visible leaks of liquid refrigerant on hoses or system fittings.
--
Look for visible leaks of liquid refrigerant.
--
Visually check the condition of all fittings, unions and pipes, above all those in contact with the engine, as well as all retainer fittings and clamps.
--
Check that the engine, condenser evaporator radiators are clean.
--
Check the conditions of the thermostatic switch (fig. 6) and check that its location, between the evaporator fins, is the original one.
--
Check that the cab external air intakes are clean (not clogged).
--
Check the condition of the condensate drain lines.
and
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, as indicated on page 23.
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SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
19
AIR CONDITIONING SYSTEM TROUBLESHOOTING (CONT.) THE SYSTEM DOES NOT WORK
1. Check fuses. 2. Check compressor drive belt tension. 3. Check if the clutch coil is receiving power. 4. Check that the earth contact is efficient.
5. Check the system control devices -- relays, wiring, thermostat, etc. 6. Visually check the condition of all fittings, unions and pipes. 7. Check the clearance between the front disk and the pulley of the electromagnetic clutch.
2
1
3
4
10
9
8
7
6
5
25374
17 Schematic diagram of the air conditioning system 1. 2. 3. 4. 5.
Compressor. Inlet pipe (low pressure). Outlet pipe (high pressure). Warm air. Condenser.
6. 7. 8. 9. 10.
Filter/dryer. Sight glass. Expansion valve with thermostatic sensor. Evaporator. Cool, dehumidified air. 87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
20
AIR CONDITIONING SYSTEM TROUBLESHOOTING (CONT.) INSUFFICIENT COOLING
HIGH DISCHARGE PRESSURE AND/OR HIGH SUCTION PRESSURE
DISCHARGE PRESSURE LOW AND/OR SUCTION PRESSURE LOW
DISCHARGE PRESSURE NORMAL AND/OR SUCTION PRESSURE NORMAL
EXCESS REFRIGERANT IN SYSTEM
Insufficient refrigerant. Possibly due to small leaks.
NOTE: during testing, the low pressure gauge reading could fall to negative values or remain normal.
Evacuate refrigerant until both pressure gauges indicate the normal pressure values shown on page 3.
CONDENSER 1. The condenser could be clogged or it might not be receiving an adequate air flow. Clean the fins on the condenser surface and check that the distance between the radiator and the condenser is correct.
EXPANSION VALVE Check the valve, as indicated on page 9. 1. If the valve fails the test, replace it.
87679925A - 12 - 2007
1. Check the system for leaks and eliminate them. 2. Add refrigerant until both pressure gauges indicate the normal pressure values shown on page 3.
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.
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
21
AIR CONDITIONING SYSTEM TROUBLESHOOTING (CONT.) INSUFFICIENT COOLING
DISCHARGE PRESSURE NORMAL AND/OR SUCTION PRESSURE NORMAL
NOTE: the high pressure gauge reading should be constant and should not fall. 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.
DISCHARGE PRESSURE LOW AND/OR SUCTION PRESSURE LOW
DISCHARGE PRESSURE NORMAL AND/OR SUCTION PRESSURE NORMAL--HIGH
RESTRICTION
ANTI--FROST SWITCH
Water or ice forms downstream of the restriction (on filter--dryer 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.
With the outside temperature below 30_ the electro--magnetic clutch is permanently engaged. 1. Check the anti--frost switch (1, fig. 6) as indicated on page 10. 2. Replace the anti--frost switch (1, fig. 6) if it does not function correctly, taking care not to crush the capillary tube. Install the new switch in exactly the same position in the evaporator as the switch that has been replaced.
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SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
22
AIR CONDITIONING SYSTEM TROUBLESHOOTING COMPRESSOR AND ELECTROMAGNETIC CLUTCH
UNUSUAL NOISE WITH CLUTCH ENGAGED
INSUFFICIENT COOLING
1. Check all compressor mountings.
The compressor runs noisily or does not run.
2. Check engine components in the vicinity of the compressor. 3. Check if the electromagnetic clutch operates intermittently or slips.
5. Check that the clutch pulley runs freely. 6. Check the oil compressor.
level
in
the
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 that there are no leaks on the compressor or in the system.
87679925A - 12 - 2007
1. Check the supply.
electrical
power
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 disk and the pulley of the electromagnetic clutch. 4. Check the clutch bearing.
UNUSUAL NOISE WITH CLUTCH DISENGAGED OR VIBRATION
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 CAB AIR CONDITIONING SYSTEM FUNCTIONAL TESTS
DANGER
23
The pressure values will depend on the external ambient conditions and the altitude, see the table on page 4.
Perform functional testing on the system following the safety regulations described on page 2.
The system is to be considered as functioning correctly if the pressure and temperature readings are within the value ranges indicated on page 3.
With the pressure gauges connected to the system hoses on the:
9. Carry out temperature checks on the high and low pressure parts of the system:
Intake side of the compressor, (for low pressure testing/reading).
--
all high pressure parts -- from the compressor delivery fitting to the expansion valve installed on the evaporator unit -- should be uniformly hot to touch;
--
all low pressure parts, -- from the evaporator 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.
Delivery side of the compressor, (for high pressure testing/reading), proceed as follows: 1. Start the engine and bring it up to a speed of 1500 rpm. 2. Set the electric fan (1, fig. 12) to maximum speed. 3. Turn the knob (2, fig. 12) to switch on the air conditioning. After the system has been in operation for about 15 minutes, check the following values: 4. Pressure on the suction side of the compressor, as indicated by the low pressure gauge. 5. Pressure on the delivery side of the compressor, as indicated by the high pressure gauge. 6. Ambient air temperature. 7. Ambient relative humidity. 8. Temperature of air leaving vents inside the cab.
10. The compressor should not be excessively noisy, there should be an audible click when the drive is engaged.
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 table for the external ambient air temperatures specified, the system is functioning efficiently. If the temperature at the vents is higher than the maximum values on the table, troubleshoot the fault as described on the following pages to restore efficient system operation.
VARIATIONS IN WORKING TEMPERATURES OF THE CAB AIR CONDITIONING SYSTEM External ambient temperature Temperature of air at vent outlets (inside cab)
20 °C
27 °C
4 ÷ 8 °C
28 °C
35 °C
6 ÷ 12 °C
36 °C
43 °C
12 ÷ 20 °C
87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
24
CHECKING FOR AND ELIMINATING ANY GAS LEAKS with leak detector 380000314
DANGER Perform functional testing on the system following the safety regulations described on page 2. With the system charged, proceed as follows: 1. Start the engine. 2. Set the cab ventilation fan to maximum speed. 3. Turn the knob (2, fig. 12) to switch on the air conditioning. 4. Bring the engine up to a speed of 1500 rpm. 5. Operate the electronic detector as described on page 16. 6. Move the probe around all pipe connections and all possible points of leakage: --
leaks are indicated by an increase in the frequency of the acoustic signal.
NOTE: The refrigerant is heavier than air, therefore it will be easier to detect the leak point from below rather than from above. 7. If leaks are found in the pipe connections, tighten the fittings in order to eliminate the leak.
ATTENTION If any of the system components need to be replaced, always follow the recovery, recycling and charging operations, using control unit 380000315.
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SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
25
COMPRESSOR DRIVE BELT
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 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: A)--Fit the belt correctly. B)--Check the belt tension. C)--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 wear out the pulley bearings and cause premature deterioration of the belt. If, on the other hand, the belt is too slack, it will start to slip and overheat and thus very rapidly deteriorate.
87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
26
COMPRESSOR DRIVE BELT Tension adjustment Only check the tension when the belt is cold (below 40 °C). 1. Disconnect the power connection (1) from the compressor and 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: 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 internal part of the belt to wear rapidly. Take the following action: --
If the belt squeaks when running, check the tension and adjust it, bearing in mind that if the tension is insufficient the belt tends to overheat and stretch.
--
If the belt is deeply cracked and continues to squeak after adjustment, replace it.
87679925A - 12 - 2007
18
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
27
AIR CONDITIONER COMPRESSOR R.I.
DANGER When removing refrigerant from the system fully respect the safety regulations noted on page 2.
1. Raise the bonnet (1). 2. Disconnect the battery negative cable. 3. Recover the refrigerant from the system using control unit 380000315.
19 4. Disconnect the power connection (1) from the compressor.
20 5. Remove the delivery/return hoses (1) from the compressor.
21
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SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
28
6. Loosen the compressor unit retaining bolts (1), then remove the belt and the air--conditioning pipes support (2) and the compressor.
DANGER If you want to use the belt again, take the greatest care over moving the belt out from the pulley. Loosen the bolts (1) slightly (so as to have a minimum clearance on the compressor) and with one hand moving the fan, with the other one use a screwdriver to move the belt out of the pulley.
22 7. To assemble, 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. --
--
Put the compressor back on the support and with the related pipe support secure it with the four bolts To mount the polyvee belt use tool 380200011.
1. Compressor clutch actuator drive bracket. 2. Polyvee belt pulley outer edge. 3. Tool recess. It is used to drive the tool; this recess houses the bracket 1. 4. Tail. Used to drive the polyvee belt in the pulley seat. 5. Hitching. Thanks to this recess, where the outer edge 2 is housed, the tool remains hitched to the compressor.
23
87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 --
Take out the bolts (1) and the related compressor clutch dust cover.
--
Make sure that the polyvee belt (2) is perfectly housed on the fan pulley.
--
Move the belt (2) near to the compressor pulley and, keeping the tool 380200011 under the belt, hook it onto the clutch of the compressor at the innermost part so as to slightly force the belt.
29
24
ATTENTION Keeping your hand on the back of the tool and always outside the pulley so as not to get your fingers crushed between the pulley and the belt after a sudden movement of the pulley. ---
-----
25
With your left hand on the fan and right hand on the tool, move both clockwise so as to take the belt onto the belt of the compressor. Put the dust cup back onto the compressor clutch and tighten the three screws taking care to spread a film of thread lock on the ends so they do not come unscrewed. Reconnect the pipes to the compressor. Reconnect the connection on the electrical system. Recharge the refrigerant in the air--conditioning system with the control unit 380000315. Reconnect the battery and close the bonnet.
87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
30
COMPRESSOR OIL -- TYPE AND QUANTITY The tractor is equipped with a SANDEN SD 7H15 for 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.
ATTENTION If the system develops significant leaks of refrigerant gas, 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 CNH service centre.
87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
31
HEATING PIPES Renew
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.
DANGER Recover the refrigerant closely following the safety regulations described on page 2. 1. Perform the disassembly sequences 1 รท 18 described in section 50 for the AIR--CONDITIONING PIPES.
26
2. Remove the two heater water supply and return pipes (1), extracting them from the top of the left--hand duct in the cab.
1
24818
27
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SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
32
3. Before assembly, thoroughly clean the parts and proceed as follows:
1
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Insert the two new heater water supply and return hoses (1) into the left--hand duct in the cab upright.
--
Remove all traces of the old seal and apply a suitable sealing compound together with the new â&#x20AC;&#x153;tarredâ&#x20AC;? seal, as shown in fig. 29.
--
Sling the roof with a cable, raise and reposition the roof on the uprights. Check that the seal is correctly positioned and secure the roof with the eight retaining bolts.
--
Reconnect the three plug connections to the fan / air--conditioning control unit.
--
Reconnect the electrical connections to the fan unit.
--
Reconnect the electrical connections to the thermostatic sensor.
--
Reassemble the two condensate discharge hoses.
--
Refit the cab heating hoses (left--hand upright).
--
Reinsert the two rigid copper pipes in the expansion valve. Attach the air--conditioning pipes to the valve using the slotted plate.
--
Insert the delivery/return pipe in the brass sleeve on the evaporator and secure with the two metal clips.
--
Carry out the assembly sequences described in section 90 for the CAB CEILING TRIM.
--
Fit the evaporator cover and the four retaining bolts back on.
--
Refit the roof hatch.
--
Top up the radiator with the liquid that was previously drained off.
--
MDE0760A
Fill the air conditioning circuit with HFC 134 a gas, using control unit 380000315.
87679925A - 12 - 2007
28
24819
29
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
33
AIR CONDITIONING PIPES Renew
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.
DANGER Recover the refrigerant closely following the safety regulations described on page 2.
1. Recover the refrigerant using control unit 380000315. 2. Detach the fitting (3) of the return pipe (2) for the coolant from the cab heater radiator connected to the underside of the coolant pump (1) and drain off the engine coolant. 3. Open the roof hatch (1) extracting the pneumatic pistons.
30
1
24790
31 4. Remove the pivot pins (1) and remove the hatch.
1
24791
32
87679925A - 12 - 2007
34
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
5. Unscrew the four bolts (1) securing the evaporator cover.
6. Carry out the disassembly sequences described in section 90 for the CAB CEILING TRIM. 7. Disconnect the loudspeaker wires (1).
1
24792
33
1
24798
8. Unscrew the retaining screw and extract the fan control unit (1).
34
1
24799
35 9. Unscrew the two bolts (1) clamping the rigid pies to the evaporator.
1
24800
36 87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
35
10. Remove the clamp (1) and extract the pipes.
1
24801
37 11. Detach the two clips (1) holding the hoses and extract the hoses from the heater.
1
24805
38 12. Detach the two condensate drainage hoses (1).
1
24807
13. Disconnect the electrical connections (1) on the temperature sensor.
39
1
24809
40 87679925A - 12 - 2007
36
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
14. Disconnect the electrical connections (1) on the fan unit (2).
41
15. Unscrew the eight bolts (1) securing the cab roof.
1
24813
42 16. Disconnect the three connections (1) on the air conditioning control unit, located on the central crosspiece.
1
24814
17. Remove the roof (1) from the support uprights.
43
1
24815
44 87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 18. Using slings (1) hitch the roof and raise with a hoist.
37
1
24816
45
19. Remove the air conditioning feed and return lines (1), extracting from the upper part of the cab right--hand upright.
1
24818
46
87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
38
20. Before assembly, thoroughly clean the parts and proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
1 --
Insert the two new air conditioning supply and return hoses (1) into the right--hand duct in the cab upright.
--
Remove all traces of the old seal and apply a suitable sealing compound together with the new â&#x20AC;&#x153;tarredâ&#x20AC;? seal, as shown in fig. 48.
--
Sling the roof with a cable, raise and reposition the roof on the uprights. Check that the seal is correctly positioned and secure the roof with the eight retaining bolts.
--
Reconnect the three plug connections to the fan / air--conditioning control unit.
--
Reconnect the electrical connections to the fan unit.
--
Reconnect the electrical connections to the thermostatic sensor.
--
Reassemble the two condensate discharge hoses.
--
Refit the cab heating hoses (left--hand upright).
--
Reinsert the two rigid copper pipes in the expansion valve. Attach the air--conditioning pipes to the valve using the slotted plate.
--
Insert the delivery/return pipe in the brass sleeve on the evaporator and secure with the two metal clips.
--
Carry out the assembly sequences described in section 90 for the CAB CEILING TRIM.
--
Fit the evaporator cover and the four retaining bolts back on.
--
Refit the roof hatch.
--
Top up the radiator with the liquid that was previously drained off.
--
Fill the air conditioning circuit with HFC 134 a gas, using control unit 380000315.
87679925A - 12 - 2007
24818
47
24819
48
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
39
AIR CONDITIONER CONDENSER Renew
DANGER When removing refrigerant from the system fully respect the safety regulations noted on page 2. 1. Raise the bonnet and recover the refrigerant using control unit 380000315. 2. Disconnect the two gas delivery and return hoses (1) on the condenser.
3. Turn the steering wheel fully to the left. Remove the top pin (1) retaining the condenser.
49
50 4. Extract the condenser radiator (1) from the left--hand side of the tractor.
ATTENTION
51
Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. -----
Refit the condenser and secure it to the upper guide with the retaining pin. Reconnect the two hoses on the condenser. Empty and charge the system with HFC 134a gas, using control unit 380000315. Close the bonnet.
87679925A - 12 - 2007
40
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
FILTER/DRYER Renew
DANGER When removing refrigerant from the system fully respect the safety regulations noted on page 2. 1. Raise the bonnet (1). 2. Disconnect the battery negative cable. 3. Recover the refrigerant from the system using control unit 380000315.
52 4. Disconnect the electrical connection (1) on the filter/dryer. 5. Detach the hose (2) connecting the condenser to the filter/dryer. 6. Detach the hose (3) connecting the filter/dryer to the vaporizer.
7. Unscrew the bolt (1) securing the filter/dryer clamp (2).
53
54
87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
41
8. Remove the filter/dryer assembly (1).
MDE0331A
55 9. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Refit the filter/dryer on the bracket and tighten the filter clamp with the retaining bolt.
--
Reconnect the hose connecting the filter/dryer to the vaporizer.
--
Reconnect the hose connecting the condenser to the filter/dryer.
--
Reconnect the electrical connection on the filter/dryer.
--
Empty and charge the system with HFC 134a gas, using control unit 380000315.
--
Reconnect the battery negative cable and close the bonnet.
87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
42
CAB HEATING UNIT R.I.
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. Detach the fitting (3) of the return pipe (2) for the coolant from the cab heater radiator connected to the underside of the coolant pump (1) and drain off the engine coolant. 2. Open the roof hatch (1) extracting the pneumatic pistons.
56
1
24790
57
3. Remove the pivot pins (1) and remove the hatch.
1
24791
58 4. Unscrew the four bolts (1) securing the evaporator cover.
5. Carry out the disassembly sequences described in section 90 for the CAB CEILING TRIM. 87679925A - 12 - 2007
1
24792
59
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
43
6. Disconnect the loudspeaker wires (1).
1
24798
7. Unscrew the retaining screw and extract the fan control unit (1).
60
1
24799
61 8. Detach the two clips (1) holding the hoses and extract the hoses from the heater.
1
24805
62
9. Remove the heating unit (1) from above.
1
24806
63 87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
44
10. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Fit the heating unit at the top of the cab roof.
--
Fit the rubber hoses on the heater and refit the two retaining clips.
--
Mount the fan control unit and fit the retaining bolts.
--
Connect the leads to the speakers.
--
Carry out the assembly sequences described in section 90 for the CAB CEILING TRIM.
--
Fit the evaporator cover and the four retaining bolts on.
--
Fit on the hatch, pneumatic pistons and pivot pins.
--
Charge with the refrigerant previously discharged from the engine block.
87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
45
AIR CONDITIONER EVAPORATOR Renew
DANGER Recover the refrigerant closely following the safety regulations described on page 2. 1. Recover the refrigerant using control unit 380000315. 2. Open the roof hatch (1) extracting the pneumatic pistons.
1
24790
64 3. Remove the pivot pins (1) and remove the hatch.
1
24791
4. Unscrew the four bolts (1) securing the evaporator cover.
5. Carry out the disassembly sequences described in section 90 for the CAB CEILING TRIM.
65
1
24792
66
87679925A - 12 - 2007
46
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
6. Disconnect the loudspeaker wires (1).
1
24798
7. Unscrew the retaining screw and extract the fan control unit (1).
67
1
24799
68 8. Unscrew the two bolts (1) clamping the rigid pies to the evaporator.
1
24800
69
9. Remove the clamp (1) and extract the pipes.
1
24801
70 87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 10. Extract the thermostatic sensor (1) from the evaporator fins.
47
1
24802
11. Extract the evaporator (1) with the expansion valve (2).
71
1
2
NOTE: The expansion valve (2) can be removed without extracting the evaporator. 12. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Fit on the evaporator with the expansion valve.
--
Fit the thermostatic sensor on the evaporator fins.
--
Fit on the pipes, retaining plate and the two bolts securing it to the evaporator.
--
Mount the fan control unit and fit the retaining bolts.
--
Connect the leads to the speakers.
--
Carry out the assembly sequences described in section 90 for the CAB CEILING TRIM.
--
Fit the evaporator cover and the four retaining bolts on.
--
Fit on the hatch, pneumatic pistons and pivot pins.
--
Charge the system with refrigerant using control unit 380000315.
24803
72
87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
48 ELECTRIC FAN R.I.
DANGER Recover the refrigerant closely following the safety regulations described on page 2. 1. Carry out the removal sequences described in this section for the CAB HEATING UNIT and the disassembly sequences described in this CONDITIONER section for the AIR
EVAPORATOR UNIT.
2. Disconnect the electrical connections (1) on the temperature sensor.
1
24809
73 3. Remove the evaporator--heater support (1).
1
24810
4. Unscrew the bolts (1) securing the fan unit (2) to the cab roof (3).
74
75
87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
49
5. Disconnect the electrical connections (1) and remove the fan unit (2).
6. To assemble, proceed as follows:
76
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
Reconnect the electrical connections then the fan unit to the cab roof with the retaining bolts.
--
Refit the evaporator--heater support and reconnect the electrical connections on the temperature sensor.
--
Carry out the installation sequences described in this section for the CAB HEATING UNIT and the assembly sequences described in this CONDITIONER section for the AIR
EVAPORATOR UNIT.
87679925A - 12 - 2007
50
87679925A - 12 - 2007
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
1
SECTION 55 -- ELECTRICAL SYSTEM Chapter 1 -- Instrument panel CONTENT Description
Page
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Analog Digital Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Liquid crystal displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Access to the setup menu via keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Calling up functions from keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Access to the setup menu with the CAL button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Calling up functions with the CAL button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
2
CONTROL PANEL 6
7
8
9
10
11
12
13
14
15
16
17
18
19
5
20
4
21
STOP
3
10
2
5
15
22
20 1000
25
1
0
AU TO
n/min X100
h
35
23
m
25
34
MDM1574A
33
32
31
Standard dashboard 1. Alternator charging indicator light (red) -Steady light indicates that the alternator is not charging. The red “Stop” warning light starts blinking and a non--critical alarm warning sounds. 2. Differential lock (amber) -- This indicator light comes on when the differential lock is engaged. 3. Four--wheel drive indicator light (green) -This indicator light comes on when front--wheel drive is also engaged. 4. Thermostarter indicator light (amber) -- Lights up when the grid thermostarter is turned on by the ignition key. 5. Trailer turn signal indicator light (green) -This indicator light flashes together with the tractor/trailer direction indicators, if the second trailer is connected. 6. The engine rev counter. 7. Trailer turn signal indicator light (green) -This indicator light flashes together with the tractor/trailer direction indicators, if a trailer is connected. 8. Parking lights (green) -- The indicator light comes on when the tractor’s lights are switched on.
87679925A - 12 - 2007
29
30
28
24
27
26
1 9. Headlight main beam (blue) -- This indicator light comes on when the tractor lights are switched to main beam. 10. Power take--off rpm. -- The indication on the rpm for obtaining 540, 540E and 1000 rpm (where applicable and if the gearbox is on the speeds) is only on the standard dashboard. 11. Stop warning light (red) -- If the red “Stop” warning light comes on, switch off the tractor immediately and look for the cause. A warning symbol will appear on the display (10) confirming the location of the fault. 12. Power take--off indicator (yellow) -- Lights up when the engine is running and the power take--off is engaged. Auto PTO indicator (yellow) -- Off. 13. Information display -- The display shows information on the operational condition of the machine in the form of symbols or code numbers. 14. Indicator light (amber) -- This indicator light comes on and the display (13.) shows a warning symbol. The light blinks for a few seconds, after which the symbol on the display disappears and the indicator light stays on steady. 15. High gear range indicator light (green) (transmission with Power--Shuttle/Dual Command (2 Speed Power Shift) only) -- Lights up when the high gear range is selected.
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 16. Engine coolant temperature gauge. 17. Electronic parking brake failure (red) -- Off. 18. Parking brake indicator light (red) -- This indicator light comes on when the ignition key is turned onto “ON” with the handbrake engaged. If you turn the ignition key “OFF” without putting on the parking brake or if you leave the driving seat without putting on the parking brake, an audible warning sounds for approximately 10 seconds or until the parking brake is put on and the driver is again seated. If the tractor speed exceeds 0.8 km/h and the handbrake is engaged, the indicator light will blink, normal operation is restored as soon as the handbrake is released or if the tractor speed drops below 0.8 km/h. 19. Trailer brake engaged indicator light (red) (Italy only) -- When the pressure of the oil delivered to the trailer brakes is too low. With air brakes it signals low brake pressure. 20. Brake pedals not connected (red) -- Japanese market only. 21. Engine oil pressure indicator light (red) -This indicator light together with the red 11. “Stop” indicator light indicates the engine oil pressure is too low. Switch off the engine and look for the cause of the trouble. 22. Front PTO (green) -- Off. 23. Work lights (amber) -- This indicator light comes on when the work lights are switched on.
3
24. Fuel gauge. 25. Fuel level indicator light (amber) -- This comes on when it is necessary to refuel the tractor. 26. Clock adjustment button -- To adjust the minutes. 27. Clock adjustment button -- To adjust the hours. 28. Right--hand digital display -- The display shows the time with the ignition key on B (ready for starting). 29. Turn indicator light (green) -- This indicator light flashes in unison with the tractor right-- or left--hand turn signal. With the tractor running, if the turn signal is not switched off within 20 seconds an intermittent alarm comes on. The audible warning lasts 5 minutes with the tractor stationary. 30. Central digital display -- The display shows the slip, the position of the lift arms and the speed of the power take--off, all the information on the HH diagnostics menu (fault codes, calibration information, etc....). 31. Left--hand digital display -- The display shows the tractor speed in km/h or MPH. 32. Brightness control. 33. Fast steering enabled (green) -- Off. 34. Fast steering on (amber) -- Off.
87679925A - 12 - 2007
4
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
ANALOG/DIGITAL INSTRUMENTATION PANEL The instrument panel comprises three analog gauges (B), three liquid crystal displays (D) and an information display (A). Besides the gauges and displays there is a set of coloured indicator lights providing information on operation or signalling faults. The push--button (E) controls the brightness of the backlighting of displays (A) and (D); The two push--buttons (C) adjust the digital clock. D 2
INSTRUMENTS Rev counter The rev counter (1) indicates the engine rpm. Each division on the scale represents 100 rev/min., therefore with the needle indicating â&#x20AC;&#x2DC;20â&#x20AC;&#x2122; the engine is running at 2000 rpm.
3
Engine coolant temperature indicator This instrument (1) indicates the temperature of the engine coolant: -- neutral area = normal temperature; -- blue area = temperature too low; -- red area = temperature too high.
1
2
Fuel level indicator This instrument (2) indicates the level of diesel in the tank and only works when the ignition key is turned onto ON. 4
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
5
LIQUID CRYSTAL DISPLAYS CLOCK There is a digital clock (1) on the right--hand side of the instrument panel. To adjust the time display turn the key--start on, press and hold the Hour or Minute button until the read out starts to flash. To adjust the hours, press button ‘H’ (2). Each time the button is pressed, the display will advance by 1 hour. Alternatively, hold the button in and the display will advance automatically. Release the button when the hour display is correct. To adjust the minutes, repeat the same procedure using button ‘M’ (3). To save the setting, do not touch the buttons for 10 seconds.
5
CENTRAL DISPLAY The information presented on the central display (3) varies depending on the tractor specification level. Use the switch on the advanced keypad (if installed) to select the various displays (2, fig. 16). The central display (3) shows the following information. -----
Side (1) rear wheel slip (with radar option only). Side (2) PTO speed. Side (2) lift arms position. It is used during the HH diagnosis programs, during calibration and to provide the user with information (during draft control the display will show “dr”).
3
6
GROUND SPEED DISPLAY The information on the left display (1) is: -- speed in Mph or in Km/h -- if calibrating the speed the display will show CAL.
7
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
6
INFORMATION MONITOR The information monitor will show: -- Hours of work. -- Fault code icons not displayed. -- Fault codes. -- SETUP MENU. -- HH MENU diagnostics menu. NOTE: On starting the tractor the monitor shows the symbol of the defective function or the fault code accompanied by the control module icon, where applicable, otherwise the display logic will be: A) -- With keypad mounted the monitor will show the function present when switching off. B) -- With no keypad and the pneumatic brake present the monitor will show the hours worked followed by the air brakes pressure gauge. If the operator wants to see the hours worked he must press the hours adjustment button (2, fig. 5) for at least 3 seconds and they will be displayed for 5 seconds after which the monitor will go back to show the air brakes pressure gauge. C) -- With no pneumatic brake and keypad the monitor will show the hours worked.
8
SETTING AND RESETTING THE HOURS WORKED -- Turn the starter switch (1, fig. 10) to A (OFF) and connect the tool 380000843 (2) to the diagnostics socket (1).
9 --
Turn the ignition switch (1) to B.
MDB1669A
10
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
7
The information monitor will show HH MENU.
HH MENU
11
Resetting hours worked It is possible to delete the displayed hours worked if the value does not exceed 20 hours for 3 times at most in the life of the tractor. To reset, proceed as follows: -- After the first 12 seconds have passed (while holding down the brightness adjustment button) the monitor will show: --
H = 3 resets available
--
F = 2 resets available
--
L = 1 reset available
--
If the button is immediately released the reset procedure is not successful. If the button is kept pressed for another 3 seconds the number of hours worked is reset. 2 seconds after deletion the display will return to HH MENU.
Setting hours worked on a new dashboard When renewing the tractorâ&#x20AC;&#x2122;s instrument panel it is possible to increase the hours worked (they cannot be decreased) of the panel being replaced, again for three times in the life of the tractor. Proceed as follows: -- Press and hold down the button (1, fig. 12) or (1, fig. 13) for more than 5 seconds but less than 12 seconds, the value shown on the monitor will start to blink.
12
2
1
4 3 13
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
8 --
Now use the push--button to set the hours (2, fig. 14) or the up button on the keypad (2, fig. 13) to increase the hours worked. If they have been increased too much, use push--button (1, fig. 14) or push--button (3, fig. 13) to decrease them. Pressing once increases or decreases the value by one unit. Pressing continuously increases or decreases the value continuously.
1
14 --
To conclude setting, press and hold down push--button (1, fig. 12) or (1, fig. 13) for 15 seconds, or if you do not want to exit setting the hours worked press push--button (1, fig. 15) or push--button (3, fig. 13) without making any changes.
15
BRIGHTNESS CONTROL With the control button (1) it is possible to vary the brightness of the displays (2). Momentarily pressing the button will modify the backlighting by degrees. Keep the button pressed to pass the backlighting through its full range of brightness, from minimum to maximum. Release the button when you obtain the required setting. The performance monitor will show a bar histogram representing the backlighting of the displays.
16
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
9
ACCESS TO THE “SETUP MENU” VIA KEYPAD With the keypad mounted it is possible to access the data setup menu as follows: -- Keep the ENTER button (1) pressed for a few seconds. the information monitor will show “SETUP MENU”. This button can be used to confirm some selections and save to memory. -- The UP button (2) scrolls up through the menu options. You can change the set number. -- The DOWN button (3) scrolls down through the menu options. You can change the set number. -- The HOME button (4) is used to exit the selected menu and pass on to the previous menu. Exit the setting in the SETUP MENU.
Once the monitor shows SETUP MENU after 2 seconds, or by pressing the H or M button, the word CAL appears and you enter the setup routine. The Options of the SETUP MENU are: A. Slip speed calibration. 1. Manual. 2. Automatic. B. 12/24--hour system clock setting. C. Speed unit of measurement setting. D. BEEP setting. E. Implement width setting. F. Slip percentage setting. G. Heavy/light maintenance setting. H. Access to the “warnings not displayed” menu. A1 -- MANUAL CALIBRATION. Go into the SETUP MENU as described above, once the monitor shows CAL, press the ENTER button to access calibration. The monitor will display “CAL MANUAL” or “CAL AUTO” select the first one with the UP and DOWN buttons then press ENTER to enter. Manual calibration allows the operator to set the rolling circumference of the wheel. Note that the value is in cm if metric units are selected, otherwise, inches if imperial units are selected.
2 4
1
3 17
18
CAL manual
19
87679925A - 12 - 2007
10
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
Set the value (read on the table) with the UP and DOWN buttons, press the ENTER button to save. After 2 seconds the monitor will again show CAL, press ENTER again and wait for 2 seconds to go back to the SETUP MENU: NOTE: If you set circumference values that are too low or too high, when saving, the system will display “Min Value 000.0” or “Max Value 000.0” indicating the minimum and maximum values to set. After saving, the system will display “Value 000.0 Saved” alternating with “Max 00.0 Km/h” twice and will then pass on to the submenu of the SETUP MENU. NOTE: The permissible setting icons are shown on the performance monitor underneath the icon indicating the program you have entered or can enter (see fig. 19) “CAL manual”: ENTER -- you can enter “CAL manual”, in this case, or save by pressing and releasing the corresponding push--button on the keypad. UP and DOWN -- you can browse among the options, in this case, or set a new value. HOME -- To exit without making any changes.
MANUAL CALIBRATION TABLE Wheel size
Make
Model
480/70R30 /
TRELLEBORG
TM700
16.9R30 420/85R30 / R
13.6R36 340/85R36 / R
87679925A - 12 - 2007
Rolling circumference mm
inches”
4425
174.2
MICHELIN
--
--
--
GOOD YEAR
DT812
4439
174.8
FIRESTONE
R8000
4472
176.1
KLEBERG
FITKER
4400
173.2
CONTI -- CGS
AC70T
4435
174.6
TRELLEBORG
TM600
4455
175.4
MICHELIN
A.BIB
4395
177.0
GOOD YEAR
STR
4404
173.4
FIRESTONE
R7000
4395
173.0
KLEBERG
TRAKER
4371
172.1
CONTI -- CGS
AC85
4414
173.8
TRELLEBORG
TM300S
4590
180.7
MICHELIN
A.BIB
4468
175.9
GOOD YEAR
STR
4493
176.9
FIRESTONE
R7000
4500
177.2
KLEBERG
TRAKER
4478
176.3
CONTI -- CGS
--
--
--
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
11
MANUAL CALIBRATION TABLE Wheel size
Make
Model
18.4R30 460/85R30 / R
TRELLEBORG
13.6R38 340/85R38 / R
16.9R34 420/85R34 / R
480/70R34 /
540/65R34 /
18.4R34 460/85R34 / R
Rolling circumference mm
inches”
TM600
4678
184.2
MICHELIN
A.BIB
4602
181.2
GOOD YEAR
STR
4622
182.0
FIRESTONE
R7000
4550
179.1
KLEBERG
TRAKER
4574
180.1
CONTI -- CGS
AC85
4618
181.8
TRELLEBORG
TM600
4665
183.7
MICHELIN
A.BIB
4705
185.2
GOOD YEAR
STR
4658
183.4
FIRESTONE
--
--
--
KLEBERG
TRAKER
4661
183.5
CONTI -- CGS
AC85
4685
184.4
TRELLEBORG
TM600
4745
186.8
MICHELIN
A.BIB
4717
185.7
GOOD YEAR
STR
4717
185.7
FIRESTONE
R8000
4744
186.8
KLEBERG
TRAKER
4693
184.8
CONTI -- CGS
AC85
4761
187.4
TRELLEBORG
TM700
4720
185.8
MICHELIN
--
--
--
GOOD YEAR
DT812
4745
186.8
FIRESTONE
R7000
4703
185.1
KLEBERG
FITKER
4745
186.8
CONTI -- CGS
AC70T
4686
184.5
TRELLEBORG
TM800
4710
185.4
MICHELIN
M.BIB
4725
186.0
GOOD YEAR
DT818
4701
185.1
FIRESTONE
R9000 EVOL
4736
186.4
KLEBERG
SUP 11L
4788
188.5
CONTI -- CGS
AC65
4709
185.4
TRELLEBORG
TM600
4945
194.6
MICHELIN
A.BIB
4942
194.6
GOOD YEAR
STR
4923
193.8
FIRESTONE
R8000
4962
195.3
KLEBERG
TRAKER
4916
193.5
CONTI -- CGS
AC85
4982
196.1
87679925A - 12 - 2007
12
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 MANUAL CALIBRATION TABLE
Wheel size
Make
Model
520/70R34 /
TRELLEBORG
TM700
MICHELIN
--
GOOD YEAR
Rolling circumference mm
inches”
4875
191.9
--
--
DT812
4927
194.0
FIRESTONE
R7000
4866
191.6
KLEBERG
FITKER
4901
192.9
CONTI -- CGS
AC70T
4927
193.9
TRELLEBORG
TM800
4920
193.7
MICHELIN
M.BIB
4896
192.7
GOOD YEAR
DT818
4925
193.9
FIRESTONE
R9000 EVOL
4924
193.8
KLEBERG
SUP 11L
4954
195.0
CONTI -- CGS
AC65
4904
193.1
GALAXI
T55
4450
175.2
FIRESTONE
TF&R
4369
172.0
TITAN
HTL
4470
175.9
18.4--30 16.9--34
GALAXI GALAXI
T55 T55
4607 4728
181.4 186.1
18.4--34
GALAXI
T55
4936
194.3
13.6--38
GALAXI
T51
4936
194.3
16.9R30
MICHELIN
AGRIBIB
4395
173.0
GOOD YEAR
STR
4404
173.3
MICHELIN
A.BIB
4602
181.2
GOOD YEAR
STR
4622
182.0
MICHELIN
A.BIB
4717
185.7
GOOD YEAR
STR
4717
185.7
MICHELIN
A.BIB
4942
194.6
GOOD YEAR
STR
4923
193.8
MICHELIN
A.BIB
4705
185.2
GOOD YEAR
STR
4658
183.4
19.5L--24 10PLY PLY
GALAXI
EZ RIDER
3860
151.9
GOOD YEAR
IND TORQUE
3914
154.0
16.9--24 10PLY PLY
GALAXI
EZ RIDER
3813
150.1
GOOD YEAR
ISG
3840
151.1
480/70R34
CONTI--CGS
EC70G
4711
185.5
440/80R34
NOKIAN
TRI2
4750
187.0
16.9R30
KLEBER
SUP G
4355
171.4
440/80R30
NOKIAN
TRI2
4430
174.4
600/65R30
CONTI--CGS
AC65
4591
180.7
600/65R34 /
16.9--30
18.4R30 16.9R34 18.4R34 13.6R38
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 A2 -- AUTOMATIC FORWARD SPEED CALIBRATION NOTE: As there is no radar, the control unit shows the ground speed calibration. On a straight and level road mark out a section of 100 m. With the tractor in motion, go into the SETUP MENU as described above once the monitor shows CAL, press the ENTER button to access calibration. The display will show “CAL MANUAL” or “CAL AUTO” select the second one with the UP and DOWN buttons then press ENTER to enter. The monitor will show CAL AUTO READY, proceed at a speed > 2 Km/h and constant, on the first mark press the ENTER button the monitor will show CAL AUTO ON, then on the second mark press ENTER again the monitor will show CAL AUTO OK, calibration is over the central display will show the conversion factor of the signal from the theoretical speed sensor, throughout calibration the left display will show CAL. Press ENTER again to save to memory the monitor will go back to the SETUP MENU options. NOTE: If during the above--described calibration, the monitor shows CAL AUTO NOT OK there has probably been an error in the calibration procedures, press HOME to stop calibration, exit and repeat it.
13
20
B -- 12/24--HOUR SYSTEM CLOCK SETTING Go into the SETUP MENU as described above, once the monitor shows CAL, press the UP or DOWN button until the monitor shows the icon of the clock display mode setting, now press ENTER to go into the setup program. Using the UP and DOWN buttons take the arrow onto 12 and 24, then press ENTER to save to memory. The monitor will show “Value 12h Saved” (if the 12--hour clock has been set) wait for 2 seconds, the monitor will go back to the SETUP MENU options.
21
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
C -- SPEED UNIT OF MEASUREMENT SETTING Go into the SETUP MENU as described above, once the monitor shows CAL, press the UP or DOWN button until the monitor shows the icon of the unit of measurement setting, now press ENTER to go into the setup program. Using the UP and DOWN buttons take the arrow onto MPH and Km/h, then press ENTER to save to memory. The monitor will show “Value Km/h Saved” (if the metric unit of measurement has been set) wait for 2 seconds, the monitor will go back to the SETUP MENU options.
22
D -- BEEP SETTING Go into the SETUP MENU as described above, once the monitor shows CAL, press the UP or DOWN button until the monitor shows the icon of the BEEP setting, now press ENTER to go into the setup program. Using the UP and DOWN buttons take the arrow onto ON and OFF, then press ENTER to save to memory. The monitor will show “Value OFF Saved” (if the beep has been set) wait for 2 seconds, the monitor will go back to the SETUP MENU options.
23
E -- IMPLEMENT WIDTH SETTING Go into the SETUP MENU as described above, once the monitor shows CAL, press the UP or DOWN button until the monitor shows the icon of the implement width setting, now press ENTER to go into the setup program. Use the UP button to change the blinking number and the DOWN button to change the number to set. After setting a maximum slip threshold with the ENTER button save to memory. The monitor will show “Value 00.00 Saved” (if the implement width has been set) wait for 2 seconds, the monitor will go back to the SETUP MENU options. 24
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15
F -- SLIP PERCENTAGE SETTING Go into the SETUP MENU as described above, once the monitor shows CAL, press the UP or DOWN button until the monitor shows the icon of the slip limit setting, now press ENTER to go into the setup program. Use the UP button to change the blinking number and the DOWN button to change the number to set. After setting a maximum slip threshold with the ENTER button save to memory. The monitor will show “Value 00 Saved” (if a slip threshold has been set) wait for 2 seconds, the monitor will go back to the SETUP MENU options. NOTE: The slip logic is described on page 20. 25 G -- HEAVY/LIGHT MAINTENANCE SETTING Go into the SETUP MENU as described above, once the monitor shows CAL, press the UP or DOWN button until the monitor shows the icon of the maintenance setting, now press ENTER to go into the setup program. Using the UP and DOWN buttons choose whether to set heavy (see fig. 28) or light (see fig. 26) maintenance, then press ENTER to go into the setup program.
27 Use the UP button to change the blinking number and the DOWN button to change the number to set. After setting the hours at which to do maintenance, with the ENTER button save to memory. The monitor will show “Value 000 Saved” wait for 2 seconds, the monitor will go back to the SETUP MENU options. NOTE: If the operator wants to disable the countdown, he has to set the value to 0. After setting both maintenance intervals, from 10 hours before the time due for heavy maintenance until it is done, then resetting the value or making another setting, the icon, with the remaining time, will appear for 4 seconds after each start. After cranking, every hour the icon will come up together with the amber lamp to the right of the monitor for 20 seconds. If the time has been exceeded the icon will appear without the remaining time.
28
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
From 2 hours before the setting for light maintenance until the maintenance is done, then setting the value or setting another value, the maintenance icon with the remaining time is displayed on the monitor at each start for a time of 4 seconds. If the time has been exceeded the icon will appear without the remaining time. NOTE: If the two intervals have been set at the same time the two icons will alternate for 4 seconds each.
29 H -- ACCESS TO THE â&#x20AC;&#x153;WARNINGS NOT DISPLAYEDâ&#x20AC;? MENU Go into the SETUP MENU as described above, once the monitor shows CAL, press the UP or DOWN button until the monitor shows the icon in the figure. Press ENTER to display the warnings. If there are any warnings not displayed, they will alternate automatically for 4 seconds, up to 3 times, at the end of which the system will automatically go back to the SETUP MENU options.
30 Warnings of a critical nature Should a critical fault occur on the tractor the red warning light to the left of the monitor lights up and the monitor shows the icon relating to the fault. Stop the tractor and repair the fault. Until the fault has been repaired the icon will remain on the monitor, accompanied by the red critical alarm warning light blinking and the buzzer will sound a critical alarm, at the same time the warning light or indicator on the dashboard will come on. Serious fault signals comprise 1. High coolant temperature. 2. Low engine oil lubrication pressure. 3. Low power steering -- transmission oil pressure. 4. Leaving the driving seat with the PTO engaged.
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31
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 Warnings of a non--critical nature Should a critical fault occur on the tractor the amber warning light to the right of the monitor lights up and the monitor shows the icon relating to the fault. The icon will appear on the monitor for a few seconds, the amber warning light to the right of the monitor will flash, the buzzer will make a non--critical sound for no longer than 4 seconds and at the same time the warning light or indicator on the dashboard will come on too. Warnings not displayed of a non--severe nature comprise: 1. Water in fuel. 2. Low air pressure in the air brakes circuit. 3. Air filter clogged. 4. Brake fluid level too low. 5. High transmission oil temperature. 6. Slip alarm. 7. Alternator charging failure. Operating errors It is possible to make operating errors of the following nature: 1. Starting with the brake engaged (disengage the handbrake). 2. Starting without the clutch pedal (put the reverser lever back into neutral and press the clutch pedal). 3. Starting with the reverser lever not in neutral (put the reverser lever into neutral). The monitor will show the corresponding icon signalled by the buzzer on for 1 second (two pulses), just repeat the incorrect operation for the signal to disappear. NOTE: This warning has high priority because it disables the transmission. Then the situation has been repaired, the display will show the other warnings. Fault codes When a fault code occurs the monitor shows the icon of the element related to the code with the number representing the written code under the icon. The codes are kept in memory and are called up and deleted, after repairing the fault or with the HH routine. NOTE: For the HH menus refer to chapter 10 of section 55 in this manual. The parts related to the codes are: 1. Differential lock. 2. Four--Wheel Drive. 3. Power take--off. 4. Dashboard. 5. Can bus. 6. Gears. 7. Lift.
17
32
33
34
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
CALLING UP FUNCTIONS FROM KEYPAD Area worked Press the button (1) to call up the area worked function on the monitor. Press the button (1) repeatedly to choose the desired option.
35 The options for counting the area worked are: -- ON = Counts the area worked irrespective of the position of the implement. -- OFF = Interrupts the count of the area worked. -- A = Counts the area worked only when the implement was lowered. Keep the button (1, fig. 35) pressed for longer than 3 sec to reset the counter. NOTE: The value of the area worked is in proportion to the width of the implement and the calibration of the ground speed. It is given in acres or hectares according to the selected unit of measurement. 36 Area per hour Press the button (1) to call up the area per hour function on the monitor.
37 The monitor will show the area that will be worked in the following hour keeping the speed constant. NOTE: The value of the area worked is in proportion to the width of the implement and the calibration of the ground speed. It is given in acres or hectares according to the selected unit of measurement.
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19
Odometer Press the button (1) to call up the odometer function on the monitor. Press the button (1) repeatedly to choose the desired option.
39 The options for counting the distance are: -- 1 = Counts the distance (memory 1). -- 2 = Counts the distance (memory 2). Keep the button (1, fig. 39) pressed for longer than 3 seconds to reset the counter displayed. NOTE: The count of the distance travelled depends on the forward speed calibration and is given in Km or Miles depending on the selected unit of measurement.
40 Maintenance periods Press the button (1) to call up the maintenance intervals function on the monitor. Press the button (1) repeatedly to choose the desired option.
41 The maintenance intervals option: -- Light -- Heavy NOTE: The logic of the maintenance intervals is explained on page 15.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
Hours worked, air brake pressure brake and battery charge Pressing the buttons in fig. 43 to call up: 1. Hours worked 2. Air brake air pressure gauge 3. Battery charge
43 the monitor will show the icons: 1. Hours worked 2. Air brake air pressure gauge 3. Battery charge
44 Wheel slip and power take--off speed Pressing the buttons in fig. 45 to call up: 1. Wheel Slip 2. PTO speed
The central display will show 1. Wheel slip percentage 2. PTO speed
45
NOTE: The slip function is only available with radar and slip calibration is essential. On reaching the set threshold (see page 15) the amber lamp for warnings not displayed (12, fig. 1) will blink and the buzzer will sound a non--critical alarm. NOTE: If the speed of the power take--off is greater than approximately 100 rpm or the engine speed reaches 2574 rpm (for the 540 rpm) or approximately 170 rpm or the engine speed reaches 2784 rpm (for the 1000 rpm) the amber warning light of the PTO will blink to signal extra speed.
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21
Rear implement position Press button (1) to call up the position of the rear lift arms.
47 The central display will show the position of the lift arms (1) in a percentage from 0 (arms fully down) to 100 (arms fully up).
48
ACCESS TO THE “SETUP MENU” WITH THE CAL BUTTON Press and hold down the CAL button (1) for 3 seconds the monitor will show SETUP MENU.
49 The Options of the SETUP MENU are: A. Slip speed calibration. 1. Manual. 2. Automatic. B. 12/24--hour system clock setting. C. Speed unit of measurement setting. D. BEEP setting. E. Access to the “warnings not displayed” menu.
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22
Use the H (2) and M (1) buttons to toggle between options as with the DOWN and UP buttons on the keypad. After selecting the option, press the CAL button (1, fig. 49) to enter as with ENTER on the keypad.
1
51 The brightness button (1) can be used as HOME on the keypad to exit the program.
52 Using the CAL, hours and minutes and brightness adjustment buttons, refer to the procedures of the SETUP MENU: A. Slip speed calibration. 1. Manual (see page NO TAG). 2. Automatic (see page 13). B. 12/24--hour system clock setting (see page 13). C. Speed unit of measurement setting (see page 14). D. BEEP setting (see page 14). E. Access to the “warnings not displayed” menu (see page 16). 53
CALLING UP FUNCTIONS WITH THE CAL BUTTON With the CAL button you can change the central display from ... --
rear PTO speed
--
rear lift arms position.
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1
SECTION 55 -- ELECTRICAL SYSTEM Chapter 2 -- Components CONTENT Description
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 instrument panel controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Controls on right--hand mudguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 In--Cab Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Controls on right--hand cab upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 External controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INTRODUCTION The components described in this section are grouped in control--types, as described below:
1. Instrument panel controls. 2. Controls on right--hand mudguard. 3. In--Cab Controls. 4. Controls on right--hand cab upright. 5. External controls.
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2
DASHBOARD CONTROLS
MDF0871A
1 Control Panel The dashboard controls are as follows: 1.
Lights/horn switch.
3.
Advanced Keypad (if installed).
2.
Measuring device.
4.
Windscreen wiper control lever.
Lights/horn switch The lights/horn switch (1) controls, the turn indicators, the headlight full beam flasher, switching from dipped to full beam front headlights.
1
The external lights will only work with the starter key in position B (1, fig. 17).
23993
2
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3
Direction indicators Moving the lever to positions A and B, indicates the intention to turn to the right (A) or to the left (B). The turn signal indicator lights on the instrument panel will also flash when the turn signals are actuated.
3 Tail/side lights, full beam, dipped beam circuit and front headlight flash By moving the lever (1) to positions C, D, E, and turning the mark (1) on the knob to symbols (2) or (3) the different functions are activated.
C
The lights selection knob functions with the starter switch (1, fig. 17) to position B.
D
1 E 24119
4 All the lights are switched OFF by turning the mark (1) on the knob to symbol (4). In this position, only the direction indicators and horn remain operative. Horn To sound the horn, press the end of the knob (5, fig. 5) in the direction indicated by the arrow.
5 Flashing hazard warning lights switch The hazard lights are activated by pressing the part of switch (1) with the triangle symbol. The switch will flash together with the direction indicators.
MDF0873A
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4
Swivel work lights switch The switch (1) is located on the left--hand side of the control panel and operates the front work lights on the bonnet.
1
7 Differential lock switch (version without cab) On the version without a cab, the switch (1) is located on the left--hand side of the control panel and has three positions: --
Switch in position A = lock disengaged;
--
Switch in position B = presetting for differential lock engagement;
--
Switch in position C = differential lock engaged. The lock is released even when only one brake pedal is pressed; or by returning the switch to position (A).
8 Differential lock switch (version with cab) The switch (1) is located on the right--hand mudguard inside the cab and has three positions: -- Switch in position A = lock disengaged; -- Switch in position B = presetting for differential lock engagement; -- Switch in position C = differential lock engaged. The lock is released even when only one brake pedal is pressed, or by returning the switch to position (A).
9
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5
Four--wheel drive switch (version with cab) Engage front--wheel drive by pressing switch (1) into position B. In this position the front--wheel drive will stay permanently on. To disengage it, press the switch again, to position A. NOTE: Front--wheel drive cuts in automatically, even when switch (1) is in position A, if the brake pedals are pressed; it is disengaged when they are released.
B A
When front--wheel drive is engaged, the indicator light on the control panel lights up.
10 Four--wheel drive switch (version without cab) The switch (1) is located on the left--hand side of the control panel and has two positions. With the switch pressed on the left, four--wheel drive is permanently engaged; to disengage it, press the switch back on the right. NOTE: Front--wheel drive cuts in automatically, even when switch (1) is in position A, if the brake pedals are pressed; it is disengaged when they are released. When front--wheel drive is engaged, the indicator light on the control panel lights up. MPF1890A
11 Full/dipped beam headlight switch for front loader (version with cab) A set of auxiliary headlights fitted at the top of the handrail for getting into the cab is available for use with the front loader to function as main/dipped beam headlights. To activate the full/dipped beam function press switch (1, fig. 12) as follows: -- Position A = headlights on the grille. -- Position B = headlights on the handrails. You pass from main to dipped beam with lever (1, fig. 2) on the left--hand side of the steering wheel.
12
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6
Modulated power take--off switch (version with cab) Gradual engagement is activated by means of a rocker switch next to the steering wheel on the left--hand side. Gradual engagement modulates the PTO clutch for a few seconds so that drive transmission takes place slowly and progressively. To activate the modulating function, use the button (1, fig. 13) as follows: -- Position A = modulating function on. -- Position B = modulating function off. 13
Advanced Keypad The advanced keypad comprises 16 keys that make it possible to select, check or program various functions and presentations on the central display. Keys 9, 11, and 12 are used to set and program many of the functions of the advanced keypad. Unless instructed otherwise, press the keys one at a time to bring up the required screen. The monitor will show the confirmation symbol for the selected function. Key:
(D) = Function monitor (C) = central digital display
1. Worked area accumulator key (D). Pressing this key displays the total area worked in hectares or acres, depending on the set unit of measurement of the ground speed. 2. Hour meter key (D). Press this key to display the total number of hours of engine operation. The hours recorded should be used as a guide to the service intervals for the tractor. 3. Worked area per hour forecast key (D). Pressing this key shows the symbol associated with the area per hour together with a forecast of the area worked in one hour at the rate of work being performed at the time of the check.
16
15
14 13
12
14
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7
4. Odometer key (D). The odometer provides a visual indication of the distance travelled in kilometres or miles, depending on the set unit of measurement of the ground speed. Two display modes are available, ‘A’ and ‘B’. 5. Battery voltage control key (D). With the engine running, press this key to display the battery symbol together with a digital battery voltage indicator. 6. Key with no functions. 7. Trailer air brake pressure gauge display button (D). Press this key to display the air brake pressure gauge. NOTE: The air brake function must be enabled in program H3 of the HH MENU on the dashboard, refer to chapter 10 in this section. 8. Power Take--Off speed key (C). Press this key to display the speed of rotation of the rear power take--off. 9. Forward scroll key for the menu or numerical value (D). Press this key repeatedly to scroll forwards in the menu or change the value of a number. 10. Exit/Cancel (D). Use this key to cancel or exit set--up and programming modes. 11. Backward scroll key for the menu or numerical value (D). Press this key to scroll backwards in the menu or change the value of a number. 12. MENU/ENTER or confirmation key (D). Press this key to select the programming setting and setting confirmation mode. 13. Rear electronic lift arms position key (C). Press this key to display the position of the rear lift arms as a percentage. NOTE: The electronic lift function must be enabled in program H3 of the HH MENU on the gearbox, refer to chapter 10 in this section.
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8
14. Rear wheel slip control key (C). The extent of the rear wheel slip is displayed in the form of a one-- or two--digit percentage (%) (only with the radar unit). 15. Key with no functions. 16. Routine maintenance reminder key (D). The routine maintenance key provides two reminder levels, identified as: “Heavy” and “Light” duty service. Instrument calibration switch (version without advanced keypad) The switch (1) is located on the right--hand side of the control panel and is used to: A Change the central display mode: 1 -- PTO speed 2 -- lift arms position. B Enter the SETUP MENU.
15 Front windscreen washer/wiper control lever The lever (1, fig. 15) operates with the starter switch in position B (see fig. 17). Lever (2, fig. 15) controls the front windscreen wiper and the windscreen washer. The lever has three settings: --
Position A = OFF.
--
Position B = standard speed.
--
Position C = speed 2.
Press on the end of the lever to operate the windscreen washer.
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9
Key--start ignition switch The starter switch (1) performs the following functions according to the position selected: A. Engine stopped: automatic activation of fuel injection cut--off. Current not supplied to any circuit (key can be removed). B. Stand--by for engine start up (with Thermostart or Start--Pilot), several users are powered--up; the indicators and instruments are operative. C. Momentary position with return to position B when released: enables starting the engine. 23235
17 Power Shuttle Reverser The shuttle lever (1), located to the left of the steering wheel, is used to select forward or reverse drive when a gear ratio is engaged. To select the drive direction, lift the lever and move it forward A for forward drive, or backward B for reverse drive. Drive direction can be selected without pressing down the clutch pedal. To change the drive direction keep the lever raised and move it either forwards or backwards. Drive direction can be changed without pressing down the clutch pedal.
18 CONTROLS ON RIGHT--HAND MUDGUARD Controls for standard cab version 1. Gear lever. 2. Range gear lever. 3. Hydraulic lift levers. 4. Handbrake lever (with push button release). 5. Auxiliary control valve levers.
19
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1. Rapid arm lowering push--button. 2. Rapid arm raising push--button. To lower the implement, press the button (1) fully down. To raise the implement, press button (1) backwards, in order to release button (2). The lift arms will fully raise.
MPF1935A
20 1. Standard PTO operation selection lever. 2. Creeper lever. 3. PTO speed selection lever.
21 Controls on right--hand mudguard (version without cab) The following controls are located on the right--hand mudguard: 1. Hand throttle. 2. Electrohydraulic PTO control switch. 3. Mechanical lift controls (Lift--o--matic).
22 Gear lever with “Dual Command (2 Speed Power Shift)” and “Clutch cut--out” push--buttons The lever (1) is positioned on the right--hand side of the driving position and is fitted with the Dual Command (2 Speed Power Shift (2 and 3 )) control push--buttons, which are used to double the gears. It is therefore possible to switch from the HIGH to the LOW position, or vice versa, without using the clutch pedal. -- By pressing button (4) you can shift between the four gears of the selected range, without using the clutch pedal. This is thanks to the RJ gearbox control unit that governs clutch discharge while changing gear. 87679925A - 12 - 2007
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
11
Ventral control valve joystick for loader The lever governs the ventral control valves on the right--hand side of the tractor. 1. Operation selection buttons. 2. Hydraulic cylinder control lever. 3. Safety catch.
24 Controls on right--hand mudguard (version with electronic lift) 1. Electrohydraulic power take--off control knob. 2. Electronic lift controls mouse. 3. Electronic lift function setting potentiometers panel. 4. Hand throttle controls.
25 Electronic lift control panels Control mouse 1. Draft setting control ring. 2. Arms position control. 3. Lift--o--matic and fast ground entry switch. 4. Arms position limiting lock control ring. 5. Arms position limiting lock.
26 Electronic lift control panels Setting potentiometers 1. Sensitivity control potentiometer. 2. Arms down speed control potentiometer. 3. Height limit control potentiometer. 4. Slip control potentiometer.
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Electronic lift control panels Warning light panel 1. Arms lifting warning light. 2. Arms lowering warning light. 3. Lift disabled warning light and lift failure warning light. 4. Slip control warning light.
28
IN--CAB CONTROLS Cab interior light The cab light (1) operates with the ignition key in position (B, fig. 17). The lamp has three positions; --
Position A = off.
--
Position B = on.
--
Position C = door operated -- light on with door open only.
B
A
C
29 Ventilation Actuate ventilation with switch (1, fig. 30) and direct the air flow by adjusting front swivel vents (2). Air can be drawn from outside or inside the cab by using the rear air recirculation vents (1, fig. 31) that can go into 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.
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13
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.
NOTE: To increase the air pressure inside the cab, use only external air (air recirculation vents 1, fig. 31 closed).
31
Electric Fan The electric fan switch (1, fig. 32) is powered up when the starter key (1, fig. 17) is in position (B). --
A. Low speed.
--
B. Medium speed.
--
C. High speed.
32
Heating You can adjust the hot air temperature using control (1) fig. 33 by reducing or increasing the circulation of coolant from the engine and, with electric fan (2) you can change the quantity of coolant entering the cab through vents (3). To adjust the hot air temperature use the control knob (1). Turn the knob to the left (anticlockwise) to interrupt hot air circulation in the cab. NOTE: The total capacity of the cooling system (including the cab heating system) is 16 litres. 33
Temperature control knob (1, fig. 33) --
Turned fully to the left in an anticlockwise direction = minimum temperature.
--
Turned fully to the right in a clockwise direction = maximum temperature.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
HVAC controls
34
Air conditioning and temperature control knob (2, fig. 34) 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) clockwise and pass the first click to turn on the air--conditioner. To lower the temperature of the air coming into the cab, turn the knob (2) clockwise.
Heater control (3, Fig. 34) 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 (1, fig. 34) The fan operates with the ignition key in the starting position. A. Low speed. B. Medium speed. C. High speed.
NOTE: To pressurise the cab see the note on page 13 in this section.
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15
CONTROLS ON RIGHT--HAND CAB UPRIGHT The following controls and components are located on the right--hand cab upright: 1. Lighting;
1
2. Rear work lights control switch; 3. Rear window washer/wiper switch; 4. Electrohydraulic PTO control switch; 5. Rotating beacon control switch; 6. Front work lights control switch. Controls lighting (1, Fig. 35) The controls lighting illuminates when the side/tail lights are switched on. Rear work lights control switch (2, Fig. 35)
6
2
5
3
The switch has two settings: --
push--button pressed = rear lights ON;
--
push--button released = rear lights OFF. 4
=
STOP
=
MPF1895A
35 Windscreen wiper/washer switch (3, Fig. 35) Operates with the ignition key in position (B). The rear window wiper is controlled by switch (1, fig. 36) and has three settings: -- position A = OFF; -- position B = wiper on; -- position C = rear wipers and washers ON: when released the switch will automatically return to position B.
A B C MPF1906A
36 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
16
Electrohydraulic PTO switch (version with cab) (4, Fig. 35) The push--button engages and disengages the power take--off: -- ON = pushbutton pulled upwards; --
OFF = push--button pressed down.
To disengage the power take--off, press push--button (2) and pull the knob (1) outwards. Engagement is controlled by an electromagnetic clutch. The indicator on the control panel comes on with a steady light to indicate that the PTO is engaged. To disengage the PTO, press knob (2) downwards. 37 Rotating beacon light ON/OFF switch (5, Fig. 35) The switch has two settings: --
push--button pressed = rotating beacon ON;
--
push--button released = rotating beacon OFF.
To power--up the rotating beacon, connect to the socket (1) located under the cab roof, on the outside (Fig. 38).
MPD3082A
38 Front work lights control switch (6, Fig. 35) The switch has two settings: --
push--button pressed = front lights ON;
--
pushbutton released = front lights OFF.
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
17
EXTERNAL CONTROLS External PTO Controls On request, on both rear mudguards, it is possible to fit a PTO button (1), which helps align the grooves of the PTO shaft with the implement and facilitates static applications of the PTO. With the engine running, press the button momentarily to cause the PTO shaft to index round to align the shaft splines. If the button is pressed for less than 10 seconds, the shaft stops turning when the switch is released. Keeping the button pressed for longer than 10 seconds activates the PTO in continuous mode. Press the button again to stop the PTO. Alternatively, the PTO may be stopped by means of the in--cab controls, as previously described.
39
Electronic lift up and down external buttons The external controls consist of switches (1) for lift arms up/down movement. The switches are located at the rear of the tractor, on the LH and RH taillights. Both switches have two settings: -- Pressed at the top -- up -- pressed at the bottom -- down By using the external controls inside the mudguards all the control unit commands located in the cab are automatically disabled.
2
27968
40
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
18 MAINTENANCE
CAUTION When handling halogen bulbs, only touch the metal parts, never the bulb. If the bulb comes into contact with your fingers, adversely affecting its service life. Front work lights lamp bulb replacement To change the bulbs, proceed as follows: --
--
Full/dipped beam headlight bulbs: --
Raise the bonnet;
--
disconnect the connection (3);
--
remove the rubber guard (2) and change the blown bulb inside with a new one of the same power.
Swivel work light bulbs: --
disconnect the connection (1);
--
turn the bulb clockwise, extract it and change it with a new one of the same power.
41
Front sidelight and direction indicator lamp bulb replacement To replace the bulb, proceed as follows: -- Remove the transparent cover (1). -- Press the bulb in and twist anticlockwise to remove. Replace the old bulbs with new bulbs of the same power: -- indicator light bulb (2): 12 V -- 21 W; -- sidelight bulb (3): 12 V -- 5W. NOTE: The transparent cover must be fitted with the orange part facing upwards.
87679925A - 12 - 2007
42
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
19
Work lights lamp bulb replacement To replace the bulb, proceed as follows: -- Extract the light (4). -- Open the plastic cover (2). -- Disconnect the wire (3). -- Remove the spring (1) and extract the lamp bulb. Replace the old bulb with a new halogen bulb of the same power (12 V -- 60 W).
28212
4 43
Replacing the rear side, stop and indicator light bulbs 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 (2) 21W; --
Brake lights (2) and side lights with double filament (3) 21W/5W.
NOTE: The transparent orange cover must be fitted facing the outside of the mudguard.
44
87679925A - 12 - 2007
20
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
1
SECTION 55 -- ELECTRICAL SYSTEM Chapter 3 -- STARTING SYSTEM
CONTENTS Description
Page
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Starter and recharging circuit, manual transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Starter and recharging circuit, Power Shuttle transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 System testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Starter motor removal--installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TECHNICAL DATA Models 56/76, 63/86, 71/97, 78/106 and 83/113 KW/HP.
SPECIFICATIONS Starting motor
Iskra AZF4591
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
kW
4,2
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V
12
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
kg
10,5
Z
10
Pinion: Number of teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3,175
TORQUE WRENCH SETTINGS Nm Starter motor and engine block assembly bolts . . . . . . . . . . . . . . . . . . . .
34
Casing on starter motor/ground wire side . . . . . . . . . . . . . . . . . . . . . . . . .
16
Solenoid valve wire nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Box nuts on starter motor side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Solenoid valve retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
87679925A2 - 02 - 2010
2
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
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 clutch pedal switch. 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.
There are four types of gearbox: two manual ones, base with mechanical reverser (12X12), base with creeper (20X12); The starter circuit (with mechanical power take--off) is illustrated on pages 3. Three electro--hydraulic ones with control via electronic modules, one with electro--hydraulic reverser (12X12), one with electro--hydraulic reverser and creeper unit (20X20) and one with Hi Lo functions (Dual Command/Two--Speed Power Shift) (24X24), the starter circuit is illustrated on pages 6.
Only one starter motor available with rated power 4.2 kW. 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 turned on with the clutch pedal pressed and the mechanical power
87679925A2 - 02 - 2010
take--off disengaged (version with manual gearbox) or the Shuttle lever in neutral (version with electro--hydraulic gearbox) the electromagnet coils are energized 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 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.
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
3
STARTER AND RECHARGING CIRCUIT MANUAL TRANSMISSION 1
Ignition key
2
Starter motor
3
Battery cut--out
4
Battery
5
Grid Heater module
6
Alternator
7
Clutch pedal switch
8
Dashboard module (ADIC)
9
Coolant temperature sensor
10
Starting advance thermometric cut--out switch
11
Grid heater relay
12
Grid heater (pre--heater)
13
Power take--off clutch lever switch
14
Engine shut--down solenoid valve
15
Grid heater control module MF3
40 AMP
Mega--fuse for starter system supply
MF
125 AMP Mega--fuse for grid heater supply
F1
5 AMP
Grid Heater module supply fuse
F5
5 AMP
Engine shut--down solenoid valve supply fuse
F18
5 AMP
Starting advance supply fuse
F28
5 AMP
Fuse for supply to clutch pedal switch, power take--off clutch lever switch and starter relay pin 85
MR1 Engine starter circuit relay (70A)
MPH2027A
1
2
Fuses and relay control unit
87679925A1 - 02 - 2008
50N
50N
4
3
1
0.5V
6R
2 3 4
5
25N
6
7
8
1AR 1RV 0.5RN 1AR 1LR 1N
9 10
4R
1HR
40A
5
1
58
4R
12
85
11
30
86
87
87
30
85
MR1
4C 0.5R
15/54
86
1AR
4R
0.5N
50a
1N
1CB 16R
4RN
0.5RN
1LR
MF3
16R
14
5A
F1
1CB 1BL 1BL
4C
1.5RN
1.5RN
15
10
5A
F5
4C
5A
F18 O.5R 4
O.5R
1CB 1ZB 1ZB
30
7
NC
3
1RV D+
2.5RN
25N 50N
5A
F28
2
1
16R
87679925A1 - 02 - 2008 1B
MMM1609A B+
M
6
9
MF--125A
16R
2
1
1HR
A B C
1NG
1B 1RN
2
0.5V
1RV
0.5RN
1NG
13
10
25
16
22
8
4 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
MOD-- 27 ADIC
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
5
FAULT DIAGNOSIS The engine does not turn over when the starter key is turned, with gearbox in neutral.
Is the battery fully charged?
Charge or replace the battery, check the battery cut--out too. Does the engine turn properly?
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?
Reconnect the wiring.
YES
NO
Is the engine seized?
YES
Find the cause of engine failure.
NO
Turn the starter key: is there a +12V reading on the electromagnet input wire (2.5 red--black wire).
YES
You can hear the electromagnet trip NO
NO
YES
The coils or brushes are probably faulty, or mechanically damaged
Electromagnet probably inefficient, remove it 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 there a +12V reading on pin 85 (0.5 red--black wire) when you turn the ignition key?
YES
Replace the relay
NO
Check the power take--off switch and the clutch pedal switch: are the wires connected? Are the switches efficient?
NO
Reconnect the wires to the switch, replace the switches if necessary.
YES
Does the instrument panel display light up when the starter key is turned? YES
NO
Check that the battery main power supplies the switch pin +30 of the key, and that on turning the key current leaves pin 15/54 and 50a of the connector.
Check the ignition key switch: if the wire is connected and in good condition, replace the switch.
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
6
STARTER AND RECHARGING CIRCUIT POWER SHUTTLE TRANSMISSIONS 1
Ignition key
2
Transmission control unit (TCM).
3
Starter motor
4
Battery cut--out
5
Battery
6
Grid Heater module
7
Alternator
8
Clutch pedal switch
9
Dashboard module (ADIC)
10
Coolant temperature sensor
11
Starting advance thermometric cut--out switch
12
Grid heater relay
13
Grid heater (pre--heater)
14
Shuttle lever
15
Engine shut--down solenoid valve
16
Grid heater control module MF3
40 AMP
Mega--fuse for starter system supply
MF
125 AMP Mega--fuse for grid heater supply
F1
5 AMP
Grid Heater module supply fuse
F5
5 AMP
Engine shut--down solenoid valve supply fuse
F18
5 AMP
Starting advance supply fuse
F28
5 AMP
Fuse for supply to clutch pedal switch, shuttle lever and starter relay pin 85
MR1 Engine starter circuit relay (70A)
MPH2027A
3 Fuses and relay control unit
87679925A1 - 02 - 2008
4 Starter motor
50N
50N
50N
5
4
1
0.5V
6R
2 3 4
5
25N
6
7
8
1AR 1RV 0.5RN 1AR 1LR 1N
9 10
4R
1HR
40A
6
1
58
4R
13
85
87
30
85
87
12
30
86
MR1
4C 0.5R
86
1AR
4R
0.5N
50a
15/54
1N
1CB 1LR 16R
4RN
0.5RN
15
5 amp
F1
1CB 1BL
1BL
MF3
16R
1.5RN
1.5RN
16
11
5A
F5
4C
5 amp
F18 O.5R 4
O.5R
1CB 1ZB 1ZB
1RV
2.5RN
25N 50N
5A
F28
D+
8
NC
3
2
1
16R
4C
B+
50
30 M
7
10
MF--125A
16R
3
7
1HR
A B C
1NG
6
Neutral
0.5B 0.5RN
5
1NG
0.5B
3
0.5V
1RV
0.5RN
2
1
Front Reverse
2K2 560 Front 2K2 560 Reverse
MMM1608A O.5B O.5B
30
2
10
25
16
22
24B
9
MOD-1/3 TCM
14
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 7
MOD-- 27 ADIC
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
8
TROUBLESHOOTING The engine does not turn over when the starter key is turned with the clutch pedal pressed and the shuttle lever in neutral.
Is the battery fully charged?
NO
YES
Charge or replace the battery, check the battery cut--out too. Does the engine turn properly? 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
Reconnect the wiring.
NO
Is the engine seized?
YES
Find the cause of engine failure.
NO
Turn the starter key: is there a +12V reading on the electromagnet input wire (2.5 red--black wire).
You can hear the electromagnet trip
YES
YES
NO
NO
The coils or brushes are probably faulty, or mechanically damaged
Electromagnet probably inefficient, remove it 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 there a +12V reading on pin 85 (0.5 red--black wire) when you turn the ignition key?
YES
Replace the relay
NO
Check the shuttle lever switch and the clutch pedal switch: are the wires connected? Are the switches efficient?
NO
Reconnect the wires to the switch, replace the switches if necessary.
YES
Does the instrument panel display light up when the starter key is turned? YES
Check the ignition key switch: if the wire is connected and in good condition, replace the switch.
87679925A1 - 02 - 2008
NO
Check that the battery main power supplies the switch pin +30 of the key, and that on turning the key current leaves pin 15/54 and 50a of the connector.
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
9
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: •
Check that the battery is fully charged
•
Check the condition of all the starting system wiring (no damaged or frayed wires, no loose connections).
•
Check that the engine is not seized.
CURRENT ABSORBED ON THE STARTER MOTOR CIRCUIT (Fig. 5) 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).
5
1
4
3. Reconnect the ground wire (negative) to the battery negative terminal (3). 4. Connect the positive voltmeter point (2) to the positive battery terminal clamp and the negative to the negative battery terminal clamp.
3
2
26630
5
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
10
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) (Fig. 6) If the voltage absorption value is too high, check the individual circuit components to find the cause of the voltage drop.
2
IMPORTANT: Disconnect the fuel injection pump shut--off solenoid valve wire.
1
V
Battery positive cable
3
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). 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.
87679925A1 - 02 - 2008
26631
6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 Starter motor ground connections (Fig. 7)
11
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
7 Battery ground lead (Fig. 8)
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 8
STARTER MOTOR REMOVAL--INSTALLATION 1. Disconnect the battery ground lead (negative). 2. Loosen and remove the nut and bolt (1) retaining the starter motor (3) guard (2).
9 3. Remove the supply terminal (1) for the starter relay and the supply terminal (4) for the safety switch. 4. Unscrew the nut (2) retaining the cables: -- connection for battery cut--off -- battery, -- alternator charger, -- maxi--fuse box supply. 5. Unscrew the starter motor assembly bolts (3) and extract the motor. 6. To reassemble the starter motor, carry out the removal operations in reverse order. 10 87679925A1 - 02 - 2008
12
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 Starter motor components
2
1
6 3 5
4
9 8
MMN0257A
7 11
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
13
Starter motor components 1. 2. 3. 4. 5.
Control side support. Electromagnet. Coupling Lever Reduction unit
6. 7. 8. 9. 10.
Armature Field coils and casing Brush holder Brush plate Armature
1. Position the starter motor in a vice with padded jaws.
7. Extract the motor casing from the armature and the bracket on the control side.
2. Disconnect the biggest braided cable that connects the field coils casing with the electromagnet.
8. Extract the control lever knuckle pin from the control side of the casing.
3. Remove the three screws from the front casing and extract the electromagnet. Remember that the plunger remains connected to the control lever. 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;&#x153;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.
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. 10. Extract the armature and control unit.
INSTALLATION 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.
87679925A1 - 02 - 2008
14
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
1
SECTION 55 -- ELECTRICAL SYSTEM Chapter 4 -- CHARGING SYSTEM CONTENTS Description
Page
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 System testing and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Alternator Removal -- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TECHNICAL DATA CHARACTERISTICS
All types
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Iskra AAK4314
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounded negative
Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V
14
Maximum Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rpm
13000
Maximum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A
120
Energizing circuit resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
â&#x201E;¦
2,7
BOLT TORQUES Nm Alternator fastening bolts
5,5
Pulley retaining nut
70
Rectifier attaching screws
4,0
Brush box and regulator screws
2,7
Terminal nuts
2,7
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
2 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.
380001268
Belt tension meter.
DESCRIPTION AND OPERATION DESCRIPTION OF THE ALTERNATOR An Iskra--type 120 A external cooling fan alternator is fitted 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 driving belt. Alternators are fitted with a built--in regulator. 1.
Alternator speed connection (terminal W) not used.
2.
Alternator charge indicator connection (D+ terminal).
3.
Battery connection (B+ terminal).
1
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
3
2 Alternator charging circuit 1. 2.
Starter switch Alternator charge LED
5. Alternator B+ Battery connector
3. 4.
Battery Alternator electronic voltage regulation circuit.
D+ Alternator charge indicator W Not used
ALTERNATOR FUNCTIONING Refer to figure 2. When the starter key is turned, low current passes from the battery through the rotor field wiring. The circuit closes between the LED indicating the charge, the alternator D+ terminal, the rotor field winding, the alternator regulator and earth (ground). At this point the LED illuminates and the rotor is partially magnetized. 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.
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 LED 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
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. 1. CHECK THE BATTERY Check all battery elements with a densimeter. The battery must be at least 70% charged and efficient. 2. CHECK THE DRIVE BELT 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 belt tensioner as indicated below.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
5
The drive belt is tensioned as follows: A. Loosen the screw in the slot of the belt tensioner and that of the pivot, then loosen the lock nut of the screw at the end of the belt tensioner. B. With the use of a special tool 380001268 measure the tension of the belt at point ’X’, by “pinging” the belt. The required measurement at ’X’ is: With normal fan 183 Hz ± 6 Hz With viscous coupling 200 Hz ± 6 Hz C. If the value is lower, screw on the screw at the end of the belt tensioner, try measuring again if the result is in the required tolerance. D. Tighten the pivot screw, the one for locking in the slot and the lock nut of the screw at the end of the belt tensioner.
1.
Alternator.
2.
Belt tensioner.
3.
Fan hub.
4.
Coolant pump.
5.
Crankshaft.
3
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
6 ALTERNATOR Removal -- Refitting
IMPORTANT: Before disconnecting the alternator wires, make sure that the starter key is in the OFF position. Refer to figures 4 and 5. 1. Disconnect the negative lead from the battery. 2. Remove the guard (1). 4 3. Loosen the 2 belt tensioner stop nuts (1) and unscrew the lock nut, loosen the screw at the end of the tensioner, loosening the belt. and the bolt (3) fastening the alternator to the belt tensioner (4).
5 4. Disconnect the battery charging cable (1) at terminal B+ and cable (2) of the charging warning light from the terminal D+.
6 5. Unscrew the two pivot screws (1) and remove the alternator. 6. 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 7
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
7
8 Alternator components 1.
Pulley
10. Terminals: B+, D+ and W
2.
Bearing
11. Gaskets
3.
Cooling fan
12. Capacitor
4.
Front support plate
13. Rear bearing
5.
Stator
14. Brush holder
6.
Rotor
15. Brushes
7.
Rear support plate
16. Rubber seal
8.
Rectifier
17. Retaining ring
9.
Cover
18. Felt gasket
87679925A1 - 02 - 2008
8
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
1
SECTION 55 -- ELECTRICAL SYSTEM Chapter 5 -- BATTERY CONTENTS Description
Page
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery checking and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 1 2 4 6
TECHNICAL DATA CHARACTERISTICS Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold start amperage . . . . . . . . . . . . . . . . . . . . . . . . Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of elements . . . . . . . . . . . . . . . . . . . . . . . . Number of plates on each element . . . . . . . . . . . . Reserve capacity (SAE) (minimum) . . . . . . . . . . . Weight (or load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounding terminal . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION AND OPERATION Both types of batteries maintenance--free”.
are
“sealed
V C.C.A Ah
kg
and
•
The 100 Ah battery, installed on the 56/76 63/86 71/97 KW/HP models, is fitted in front of the radiator, inside the front axle support.
•
The 132 Ah battery is fitted on 56/76 63/86 71/97 78/106 and 83/113 KW/HP models, provided with cab air--conditioning system, and installed on top of the front axle support. NOTE: “Maintenance--free” means that the battery does not leak electrolyte in normal conditions of use. Leaks 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.
TYPE OF BATTERY Mod. 56/76 63/86 Mod. 56/76 71/97 78/106 83/113 63/86 71/97 KW/HP KW/HP 12 1x800 1x960 100 132 6 16 21 160 210 25 35 Negative
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.
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
2
REMOVAL AND INSTALLATION Battery Located on top of the front axle support. To access the battery (on both versions), proceed as follows: 1. Raise the bonnet. 2. Disconnect the negative lead from the tractor frame and secure out of the way. 3. Loosen the bolts on both terminals and disconnect the negative and positive cables from the battery, making sure that they do not touch the battery. 4. Using the handles, fitted on both ends of the battery, lift and remove the battery from its housing. 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 suitably (but not excessively) tightened.
•
The radio and the clock will lose their data stored in memory and 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.
87679925A2 - 02 - 2010
23753
1
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
3
BATTERIES TESTING AND CHARGING PROCEDURES The tractor ranges use two different types of battery (two 100Ah and two 132Ah) that require different charging procedures. NOTE: All claims under warranty concerning the batteries must indicate the battery date code. Batteries type A NOTE: The following batteries are used only in production. They can be identified by: --
The part number hot stamped on the top of the battery casing or given on the label (even though necessarily at times these do not correspond to the numbers used as spares).
--
The position of the production date code. The date code is on the bottom right--hand side of the positive terminal.
Example of date code: 14L 7 044 14 L = Production plant 7 = Year (2007) 044 = Progressive number
2 Batteries type B NOTE: The following batteries are used in production and in the spare parts service for changing batteries. They can be identified by: --
The part number hot stamped on the top of the battery casing or given on the label (even though necessarily at times these do not correspond to the numbers used as spares).
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
4 --
The position of the production date code. The date code is on the bottom right--hand side of the positive terminal.
Example of date code: 7C CW06 7 = Year (2007) Production plant C = Month (February) A = December, B = January, C = February, D = March, E = April, F = May, G = June, H = July, J = August, K = September, L = October, M = November. CW06= Production plant
NOTE: Refer to the work flow diagrams on the following pages to check, test and charge the batteries.
87679925A1 - 02 - 2008
3
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
5
1. -- Flow chart for battery maintenance: Test Instructions
Dry battery suspected of being flat Check visually (see flow chart 2). Has the problem been identified?
YES
Correct the problem as required
YES
The battery must be fully charged before proceeding to the high charge test.
NO
Test the charge status [specific gravity or open circuit voltage test (*). See flow charts 3 and 4] NO
Test the high charge status (see flow chart 5). Is the measured voltage less than 9.6 volts?
YES
The battery power level is inadequate and its charge must be tested before being fully charged.
NO
The battery has adequate power and can be charged normally.
(*) The charge status can be tested using a hydrometer and a voltmeter. The most effective method to determine the battery charge status consists in measuring the specific gravity of the electrolyte in the battery and, where possible, this is preferable to the open circuit voltage method.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
6
2. -- Battery test procedure: Visual check
Remove the battery cover (if fitted).
Identify the battery size, part number and supplier.
Is the battery casing cracked or are the battery poles loose?
YES
A cracked casing or loose/broken poles can cause electrolyte leakage, then it is necessary to replace the battery.
YES
Clean/tighten/replace/repair as required and continue to test the battery.
NO
Are the cables and connections damaged, dirty or loose? NO
Are the battery terminals corroded?
YES
NO
The battery connector or terminal is loose.
Clean the terminals using water and sodium bicarbonate (baking soda). A wire brush may be required to remove heavy corrosion. Dry the battery and continue with the test.
YES
Tighten, if necessary, and continue with the battery test.
YES
Top up with distilled or de--mineralized water. Do not overfill and do not use tap water or rain water. Continue with the battery test.
YES
This could be due to a high level of battery self--discharge. Correct the cause of the problem, then replace the battery.
NO
Check the electrolyte level. The electrolyte should be around 17 mm above the plates. Is the electrolyte level low in any of the cells? NO
Using a hydrometer, check whether the electrolyte is excessively cloudy or discoloured (discolouring could be due to overfilling or vibration). Is it discoloured or cloudy? NO
Continue testing the charge status (*). (*) The charge status can be tested using a hydrometer and a voltmeter. The most effective method to determine the battery charge status consists in measuring the specific gravity of the electrolyte in the battery and, where possible, this is preferable to the open circuit voltage method.
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
7
3. -- Battery test procedure: specific gravity (charge status test). NOTE: State of charge tests are used to determine if there is sufficient charge in the battery to perform a high charge test, but does NOT verify the capacity of a battery to start the engine.
If the electrolyte level is too low, add distilled water up to the recommended level of 17 mm above the plates in order to carry out the test. Charge the battery for two hours, then leave it disconnected for 15 minutes before the test. (Refer to the charge flow chart 6).
Taking special care no electrolyte comes out, shake the battery to mix the electrolyte in the battery cells. Take the caps off the holes and draw up the electrolyte with a hydrometer. Note the specific gravity (SG) of each cell, starting with the cell nearest the positive terminal of the battery.
Adjust the hydrometer readings for all the temperature variations (+/-- 0.004 SG for every +/-- 5.5Ů&#x203A; C change in hydrometer temperature).
Adjust the SG values for each cell. Is there a variance greater than 0.025 between the cells?
YES
If one or more battery cells are defective, replace the battery.
NO
Refer to the following table to determine the state of charge.
STATE OF CHARGE
CORRECT SG AT 15_ _C
CORRECT SG AT 25_ _C
MEAN BATTERY VOLTAGE
100%
1,295
1,287
12,60
75%
1,253
1,246
12,40
50%
1,217
1,210
12,20
25%
1,117
1,170
12,00
DISCHARGED
1,137
1,130
11,80
FOLLOWING PHASES Continue with the high charchar ge test. Fully recharge the battery before performing a high charge test. (Refer to flow chart 6). Battery flat. A slow charge is necessary. (Refer to flow chart 6).
NOTE: SG = Specific gravity.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
8
4. -- Battery test procedure: open circuit voltage. (charge status test).
To eliminate any surface charge of the battery, switch on the vehicleâ&#x20AC;&#x2122;s headlights for a minute, then turn them off and leave the vehicle for 5 minutes.
Measure the open circuit voltage by connecting a digital voltmeter across the battery terminals.
Refer to the following table to determine the state of charge of the battery.
VOLTAGES
STATE OF CHARGE
FOLLOWING PHASES
Greater than 12.4 volts
Greater than 75%
Continue with the high charge test refer to flow chart 5).
12.0 -- 12.4 volts
25% á 75%
Charge the battery fully (refer to the charge work flow chart 6) before running a high charge test (refer to flow chart 5).
Less than 12 volts
less than 25%
Battery flat. A slow charge is necessary. (Refer to the charge flow chart 6).
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
9
5. -- Battery test procedure: high discharge test.
Check that the battery charge status is at least 75% (12.4 volts)
Determine the nominal battery power as stated on the label (800CCA or 960CCA).
Connect the high charge tester to the battery terminals, on the correct poles.
Charge the battery to a current equal to three times the nominal power Amp--h (Ah) or half the nominal power, in amps, needed for cold starting (CCA).
To eliminate the surface charge, connect the tester to the battery for 15 seconds at the specific discharge current, then disconnect and leave cut off for 5 minutes.
Apply the charge for no longer than 15 seconds and note the voltmeter reading.
Is the voltage on the terminal less tan 9.6 volts? NO
YES
The battery has adequate power and must be charge tested before being completely charged and re--tested (refer to flow chart 7).
The battery has adequate power and accepts the normal charge, if necessary, (refer to the charge flow chart 6), or it can be put back into operation.
87679925A1 - 02 - 2008
10
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 6. -- Battery charge flow chart: Charge Instructions.
Before charging the battery, check that the level of electrolyte is adequate. Clean the battery casing and cell covers with diluted ammonia and hot water. Clean the battery terminals if necessary.
If the battery has not passed the high charge test, carry out the permissible charge test (see flow chart 7) to determine whether the battery can take the charge.
Charge the battery following the “standard” method or “slow charge” for excessively discharged/sulphated batteries (*) (the charge procedures recommended by manufacturers are given in flow charts 8 and 9).
After charging, run the high discharge test (see flow chart 5) to check that battery performance is sufficient.
(*) A battery that has been discharged too much, that is with a charge status equal to or less than 25%, for an extended length of time becomes sulphated. The higher the level of sulphation and the more likely it is that the battery will not take the charge and must be replaced.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
11
7. -- Battery charge work flow chart: permissible charge test.
This test is for batteries that have not passed the high charge test. Charge the battery with a high rate charger set to 40A for 2 -- 3 minutes and note the battery voltage.
Is the voltage less than 11 volts or greater than 16 volts? NO
YES
The battery is probably sulphated or defective and must be replaced.
The battery probably takes a full charge. Refer to the manufacturerâ&#x20AC;&#x2122;s charging procedures (flow chart 8 and 9).
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
12
8. -- Battery charge work flow chart: procedure for charging A--type batteries.
Check that the battery is TYPE A by checking its identification label.
Check that the battery voltage is less than 12.6 volts by testing the charge status (flow chart 3 or 4).
Refer to the following table for the recommended charge currents.
BATTERY VOLTAGE
RECHARGE CURRENT
RECHARGE TIME
RECHARGE VOLTAGE
Volts
Amps
Hours
Volts
12.2 รท 12.6
10% of the nominal value Ahr
4
15.9 รท 16.2
Below 12.2
10% of the nominal value Ahr
8
15.9 รท 16.2
Check the battery voltage after 24 hours to make sure the battery is fully charged (equal to or greater than 12.6 volts).
NOTE: Check that the charger used to charge the A- Type battery does not have a capacity greater than 16.2 volts, otherwise the battery could get damaged.
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
13
9. -- Battery charge work flow chart: procedure for charging B--type batteries.
Check that the battery is TYPE B by checking its identification label.
Check that the battery voltage is less than 12.6 volts by testing the charge status (flow chart 3 or 4).
Refer to the following table for the recommended charge currents.
BATTERY VOLTAGE
RECHARGE CURRENT
RECHARGE TIME
RECHARGE VOLTAGE
Volts
Amps
Hours
Volts
12.45 ÷ 12.65
10% of the nominal value Ahr
6
14.7 ÷ 14.8
12.20 ÷ 12.44
10% of the nominal value Ahr
8
14.7 ÷ 14.8
Below 12.2
Sulphate crystals have formed on the electrodes, it is therefore necessary to perform the two separate charging sequences described below
First recharge sequence
1 (or the lowest possible setting)
24
14.7 ÷ 14.8
Second recharge sequence
10% of the nominal value Ahr
8
14.7 ÷ 14.8
Check the battery voltage after 24 hours to make sure the battery is fully charged (equal to or greater than 12.6 volts).
NOTE: Check that the charger used to charge the B- Type battery is no greater than 14.8 volts, otherwise the battery could get damaged.
87679925A1 - 02 - 2008
14
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
1
SECTION 55 -- ELECTRICAL SYSTEM Chapter 6 -- ELECTRICAL CIRCUITS CONTENTS Description
Page
Maxi power fuses box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fuse and relay box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuse and relay layout (model with cab, version with Power Shuttle and electronic lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuse and relay layout (model with cab, Standard version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fuse and relay layout (model without cab, version with Power Shuttle -- ISO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Fuse and relay layout (model without cab, Standard version -- ISO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fuse and relay layout (model without cab, version with Power Shuttle -- North America) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fuse and relay layout (model without cab, Standard version -- North America) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Power sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Grid heater relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Grid heater control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Electronic flasher module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Ground location points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 How to use the wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Electric wire colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Symbols used in electrical circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Wiring diagram components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Version index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Version with Power Shuttle and electronic lift (Cab version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Standard version (Cab version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Version with ISO Power Shuttle -- (Deck version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Standard ISO version (Deck version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Version with Power Shuttle for North America -- (Deck version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Standard version for North America -- (Deck version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Front loader circuit TL series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 Electronic battery cut--out circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 Input/output wiring diagram for the transmission electronic control unit (TCM) Power Shuttle 12X12 version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 Input/output wiring diagram for the transmission electronic control unit (TCM) Power Shuttle 24X24 version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 Input/output wiring diagram for the electronic control unit of the instrument panel (ADIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
2 MAXI FUSE BOX
The maxi fuse box is located inside the engine compartment, on the left--hand side near the brake fluid reservoir.
MPM1220A
1 MODEL WITH CAB Version with Power Shuttle and electronic lift Valves
PROTECTED CIRCUITS
1
MF1--40A
25A (ISO) / 45A (North America) power socket
2
MF2--70A
MF31
Power supply fuses F6 -- F12 (*).
MF32
Power supply fuses F7 -- F8 -- F9 -- F33 -- F34 + relay for side lights (fuses F16 -- F29 -- F30)
3
MF3--40A
Power supply +30 starter relay Power supply +30 starter switch
15/54
(fuses F1 -- F2 --F3 -- F4 (**) -- F5 -- F15 -- F18 -- F19 -F21 -- F23 -- F24 -- F27)
58
(fuses F17 -- F22 -- F35)
50a
(fuse F28)
4
MF4--50A
Power supply fuses F25 -- F36 -- F37 -- F38 -- F40
--
MF--125A
Inlet Grid Heater
(*) (**)
If there is a battery cut--out (mechanical/electronic) the fuse F12 always receives current straight from the battery The fuse F4 is only on the version with electronic lift
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
3
STANDARD version Valves
PROTECTED CIRCUITS
1
MF1--40A
25A (ISO) / 45A (North America) power socket
2
MF2--70A
Power supply pp y fuses F6 -- F7 -- F8 -- F9 -- F12 (*) ( ) -- F33 -- F34 + relayy for side lights g (f (fuses F16 F -- F29 F -- F30) F )
3
MF3--40A
Power supply +30 starter relay Power supply +30 starter switch
15/54
(fuses F1 -- F3 -- F5 -- F15 -- F18 -- F19 -- F20 -- F21 -F26 -- F27)
58
(fuses F17 -- F22 -- F35)
50a
(fuse F28)
4
MF4--50A
Power supply fuses F25 -- F36 -- F37 -- F38 -- F40
--
MF--125A
Inlet Grid Heater
VERSION WITHOUT CAB Power Shuttle ISO version PROTECTED CIRCUITS
Valves 1
MF1--40A
25A (ISO) power socket
2
MF2--70A
Power supply pp y fuses F7 -- F9 -- F12 (*) ( ) -- F33 -- F34 -- F36 + relayy for side lights g (fuses F16 -- F29 -- F30)
3
MF3--40A
Power supply +30 starter relay Power supply +30 starter switch
4
MF4--50A
Not used
--
MF--125A
Inlet Grid Heater
15/54
(fuses F1 -- F2 -- F3 -- F5 -- F14 -- F15 -- F18 -- F23 -F24 -- F27)
58
(fuse F35)
50a
(fuse F28)
Standard ISO version PROTECTED CIRCUITS
Valves 1
MF1--40A
25A (ISO) power socket
2
MF2--70A
Power supply pp y fuses F7 -- F9 -- F12 (*) ( ) -- F33 -- F34 -- F36 + relayy for side lights g (f (fuses F16 F -- F29 F -- F30) F )
3
MF3--40A
Power supply +30 starter relay Power supply +30 starter switch
4
MF4--50A
Not used
--
MF--125A
Inlet Grid Heater
15/54
(fuses F1 -- F3 -- F5 -- F14 -- F15 -- F18 -- F20 -- F26 -F27)
58
(fuse F35)
50a
(fuse F28)
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
4
Power Shuttle North America version PROTECTED CIRCUITS
Valves 1
MF1--40A
45A (North America) power socket
2
MF2--70A
Power supply pp y fuses F7 -- F9 -- F12 (*) ( ) -- F33 -- F34 -- F36 + relayy for side lights g (f (fuses F16 F -- F29 F -- F30) F )
3
MF3--40A
Power supply +30 starter relay Power supply +30 starter switch
4
MF4--50A
Not used
--
MF--125A
Inlet Grid Heater
15/54
(fuses F1 -- F2 -- F3 -- F5 -- F14 -- F15 -- F18 -- F23 -F24 -- F27)
58
(fuse F35)
50a
(fuse F28)
North America Standard version PROTECTED CIRCUITS
Valves 1
MF1--40A
45A (North America) power socket
2
MF2--70A
Power supply pp y fuses F7 -- F9 -- F12 (*) ( ) -- F33 -- F34 -- F36 + relayy for side lights g (f (fuses F16 F -- F29 F -- F30) F )
3
MF3--40A
Power supply +30 starter relay Power supply +30 starter switch
(*)
4
MF4--50A
Not used
--
MF--125A
Inlet Grid Heater
15/54
(fuses F1 -- F3 -- F5 -- F14 -- F15 -- F18 -- F20 -- F26 -F27)
58
(fuse F35)
50a
(fuse F28)
If there is a battery cut--out (mechanical/electronic) the fuse F12 always receives current straight from the battery.
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
5
FUSE AND RELAY BOX
The fuse and relay box is located inside the dashboard, on the right--hand side, and can be accessed by removing the side panel (1, fig. 2) using the two screw knobs (2, fig. 2).
2
Main fuse and relay box location.
MPH2027A
3
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
6
FUSE AND RELAY LAYOUT (Model with cab, version with Power Shuttle and electronic lift)
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.
Ready for: -----
Electrohydraulic differential lock. Electrohydraulic 4WD. Trailer brake circuit. Air brake circuit
-----
Electrohydraulic power take--off. North America lights circuit. Front loader. Electronic rear lift.
MPM1054A
4
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
7
Fuses VERSION WITH POWER SHUTTLE AND ELECTRONIC LIFT Valves
Amps.
PROTECTED CIRCUITS
F1
5
(+12V 15/54 Key) -- Instrument (ADIC)
F2
5
(+12V 15/54 Key) -- Turn indicators, four--wheel drive circuit, differential lock and power take--off
F3
5
(+12V 15/54 Key) -- Brake pressure switches
F4
5
(+12V 15/54 Key) -- Electronic lift circuit (EDC)(*)
F5
5
(+12V 15/54 Key) -- Engine stop circuit
F6
25
(+12V F31 -- 30A) -- Air--conditioner compressor circuit
F7
15
(+12V F32 -- 40A) -- Direction indicator and hazard lights
F8
7.5
(+12V F32 -- 40A) -- Rotating beacon, overhead lighting
F9
10
(+12V F32 -- 40A) -- Horn, 8A power socket, cigar lighter
F10
--
Not used
F11
--
Not used
F12
5
(+12V F31 -- 30A)-- Control unit for transmission, instrument, handbrake indicator light, fault diagnosis socket, car radio
F13
--
Not used
F14
--
Not used
F15
7.5
(+12V 15/54 Key) -- Front loader circuit
F16
10
(+12V R2) -- Front right--hand and rear left--hand side lights, cigar lighter indicator light
F17
7.5
(+12V 58 Key) -- ISO 11786 power socket
F18
5
(+12V 15/54 Key) -- Engine and transmission services
F19
10
(+12V 15/54 Key) -- Rear wiper and washer pump
F20
--
F21
10
(+12V 15/54 Key)-- Front wiper and washer pump
F22
5
(+12V 58 Key) -- Ventilation/air--conditioning unit, radio
F23
10
(+12V 15/54 Key) -- Transmission control unit
F24
5
(+12V 15/54 Key) -- Power Shuttle lever
F25
15
(+12V MF4--50A) -- Cab front work lights (inside)
F26
--
Not used
F27
5
(+12V 15/54 Key) -- Trailer brake circuit
F28
5
(+12V 50a Key) -- Starter safety circuit
Not used
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
8
VERSION WITH POWER SHUTTLE AND ELECTRONIC LIFT Valves
Amps.
F29
5
(+12V R2) -- Side lights, controls lighting
F30
10
(+12V R2) -- Front left--hand and rear right--hand side lights, controls and instruments lighting
F31
30
(+12V MF2 -- 70A) -- Memory and air--conditioner circuit
F32
40
(+12V MF2 -- 70A) -- Cab main
F33
15
(+12V F32 -- 40A) -- Full beam headlights
F34
15
(+12V F32 -- 40A) -- Dipped beam headlights
F35
10
(+12V 58 Key) -- Brake lights, seat
F36
15
(+12V MF4 -- 50A) -- Front swivel work lights
F37
15
(+12V MF4 -- 50A) -- Cab front work lights
F38
15
(+12V MF4 -- 50A) -- Front work lights on grab handles
F39
--
F40
15
(*)
PROTECTED CIRCUITS
Not used (+12V MF4 -- 50A) -- Cab rear work lights
With version without electronic lift there is no F4.
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
9
P
MPM1055A
5 Relays R1
Handbrake
R11
R2.
Side lights circuit
R12 Front work lights circuit on grab handle
R3
Full beam headlight circuit
R14 Cab rear lights circuit
R4
Dipped beam headlight circuit
R15 Cab front work lights circuit (inside)
R5
Brake lights circuit
R27 Trailer brake circuit
R6
Front swivel lights circuit
R28 Trailer brake circuit
R9
Air--conditioner compressor
MR1 Engine starter circuit
Cab front work lights circuit
R10. Air--conditioner circuit
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
10
FUSE AND RELAY LAYOUT (Model with cab, Standard version)
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.
Ready for: -----
Electrohydraulic differential lock. Electrohydraulic 4WD. Electrohydraulic power take--off. Trailer brake circuit.
----
Air brake circuit North America lights circuit. Front loader.
MPM1064A
6
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
11
Fuses STANDARD VERSION Valves
Amps.
PROTECTED CIRCUITS
F1
5
(+12V 15/54 Key) -- Instrument (ADIC)
F2
--
Not used
F3
5
(+12V 15/54 Key) -- Brake pressure switches
F4
--
Not used
F5
5
(+12V 15/54 Key) -- Engine stop circuit
F6
25
(+12V MF2 -- 70A) --Air--conditioner compressor circuit
F7
15
(+12V MF2 -- 70A) -- Direction indicator and hazard lights
F8
7.5
(+12V MF2 -- 70A) -- Rotating beacon, overhead lighting
F9
10
(+12V MF2 -- 70A) -- Horn, 8A power socket, cigar lighter
F10
--
Not used
F11
--
Not used
F12
5
(+12V MF2 -- 70A) -- Control unit for transmission, instrument, handbrake indicator light, fault diagnosis socket, car radio
F13
--
Not used
F14
--
Not used
F15
7.5
(+12V 15/54 Key) -- Front loader circuit
F16
10
(+12V R2) -- Front right--hand and rear left--hand side lights, cigar lighter indicator light
F17
7.5
(+12V 58 Key) -- ISO 11786 power socket
F18
5
(+12V 15/54 Key) -- Engine and transmission services
F19
10
(+12V 15/54 Key)-- Rear wiper and washer pump
F20
5
(+12V 15/54 Key) -- Four--wheel drive and differential lock circuit
F21
10
(+12V 15/54 Key)-- Front wiper and washer pump
F22
5
(+12V 58 Key)-- Ventilation/air--conditioning unit, radio
F23
--
Not used
F24
--
Not used
F25
15
(+12V MF4--50A) -- Cab front work lights (inside)
F26
5
(+12V 15/54 Key) -- Rear power take--off circuit
F27
5
(+12V 15/54 Key) -- Trailer brake circuit
F28
5
(+12V 50a Key) -- Starter safety circuit
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
12
STANDARD VERSION Valves
Amps.
F29
5
(+12V R2) -- Side lights, controls lighting
F30
10
(+12V R2) -- Front left--hand and rear right--hand side lights, controls and instruments lighting
F31
--
Not used
F32
--
Not used
F33
15
(+12V MF2 -- 70A)-- Full beam headlights
F34
15
(+12V MF2 -- 70A)-- Dipped beam headlights
F35
10
(+12V 58 Key) -- Brake lights, seat
F36
15
(+12V MF4 -- 50A)-- Front swivel work lights
F37
15
(+12V MF4 -- 50A)-- Cab front work lights
F38
15
(+12V MF4 -- 50A)-- Front work lights on grab handles
F39
--
F40
15
87679925A1 - 02 - 2008
PROTECTED CIRCUITS
Not used (+12V MF4 -- 50A)-- Cab rear work lights
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
13
P
MPM1065A
7 Relays R1
Handbrake
R15 Cab front work lights circuit (inside)
R2.
Side lights circuit
R17 Four--wheel drive, differential lock circuit
R3
Full beam headlight circuit
R18 Differential lock circuit
R4
Dipped beam headlight circuit
R19 Differential lock circuit
R5
Brake lights circuit
R20 Four--wheel drive circuit
R6
Front swivel lights circuit
R23 Rear power take--off circuit
R9
Air--conditioner compressor
R24 Rear power take--off circuit
R10. Air--conditioner circuit
R27 Trailer brake circuit
R11
R28 Trailer brake circuit
Cab front work lights circuit
R12 Front work lights circuit on grab handle
MR1 Engine starter circuit
R14 Cab rear lights circuit
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
14
FUSE AND RELAY LAYOUT (Version without cab, version with Power Shuttle -- ISO)
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.
Ready for: ---
Electrohydraulic differential lock. Electrohydraulic 4WD.
---
Electrohydraulic power take--off. Trailer brake circuit.
MPM1062A
8
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
15
Fuses VERSION WITH POWER SHUTTLE - (ISO) Valves
Amps.
PROTECTED CIRCUITS
F1
5
(+12V 15/54 Key) -- Instrument (ADIC)
F2
5
(+12V 15/54 Key) -- Turn indicators, four--wheel drive circuit, differential lock and power take--off
F3
5
(+12V 15/54 Key) -- Brake pressure switches
F4
--
Not used
F5
5
(+12V 15/54 Key) -- Engine stop circuit
F6
--
Not used
F7
15
F8
--
F9
10
F10
--
Not used
F11
--
Not used
F12
5
(+12V MF2 -- 70A) -- Control unit for transmission, instrument, handbrake indicator light, fault diagnosis socket, car radio
F13
--
Not used
F14
7.5
(+12V 15/54 Key) Rear work lamp
F15
7.5
(+12V 15/54 Key) -- Front loader circuit
F16
10
(+12V R2) -- Front right--hand and rear left--hand side lights, cigar lighter indicator light
F17
--
Not used
F18
5
(+12V 15/54 Key) -- Engine and transmission services
F19
--
Not used
F20
--
Not used
F21
--
Not used
F22
--
Not used
F23
10
(+12V 15/54 Key) -- Transmission control unit
F24
5
(+12V 15/54 Key) -- Power Shuttle lever
F25
--
Not used
F26
--
Not used
F27
5
(+12V 15/54 Key) -- Trailer brake circuit
F28
5
(+12V 50a Key) -- Starter safety circuit
(+12V MF2 -- 70A) -- Direction indicator and hazard lights Not used (+12V MF2 -- 70A) -- Horn, 8A power socket, cigar lighter
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
16
VERSION WITH POWER SHUTTLE - (ISO) Valves
Amps.
F29
5
(+12V R2) -- Side lights, controls lighting
F30
10
(+12V R2) -- Front left--hand and rear right--hand side lights, controls and instruments lighting
F31
--
Not used
F32
--
Not used
F33
15
(+12V MF2 -- 70A)-- Full beam headlights
F34
15
(+12V MF2 -- 70A)-- Dipped beam headlights
F35
10
(+12V 58 Key) -- Brake lights, seat
F36
15
(+12V MF2 -- 70A)-- Front swivel work lights
F37
--
Not used
F38
--
Not used
F39
--
Not used
F40
--
Not used
87679925A1 - 02 - 2008
PROTECTED CIRCUITS
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
17
P
MPM1063A
9 Relays R1
Handbrake
R6
R2.
Side lights circuit
R27 Trailer brake circuit
R3
Full beam headlight circuit
R28 Trailer brake circuit
R4
Dipped beam headlight circuit
R50 Electronic flasher
R5
Brake lights circuit
MR1 Engine starter circuit
Front swivel lights circuit
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
18
FUSE AND RELAY LAYOUT (Model without cab, Standard version -- ISO)
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.
Ready for: ---
Electrohydraulic differential lock. Electrohydraulic 4WD.
---
Electrohydraulic power take--off. Trailer brake circuit.
MPM1058A
10
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
19
Fuses STANDARD VERSION - (ISO) Valves
Amps.
PROTECTED CIRCUITS
F1
5
(+12V 15/54 Key) -- Instrument (ADIC)
F2
--
Not used
F3
5
(+12V 15/54 Key) -- Brake pressure switches
F4
--
Not used
F5
5
(+12V 15/54 Key) -- Engine stop circuit
F6
--
Not used
F7
15
F8
--
F9
10
F10
--
Not used
F11
--
Not used
F12
5
(+12V MF2 -- 70A) -- Control unit for transmission, instrument, handbrake indicator light, fault diagnosis socket, car radio
F13
--
Not used
F14
7.5
(+12V 15/54 Key) Rear work lamp
F15
7.5
(+12V 15/54 Key) -- Front loader circuit
F16
10
(+12V R2) -- Front right--hand and rear left--hand side lights, cigar lighter indicator light
F17
--
Not used
F18
5
(+12V 15/54 Key) -- Engine and transmission services
F19
--
Not used
F20
5
(+12V 15/54 Key) -- Four--wheel drive and differential lock circuit
F21
--
Not used
F22
--
Not used
F23
--
Not used
F24
--
Not used
F25
--
Not used
F26
5
(+12V 15/54 Key) -- Rear power take--off circuit
F27
5
(+12V 15/54 Key) -- Trailer brake circuit
F28
5
(+12V 50a Key) -- Starter safety circuit
(+12V MF2 -- 70A) -- Direction indicator and hazard lights Not used (+12V MF2 -- 70A) -- Horn, 8A power socket, cigar lighter
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
20
STANDARD VERSION - (ISO) Valves
Amps.
F29
5
(+12V R2) -- Side lights, controls lighting
F30
10
(+12V R2) -- Front left--hand and rear right--hand side lights, controls and instruments lighting
F31
--
Not used
F32
--
Not used
F33
15
(+12V MF2 -- 70A)-- Full beam headlights
F34
15
(+12V MF2 -- 70A)-- Dipped beam headlights
F35
10
(+12V 58 Key) -- Brake lights, seat
F36
15
(+12V MF2 -- 70A)-- Front swivel work lights
F37
--
Not used
F38
--
Not used
F39
--
Not used
F40
--
Not used
87679925A1 - 02 - 2008
PROTECTED CIRCUITS
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
21
P
MPM1059A
11 Relays R1
Handbrake
R19 Differential lock circuit
R2.
Side lights circuit
R20 Four--wheel drive circuit
R3
Full beam headlight circuit
R23 Rear power take--off circuit
R4
Dipped beam headlight circuit
R24 Rear power take--off circuit
R5
Brake lights circuit
R27 Trailer brake circuit
R6
Front swivel lights circuit
R28 Trailer brake circuit
R17 Four--wheel drive, differential lock circuit
R50 Electronic flasher
R18 Differential lock circuit
MR1 Engine starter circuit
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
22
FUSE AND RELAY LAYOUT (Version without cab and version with Power Shuttle -- North America)
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.
Ready for: ---
Electrohydraulic differential lock. Electrohydraulic 4WD.
---
Electrohydraulic power take--off. Trailer brake circuit.
MPM1060A
12
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
23
Fuses VERSION WITH POWER SHUTTLE - (NORTH AMERICA) Valves
Amps.
PROTECTED CIRCUITS
F1
5
(+12V 15/54 Key) -- Instrument (ADIC)
F2
5
(+12V 15/54 Key) -- Turn indicators, four--wheel drive circuit, differential lock and power take--off
F3
5
(+12V 15/54 Key) -- Brake pressure switches
F4
--
Not used
F5
5
(+12V 15/54 Key) -- Engine stop circuit
F6
--
Not used
F7
15
F8
--
F9
10
F10
--
Not used
F11
--
Not used
F12
5
(+12V MF2 -- 70A) -- Control unit for transmission, instrument, handbrake indicator light, fault diagnosis socket, car radio
F13
--
Not used
F14
7.5
(+12V 15/54 Key) Rear work lamp
F15
7.5
(+12V 15/54 Key) -- Front loader circuit
F16
10
(+12V R2) -- Front right--hand and rear left--hand side lights, cigar lighter indicator light
F17
--
Not used
F18
5
(+12V 15/54 Key) -- Engine and transmission services
F19
--
Not used
F20
--
Not used
F21
--
Not used
F22
--
Not used
F23
10
(+12V 15/54 Key) -- Transmission control unit
F24
5
(+12V 15/54 Key) -- Power Shuttle lever
F25
--
Not used
F26
--
Not used
F27
5
(+12V 15/54 Key) -- Trailer brake circuit
F28
5
(+12V 50a Key) -- Starter safety circuit
(+12V MF2 -- 70A) -- Direction indicator and hazard lights Not used (+12V MF2 -- 70A) -- Horn, 8A power socket, cigar lighter
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
24
Valves
Amps.
F29
5
(+12V R2) -- Side lights, controls lighting
F30
10
(+12V R2) -- Front left--hand and rear right--hand side lights, controls and instruments lighting
F31
--
Not used
F32
--
Not used
F33
15
(+12V MF2 -- 70A)-- Full beam headlights
F34
15
(+12V MF2 -- 70A)-- Dipped beam headlights
F35
10
(+12V 58 Key) -- Brake lights, seat
F36
15
(+12V MF2 -- 70A)-- Front swivel work lights
F37
--
Not used
F38
--
Not used
F39
--
Not used
F40
--
Not used
87679925A1 - 02 - 2008
PROTECTED CIRCUITS
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
25
P
MPM1061A
13
Relays R1
Handbrake
R6
R2.
Side lights circuit
R27 Trailer brake circuit
R3
Full beam headlight circuit
R28 Trailer brake circuit
R4
Dipped beam headlight circuit
MR1 Engine starter circuit
R5
Brake lights circuit
Front swivel lights circuit
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
26
FUSE AND RELAY LAYOUT (model without cab, Standard version -- North America)
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.
Ready for: ---
Electrohydraulic differential lock. Electrohydraulic 4WD.
---
Electrohydraulic power take--off. Trailer brake circuit.
MPM1056A
14
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
27
Fuses STANDARD VERSION - (NORTH AMERICA) Valves
Amps.
PROTECTED CIRCUITS
F1
5
(+12V 15/54 Key) -- Instrument (ADIC)
F2
--
Not used
F3
5
(+12V 15/54 Key) -- Brake pressure switches
F4
--
Not used
F5
5
(+12V 15/54 Key) -- Engine stop circuit
F6
--
Not used
F7
15
F8
--
F9
10
F10
--
Not used
F11
--
Not used
F12
5
(+12V MF2 -- 70A) -- Control unit for transmission, instrument, handbrake indicator light, fault diagnosis socket, car radio
F13
--
Not used
F14
7.5
(+12V 15/54 Key) Rear work lamp
F15
7.5
(+12V 15/54 Key) -- Front loader circuit
F16
10
(+12V R2) -- Front right--hand and rear left--hand side lights, cigar lighter indicator light
F17
--
Not used
F18
5
(+12V 15/54 Key) -- Engine and transmission services
F19
--
Not used
F20
5
(+12V 15/54 Key) -- Four--wheel drive and differential lock circuit
F21
--
Not used
F22
--
Not used
F23
--
Not used
F24
--
Not used
F25
--
Not used
F26
5
(+12V 15/54 Key) -- Rear power take--off circuit
F27
5
(+12V 15/54 Key) -- Trailer brake circuit
F28
5
(+12V 50a Key) -- Starter safety circuit
(+12V MF2 -- 70A) -- Direction indicator and hazard lights Not used (+12V MF2 -- 70A) -- Horn, 8A power socket, cigar lighter
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
28
STANDARD VERSION - (NORTH AMERICA) Valves
Amps.
F29
5
(+12V R2) -- Side lights, controls lighting
F30
10
(+12V R2) -- Front left--hand and rear right--hand side lights, controls and instruments lighting
F31
--
Not used
F32
--
Not used
F33
15
(+12V MF2 -- 70A)-- Full beam headlights
F34
15
(+12V MF2 -- 70A)-- Dipped beam headlights
F35
10
(+12V 58 Key) -- Brake lights, seat
F36
15
(+12V MF2 -- 70A)-- Front swivel work lights
F37
--
Not used
F38
--
Not used
F39
--
Not used
F40
--
Not used
87679925A1 - 02 - 2008
PROTECTED CIRCUITS
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
29
P
MPM1057A
15 Relays R1
Handbrake
R19 Differential lock circuit
R2.
Side lights circuit
R20 Four--wheel drive circuit
R3
Full beam headlight circuit
R23 Rear power take--off circuit
R4
Dipped beam headlight circuit
R24 Rear power take--off circuit
R5
Brake lights circuit
R27 Trailer brake circuit
R6
Front swivel lights circuit
R28 Trailer brake circuit
R17 Four--wheel drive, differential lock circuit
MR1 Engine starter circuit
R18 Differential lock circuit
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
30
POWER SOCKETS (Fig. 16) 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
16 Seven--pole power socket (Fig. 17) The PTO contacts carry out the following functions: 1 -- L.
Indicator Left.
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
17 25 A two--pole power socket (ISO version) (Fig. 18) 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
18 40 A power socket (North America version) (Fig. 19) Provides the following positions: 82.
Key--controlled power.
54.
Direct power.
31.
Ground.
58L.
Earth.
58R.
Direct power. MPE0202A
19 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 8 Ah one--pole power socket (Fig. 20)
31
1
The power socket (1) is used for connecting the low amp electric instruments (beacon, lamps, etc.).
20 ISO 11786 implement socket with 7 pins (Fig. 21) The socket (1) is located on the right--hand mudguard inside the cab. Pin 1. True ground speed. (radar sensed) Pin 2. Theoretical ground speed. (wheel sensed) Pin 3. Rear PTO speed. Pin 4. Rear 3--point hitch, in work/out of work. Pin 5. Not used Pin 6. 5 amp power supply. Pin 7. Common ground connection.
1
MPM1017A
21
GRID HEATER RELAY (Fig. 22) The power relay for the starter pre--heating system (1) is located in the engine compartment near 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 2 MPF0642A
22 GRID HEATER CONTROL MODULE (Fig. 23) The pre--heating control module (1) is located inside the panel and it controls the above--described power relay.
1
MPF1888A
23 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
32
ELECTRONIC FLASHER MODULE (Fig. 24) This module (1) is located inside the panel on the right--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
MPH2027A
24
GROUND LOCATION POINTS A.
Control panel ground.
B.
Battery ground.
C. Cab RH side ground. D. Cab RH upper side ground. E.
Cab LH side ground.
F.
Main rear ground (transmission).
G. Cab frame/body connecting ground.
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
33
GROUND POINTS LAYOUT
MPF0658A
25 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
34
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 portion of cir-
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
cuit 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
26 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.
87679925A - 12 - 2007
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.
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
35
3. On each connecting wire there is an abbreviation composed as follows: 1 -- Cable identification (if printed); 2 -- Wire main colour; 3 -- Colour of the striping along the wire; 4 -- Wire section in mm2.
MPM1066A
27 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. 28, 29).
MPM0699A
28
MPM0700A
29 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. 30).
MPM0699A
30 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
36
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
31
WIRE COLOUR CODING A
Light Blue
HV
Grey/green
AN
Light blue/black
HG
Grey/yellow
AG
Light blue/yellow
L
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
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
37
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
Connection
Rotating beacon power socket
Power fuse
Lamp
Relays
Battery
MPD2703A
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
38
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: -- Numerical order (increasing) at the start of each diagram;
ALT
Alternator
AUD
Audio devices
BAT
Battery
CB
Battery cut--out
CAP
Functional order (divided by type of components) page 39. Below is an explanation of the suffixes related to each component.
DESCRIPTION
SUFFIX
C
--
Connections Capacitor
D
Diode
F
Fuse
GND
Ground
LMP
Lamps
LEDs
LEDs
MOD
Control units
M
Motor
RLY
Relays
RES
Resistor
SEN
Sensor
SOL
Solenoid valve
SW
Switch
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
39
ELECTRICAL CIRCUIT COMPONENTS CODE DESCRIPTION
ALTERNATOR ALT--301/314 Alternator AUDIO DEVICES AUD--63 LH speaker AUD--150 RH speaker AUD--169 Audible beep BATTERY BAT--500 Battery CONNECTIONS C--1 Cab/engine main connection C--2 Cab/transmission main connection C--8 Cab/front loader main connection C--11 Cab/trailer brake main connection C--12 Cab/air--conditioning main connection C--21 Transmission/seven--pin socket connection C--23 Connection for switch of indicator light/mechanical power take--off safety device C--33 Engine/front lights connector C--34 ISO rear power socket connector/North America C--37 Extension connector ISO 11786 C--40A Connector for positive cable on motor / alternator side of battery cut--off module C--40B Connector for positive cable on battery side C--46 Connector for cab/battery cut--off cable C--50 Front loader prearrangement connector C--57 Pneumatic seat supply connector C--58 Connector of fitting for ISO 11786 power socket C--60 Implement locking switch arrangement connector C--60A Antidumping switch arrangement connector C--69 Grid heater relay connector (coil) C--75 Ignition switch connection C--76 Ignition switch connection C--77 Ignition switch connection C--78 Ignition switch connection C--81 Connector with 3 additional electro--hydraulic functions C--84 Connector with 6 additional electro--hydraulic functions
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
40
CODE DESCRIPTION
C--89 Connection of fitting for 80 litre pump variant C--117 Diagnostic socket C--143 Right--hand rotating beacon socket C--144 Left--hand rotating beacon socket C--319 Control unit memory connector C--320 Fuse box protecting memory and safety systems C--351 Battery cut--off module cable connector JUMPERS CB--8A Jumper on front loader connection CB--50A Jumper on front loader arrangement connector DIODE D--47 Starter circuit diode D--50B Loader arrangement connector jumper diode D--130 Diode for circuit of main beam headlights on handrail lights FUSES F--30/31 Mega--fuse box F--160 Grid Heater mega--fuse F--320 Fuse protecting memory and safety systems GROUND GND--92 GND--136 GND--146 GND--151 GND--159 GND--325
Cab right upright top ground Transmission ground Ground on left mudguard Ground on right mudguard Dashboard ground Battery ground
LAMPS LMP--17 LMP--26 LMP--28 LMP--49 LMP--66A LMP--66B LMP--68 LMP--72 LMP--74 LMP--95
Front LH light Work light on right handrail Work light on left handrail Front right work light on cab (outside) Rear right direction indicator on cab roof Right rear work light Overhead lighting LH two--faced headlight RH two--faced headlight Front right work light on cab (inside)
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
41
CODE DESCRIPTION
LMP--96 LMP--98 LMP--99 LMP--121 LMP--123 LMP--124 LMP--126
Front left work light on cab (inside) Right--hand rotating beacon Left--hand rotating beacon RH number plate light RH tail light LH number plate light Front RH light
LMP--128 Rear work light LMP--139 Front left work light LMP--148A Rear left direction indicator on cab roof LMP--148B Rear left work light on cab roof LMP--152 LH tail light LMP--161 Cab upright red light LMP--162 EDC Potentiometer backlighting LMP--170 Left grille work light LMP--171 Right grille work light LMP--172 Left--hand light LMP--173 Right--hand light LMP--180 Left--hand light on handrail LMP--181 Right--hand light on handrail MOTORS M--138 Wiper Motor M--147 Windscreen wiper pump M--149 Rear wiper motor M--163 Rear window wiper pump M--188A Electric fan 1 M--188B Electric fan 2 M--302/308 Starter motor M--304 Air conditioning compressor ELECTRONIC MODULES - CONTROL UNITS MOD--1/3 TCM transmission control unit MOD--27 Instrument MOD--40/41 Electronic battery cut--off relay module MOD--43 Battery cut--off module MOD--53 EDC Potentiometers panel MOD--54 EDC Mouse MOD--55 EDC LED panel
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
42
CODE DESCRIPTION
MOD--56 Radio MOD--61 Grid heater control unit MOD--70 Flasher MOD--100 Fuse box and main relay MOD--166 Key Pad (keypad) MOD--310 Injection pump advance device RESISTORS RES--156 Clutch pedal potentiometer RES--174 Inlet Grid Heater RELAYS RLY--40 Safety relay RLY--41 Timed relay RLY--70A Flasher relay RLY--131 Front loader RL1 relay RLY--132 Front loader RL2 relay RLY--133 Front loader RL3 relay RLY--134 Front loader RL4 relay (high beam headlights) RLY--135 Front loader RL5 relay (high beam headlights) RLY--175 Grid heater relay SENSORS SEN--190 Electronic thermostat SEN--196 Actuated trailer brake warning light pressure switch 10 bar (10.13 kg/cm) SEN--198 Trailer brake circuit safety pressure switch 3.5 bar (3.57 kg/cm) SEN--201 Transmission oil temperature sensor SEN--206 Safety pressure switch clutch A SEN--207 Safety pressure switch clutch B SEN--212 Fuel level sensor SEN--217 Theoretical wheel speed sensor SEN--217B Theoretical wheel speed sensor (PS version with creeper unit 20X20) SEN--218 PTO speed sensor SEN--221 RH draft sensor SEN--224 Arms position sensor SEN--225 LH draft sensor SEN--227 Radar SEN--305 Sediment filter
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
43
CODE DESCRIPTION
SEN--306 Coolant temperature sensor SEN--309 Thermometric sensor SEN--311 Gearbox oil pressure switch SEN--313 Engine oil pressure switch SEN--315 Engine rpm sensor SEN--317 Air drier filter SEN--340 Air brake pressure switch SOLENOID VALVES SOL--197 Trailer brake solenoid valves SOL--202 Clutch A solenoid valve SOL--203 Clutch B solenoid valve SOL--204 Clutch C solenoid valve (dump solenoid valve Vers. PS 12X12) SOL--205 Clutch D solenoid valve SOL--213 Power take--off solenoid valve SOL--214 Four--wheel drive solenoid valve SOL--215 Differential lock solenoid valve SOL--222 Lifting solenoid valve SOL--223 Lowering solenoid valve SOL--307 Engine shut--down solenoid valve SOL--330 80 litre supplement solenoid valve CONTROL SWITCHES SW--13 Gear lever switch SW--18 Emergency switch SW--23 Safety switch / mechanical power take--off indicator light SW--29 Front Windshield Wiper Switch SW--35 Clutch pedal switch SW--44 Rotating beacon switch SW--45 Rear wiper switch SW--59 Operator present switch SW--64 Lift--O--Matic switch SW--71 Lights switch SW--73 Hand brake switch SW--75/76/77 Key--start ignition switch /78 SW--79 Shuttle lever switch SW--80 Hydraulic power take--off switch
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
44
CODE DESCRIPTION
SW--82/83 Front loader joystick SW--97 Mechanical battery cut--out switch SW--97A Electronic battery cut--off switch SW--104 Four--wheel drive switch SW--108 Modulated PTO switch SW--112 Grille work lights switch SW--115 Differential lock switch SW--116 Cab dipped beam headlights switch SW--116A Cab dipped beam headlights switch SW--122 CAL/SEL Switch SW--125 Power take--off switch on left--hand mudguard SW--127 Power take--off switch on right--hand mudguard SW--145 Door light switch SW--158 Brake pedals not connected switch SW--164 Raise and lower switch on right--hand mudguard EDC SW--165A Electric fan switch SW--165C Air conditioner switch SW--167 Raise and lower switch on left--hand mudguard EDC SW--178 Front work lights switch SW--179 Rear work lights switch SW--209 G gear lever status switch SW--210 R1 range lever status switch SW--211 R2 range lever status switch SW--216 Differential lock warning light switch SW--303 Air filter clogged switch SW--312 Brake oil level switch SW--316 Left brake switch SW--318 Right brake switch SW--331 80 litre switch SW--296 Creeper unit lever status switch POWER SOCKETS C--21A ISO seven--pin socket C--21B North American seven--pin socket C--81A Extension with 8 Amp socket for additional electro--hydraulic functions C--84A Extension with 7--pole socket for additional electro--hydraulic functions C--88 Cigar/Cigarette Lighter C--142 8A auxiliary power socket
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
45
VERSION INDEX The following pages contain the wiring diagrams for the two versions of the cab model and the three versions of the model without the cab, specifically:
TYPES OF VERSIONS FOR TRACTORS WITH CAB VERSION
DESCRIPTION
PAGE
1
VERSION WITH POWER SHUTTLE AND ELECTRONIC LIFT
47 to 89
2
STANDARD VERSION
91 to 127
TYPES OF VERSIONS FOR TRACTORS WITHOUT CAB VERSION
DESCRIPTION
PAGE
3
VERSION WITH POWER SHUTTLE -- (ISO)
129 to 157
4
STANDARD VERSION -- (ISO)
159 to 185
5
VERSION WITH POWER SHUTTLE -- (NORTH AMERICA)
187 to 215
6
STANDARD VERSION -- (NORTH AMERICA)
217 to 243
TYPES OF VARIANTS FOR TRACTORS WITH CAB VERSION
DESCRIPTION
PAGE
A
FRONT LOADER CIRCUIT TL SERIES
244 and 245
B
ELECTRONIC BATTERY CUT--OUT CIRCUIT
246 and 247
87679925A2 - 02 - 2010
46
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
47
VERSION 1 VERSION WITH POWER SHUTTLE AND ELECTRONIC LIFT -- (Cab version)
Description
Wiring diagram circuits
Page
Diagram 1
Battery cut--out and handbrake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Diagram 2
CAN line circuit and fault diagnosis connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Diagram 3
Radio and auxiliary functions circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Diagram 4
Brakes and differential lock circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Diagram 5
Engine, sensors and transmitters circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Diagram 6
Front loader and 80 litre combined valve circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Diagram 7
Cab ventilation and air--conditioning circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Diagram 8
Instrument circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Diagram 9
Direction indicator and hazard lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Diagram 10
External lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Diagram 11
Power supplies circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Diagram 12
Rear PTO circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Diagram 13
Grid heater and engine starter circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Diagram 14
Power sockets and trailer brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Diagram 15
Windscreen and rear window washer/wiper circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Diagram 16
Work lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Diagram 17
Power Shuttle circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Diagram 18
Electronic lift circuit (EDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
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ELECTRICAL CIRCUITS COMPONENTS VERSION 1
COMPONENT C--1
NUMBER DIAGRAM 1, 4, 5, 7, 10, 11, 13, 16
DESCRIPTION Cab/engine main connection
MOD--1/3
1, 2, 4, 12, 17, 18
TCM transmission control unit
C--2
4, 5, 12, 14, 17, 18
Cab/transmission main connection
C--8
6
Cab/front loader main connection
CB--8A
6
Jumper on front loader connection
C--11
14
Cab/trailer brake main connection
C--12
7
Cab/air--conditioning main connection
SW--13
17
Gear lever switch
LMP--17
9
Front LH light
SW--18
9
Emergency switch
C--21
14
Transmission/seven--pin socket connection
C--21A
14
ISO seven--pin socket
C--21B
14
North American seven--pin socket
LMP--26
16
Work light on right handrail
MOD--27 1, 2, 4, 5, 8, 9, 12, 13, Instrument 14 LMP--28
16
Work light on left handrail
SW--29
15
Front Windshield Wiper Switch
F--30/31
11
Mega--fuse box
C--33
10, 16
C--34
11
ISO rear power socket connector/North America
SW--35
17
Clutch pedal switch
C--37
8
Extension connector ISO 11786
SW--44
3
Rotating beacon switch
SW--45
15
Rear wiper switch
C--46
1
Cab / battery cut--off cable connection
LMP--49
16
Front right work light
MOD--53
18
EDC Potentiometers panel
MOD--54
18
EDC Mouse
MOD--55
18
EDC LED panel
MOD--56
3
Radio
C--57
11
Pneumatic seat supply connector
C--58
8
Connector of fitting for ISO 11786 power socket
SW--59
8
Operator present switch
MOD--61
13
Grid heater control unit
AUD--63
3
LH speaker
87679925A2 - 02 - 2010
Engine/front lights connector
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
COMPONENT
NUMBER DIAGRAM
49
DESCRIPTION
SW--64
8
Lift--O--Matic switch
LMP--66A
10
Rear right direction indicator on cab roof
LMP--66B
16
Right rear work light
LMP--68
3
Overhead lighting
C--69
13
Grid heater relay connector (coil)
MOD--70
9
Flasher
SW--71
9
Lights switch
SW--73
1
Hand brake switch
C--75
11
Ignition switch connection
C--76
11
Ignition switch connection
C--77
11
Ignition switch connection
C--78
11
Ignition switch connection
SW--75/76/77/78
11
Key--start ignition switch
SW--79
17
Shuttle lever switch
SW--80
12
Hydraulic power take--off switch
C--81
6
Connector with 3 additional electro--hydraulic functions
C--81A
6
Extension with 8 Amp socket for additional electro--hydraulic functions
SW--82/83
6
Front loader joystick
C--88
3
Cigar/Cigarette Lighter
C--89
6
Connection of fitting for 80 litre pump variant
GND--92
3, 7, 10, 15, 16
SW--97
13
MOD--100
Cab right upright top ground Mechanical battery cut--out switch
1, 3, 4, 6, 7, 8, 9, 10, Fuse box and main relay 11, 13, 14, 15, 16, 17, 18
SW--104
4
Four--wheel drive switch
SW--108
12
Modulated PTO switch
SW--115
4
Differential lock switch
SW--116
6
Cab dipped beam headlights switch
C--117
2, 8
Diagnostic socket
LMP--121
9
RH number plate light
SW--122
8
CAL/SEL Switch
LMP--123
9
RH tail light
LMP--124
9
LH number plate light
SW--125
12
Power take--off switch on left--hand mudguard
LMP--126
9
Front RH light
SW--127
12
Power take--off switch on right--hand mudguard
D--130
6
Diode for circuit of main beam headlights on handrail lights
RLY--131
6
Front loader RL1 relay
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COMPONENT
NUMBER DIAGRAM
DESCRIPTION
RLY--132
6
Front loader RL2 relay
RLY--133
6
Front loader RL3 relay
RLY--134
6
Front loader RL4 relay (high beam headlights)
RLY--135
6
Front loader RL5 relay (high beam headlights)
GND--136
4, 14, 18
Transmission ground
M--138
15
Wiper Motor
LMP--139
16
Front left work light
C--142
3
8A auxiliary power socket
C--143
3
Right--hand rotating beacon socket
C--144
3
Left--hand rotating beacon socket
SW--145
3
Door light switch
GND--146
3, 9, 15, 16
Ground on left mudguard
M--147
15
Windscreen wiper pump
LMP--148A
10
Rear left direction indicator on cab roof
LMP--148B
16
Rear left work light on cab roof
M--149
15
Rear wiper motor
AUD--150
3
RH speaker
GND--151
3, 4, 9, 12, 15, 16, 18 Ground on right mudguard
LMP--152
9
LH tail light
RES--156
17
Clutch pedal potentiometer
SW--158
8
Brake pedals not connected switch
GND--159
1, 2, 5, 6, 7, 8, 9, 10, 11, 13, 14, 16, 17, 18
Dashboard ground
F--160
13
Grid Heater mega--fuse
LMP--161
3
Cab upright red light
LMP--162
18
EDC Potentiometer backlighting
M--163
15
Rear window wiper pump
SW--164
18
Raise and lower switch on right--hand mudguard EDC
SW--165A
7
Electric fan switch
SW--165C
7
Air conditioner switch
MOD--166
2
Key Pad (keypad)
SW--167
18
Raise and lower switch on left--hand mudguard EDC
AUD--169
16
Audible beep
LMP--170
16
Left grille work light
LMP--171
16
Right grille work light
LMP--172
10
Left--hand light
LMP--173
10
Right--hand light
RES--174
13
Inlet Grid Heater
RLY--175
13
Grid heater relay
SW--178
16
Front work lights switch
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
COMPONENT
NUMBER DIAGRAM
51
DESCRIPTION
SW--179
16
Rear work lights switch
LMP--180
6
Left--hand light on handrail
LMP--181
6
Right--hand light on handrail
M--188A
7
Electric fan 1
M--188B
7
Electric fan 2
SEN--190
7
Electronic thermostat
SEN--196
14
Actuated trailer brake warning light pressure switch 10 bar (10.13 kg/cm)
SOL--197
14
Trailer brake solenoid valves
SEN--198
14
Trailer brake circuit safety pressure switch 3.5 bar (3.57 kg/cm)
SEN--201
17
Transmission oil temperature sensor
SOL--202
17
Clutch A solenoid valve
SOL--203
17
Clutch B solenoid valve
SOL--204
17
Clutch C solenoid valve (dump solenoid valve Vers. PS 12X12)
SOL--205
17
Clutch D solenoid valve
SEN--206
17
Safety pressure switch clutch A
SEN--207
17
Safety pressure switch clutch B
SW--209
17
G gear lever status switch
SW--210
17
R1 range lever status switch
SW--211
17
R2 range lever status switch
SEN--212
5
Fuel level sensor
SOL--213
12
Power take--off solenoid valve
SOL--214
4
Four--wheel drive solenoid valve
SOL--215
4
Differential lock solenoid valve
SW--216
4
Differential lock warning light switch
SEN--217
17
Theoretical wheel speed sensor
SEN--217B
17
Theoretical wheel speed sensor (PS version with creeper unit 20X20)
SEN--218
12
PTO speed sensor
SEN--221
18
RH draft sensor
SOL--222
18
Lifting solenoid valve
SOL--223
18
Lowering solenoid valve
SEN--224
18
Arms position sensor
SEN--225
18
LH draft sensor
SEN--227
18
Radar
SW--296
17
Creeper unit lever status switch
ALT--301/314
13
Alternator
M--302/308
13
Starter motor
SW--303
5
Air filter clogged switch
M--304
7
Air conditioning compressor
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
52
COMPONENT
NUMBER DIAGRAM
DESCRIPTION
SEN--305
5
Sediment filter
SEN--306
5
Coolant temperature sensor
SOL--307
11
Engine shut--down solenoid valve
SEN--309
5
Thermometric sensor
MOD--310
5
Injection pump advance device
SEN--311
5
Gearbox oil pressure switch
SW--312
5
Brake oil level switch
SEN--313
5
Engine oil pressure switch
SEN--315
5
Engine rpm sensor
SW--316
4
Left brake switch
SEN--317
7
Air drier filter
SW--318
4
Right brake switch
C--319
1
Control unit memory connector
C--320
13
Fuse box protecting memory and safety systems
F--320
13
Fuse protecting memory and safety systems
GND--325
13
Battery ground
SOL--330
6
80 litre supplement solenoid valve
SW--331
6
80 litre switch
SEN--340
14
Air brake pressure switch
BAT--500
13
Battery
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87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
54
BATTERY CUT--OUT AND HANDBRAKE CIRCUIT (Diagram 1)
C--1 Cab/engine main connection MOD--1/3 TCM transmission control unit MOD--27 Instrument C--46 Cab/battery cut--off cable connection SW--73 Hand brake switch MOD--100 Fuse box and main relay F--12 (+12V MF2 -- 70A) -- Control unit for transmission, instrument, handbrake indicator light, fault diagnosis socket, car radio GND--159 Dashboard ground C--319 Control unit memory connector
* **
Jumper valid on model without mechanical battery cut--out. For version with electronic battery cut--off refer to the circuit on page 247.
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
55
BATTERY CUT--OUT AND HANDBRAKE CIRCUIT -- DIAGRAM 1
** ** *
MPM0745A
87679925A2 - 02 - 2010
56
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 DIAGNOSTICS CONNECTION AND CAN LINE CIRCUIT
(Diagram 2)
MOD--1/3 TCM transmission control unit MOD--27 Instrument C--117 Diagnostic socket GND--159 Dashboard ground MOD--166 Key Pad (keypad)
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
57
DIAGNOSTICS CONNECTION AND CAN LINE CIRCUIT -- DIAGRAM 2
MPM0746
87679925A1 - 02 - 2008
58
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 RADIO AND AUXILIARY FUNCTIONS CIRCUIT (Diagram 3)
SW--44 Rotating beacon switch MOD--56 Radio AUD--63 LH speaker LMP--68 Overhead lighting C--88 Cigar/Cigarette Lighter GND--92 Cab right upright top ground LMP--98 Right--hand rotating beacon LMP--99 Left--hand rotating beacon MOD--100 Fuse box and main relay F--8 (+12V MF2 -- 70A) -- Rotating beacon, overhead lighting F--9 (+12V MF2 -- 70A) -- Horn, 8A power socket, cigar lighter C--142 8A auxiliary power socket C--143 Right--hand rotating beacon socket C--144 Left--hand rotating beacon socket SW--145 Door light switch GND--146 Ground on left mudguard AUD--150 RH speaker GND--151 Ground on right mudguard LMP161 Cab upright red light
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
59
RADIO AND AUXILIARY FUNCTIONS CIRCUIT -- DIAGRAM 3
MPM1208A
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
60
BRAKES AND DIFFERENTIAL LOCK CIRCUIT (Diagram 4)
C--1 Cab/engine main connection MOD--1/3 TCM transmission control unit C--2 Cab/transmission main connection MOD--27 Instrument MOD--100 Fuse box and main relay F--3 (+30 Key) -- Brake pressure switches SW--104 Four--wheel drive switch SW--115 Differential lock switch GND--136 Transmission ground GND--151 Ground on right mudguard SOL--214 Four--wheel drive solenoid valve SOL--215 Differential lock solenoid valve SW--216 Differential lock warning light switch SW--316 Left brake switch SW--318 Right brake switch
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
61
BRAKES AND DIFFERENTIAL LOCK CIRCUIT -- DIAGRAM 4
MPM0748
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
62
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT (Diagram 5)
C--1 Cab/engine main connection C--2 Cab/transmission main connection MOD--27 Instrument GND--159 Dashboard ground SEN--212 Fuel level sensor SW--303 Air filter clogged switch SEN--305 Sediment filter SEN--306 Coolant temperature sensor SEN--309 Thermometric sensor MOD--310 Injection pump advance device SEN--311 Gearbox oil pressure switch SW--312 Brake fluid level switch SEN--313 Engine oil pressure switch SEN--315 Engine rpm sensor
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
63
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT -- DIAGRAM 5
1073 N 1.0
MPM0749A
87679925A2 - 02 - 2010
7--AN
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
64
FRONT LOADER AND 80 LITRE COMBINED VALVE CIRCUIT
(Diagram 6)
C--8 Cab/front loader main connection CB--8A Jumper on front loader connection (to be inserted if there is no front loader) C--81 Connector with 3 additional electro--hydraulic functions. C--81A Extension with 8 Amp socket for additional electro--hydraulic functions. SW--82/83 Front loader joystick C--89 Connection of fitting for 80 litre pump variant MOD--100 Fuse box and main relay F--15 (+30 Key)-- Front loader circuit SW--116 Cab dipped beam headlights switch D--130 Diode for circuit of main beam headlights on handrail lights RLY--131 Front loader RL1 relay RLY--132 Front loader RL2 relay RLY--133 Front loader RL3 relay RLY--134 Front loader RL4 relay (high beam headlights) RLY--135 Front loader RL5 relay (high beam headlights) GND--159 Dashboard ground LMP--180 Left--hand light on handrail LMP--181 Right--hand light on handrail SOL--330 80 litre supplement solenoid valve SW--331 80 litre switch
* Jumper to be inserted when there is no front loader. *** For version with new front loader TL series (from chassis frame no. Z9JH18085), please refer to the circuit on page 245.
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
65
FRONT LOADER AND 80 LITRE COMBINED VALVE CIRCUIT -- DIAGRAM 6
1086 N 1.0 1
1080 N 1.5
3
17 V 1.5
2
134B LR 1.5
D--130 134A GN 1.5 130B-1
** *
130A-1
1085 N 0.5
* 5
13 H 1.5
4
144 HV 1.5
823B RN 1.0
1087 N 1.0 823A RN 1.0
823 RN 1.5 1084 N 0.5
166H ZB 0.5
805A BR 0.5
805 ZR 0.5 813 Z 0.5
6
166C ZB 0.5
166A ZB 1.0 166F ZB 1.0 1083 N 0.5
814 BN 0.5
166E ZB 1.0 1082 N 0.5
166D ZB 0.5
166C ZB 1.0 1081 N 0.5
812 ZN 0.5
L 1.0
809 L 1.0 163 Z 1.0
810 H 1.0
H 1.0
811 V 1.0
V 1.0
C--81
MPM0750A
87679925A2 - 02 - 2010
C--81A
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
66
CAB VENTILATION AND AIR--CONDITIONING CIRCUIT (Diagram 7)
C--1 Cab/engine main connection C--12 Cab/air--conditioning main connection GND--92 Cab right upright top ground MOD--100 Fuse box and main relay F--6 (+12V MF2 -- 70A) --Air--conditioner compressor circuit RLY--9 Air conditioner compressor RLY--10 Air--conditioner circuit GND--159 Dashboard ground SW--165A Electric fan switch SW--165C Air conditioner switch M--188A Electric fan 1 M--188B Electric fan 2 SEN--190 Electronic thermostat M--304 Air conditioning compressor SEN--317 Air drier filter
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
67
CAB VENTILATION AND AIR--CONDITIONING CIRCUIT -- DIAGRAM 7
1073 N 1.0
MPM0751A
87679925A2 - 02 - 2010
5--AN
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
68
INSTRUMENT CIRCUIT
(Diagram 8)
MOD--27 Instrument C--37 Extension connector ISO 11786 C--58 Connector of fitting for ISO 11786 power socket SW--59 Operator present switch SW--64 Lift--O--Matic switch MOD--100 Fuse box and main relay F--17 (+30 Key)-- ISO 11786 power socket C--117 Diagnostic socket SW--122 CAL/SEL Switch SW--158 Brake pedals not connected switch GND--159 Dashboard ground
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
69
INSTRUMENT CIRCUIT -- DIAGRAM 8
MPM0752
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
70
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (Diagram 9)
LMP--17 Front LH light SW--18 Emergency switch MOD--27 Instrument MOD--70 Flasher SW--71 Lights switch MOD--100 Fuse box and main relay F--7 (+12V MF2 -- 70A) -- Direction indicator and hazard lights F--16 (+12V MF2 -- 70A) -- Front right--hand and rear left--hand side lights, cigar lighter indicator light F--29 (+12V MF2 -- 70A) -- Side lights, controls lighting F--30 (+12V MF2 -- 70A) -- Front left--hand and rear right--hand side lights, controls and instruments lighting RLY--2 Side lights circuit RLY--5 Brake lights circuit LMP--121 RH number plate light LMP--123 RH tail light LMP--124 LH number plate light LMP--126 Front RH light GND--146 Ground on left mudguard GND--151 Ground on right mudguard LMP--152 LH tail light GND--159 Dashboard ground
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
71
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT -- DIAGRAM 9
MPM0753
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
72
EXTERNAL LIGHTS CIRCUIT (Diagram 10)
C--1 Cab/engine main connection C--33 Engine/front lights connector LMP--66A Rear right direction indicator on cab roof GND--92 Cab right upright top ground MOD--100 Fuse box and main relay F--33 (+12V MF2 -- 70A) -- Full beam headlights F--34 (+12V MF2 -- 70A) -- Dipped beam headlights RLY--3 Full beam headlight circuit RLY--4 Dipped beam headlight circuit LMP--148A Rear left direction indicator on cab roof GND--159 Dashboard ground LMP--172 Left--hand light LMP--173 Right--hand light
87679925A1 - 02 - 2008
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73
EXTERNAL LIGHTS CIRCUIT -- DIAGRAM 10
MPM1209A
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
74
POWER SUPPLIES CIRCUIT (Diagram 11)
C--1 Cab/engine main connection F--30/31 Mega--fuse box F--1 25A (ISO) / 40A (North America) power socket F--2 Power supply fuses No. 6 -- 7 -- 8 -- 9 -- 12 -- 33 -- 34, side lights relay (fuses 16 -- 29 -- 30) F--3 Power supply +30 starter switch (fuses no. 1 -- 3 -- 5 -- 15 -- 17 -- 18 -- 19 -20 -- 21 -- 22 -- 26 -- 27 -- 28 -- 35) and +30 starter relay F--4 Power supply fuses No. 36 -- 37 -- 38 -- 40 C--34 ISO rear power socket connector/North America C--57 Pneumatic seat supply connector C--75 Ignition switch connection C--76 Ignition switch connection C--77 Ignition switch connection C--78 Ignition switch connection SW--75/76/77/78 Key--start ignition switch MOD--100 Fuse box and main relay F--1 (+30 Key) -- Instrument (ADIC) F--2 (+30 Key) -- Turn indicators, four--wheel drive circuit, differential lock and power take--off F--5 (+30 Key) -- Engine stop circuit F--18 (+30 Key) -- Engine and transmission services F--22 (+30 Key) -- Ventilation/air--conditioning unit, radio F--31 Memory and air--conditioner circuit F--32 Cab main F--35 (+30 Key)-- Brake lights, seat GND--159 Dashboard ground SOL--307 Engine shut--down solenoid valve
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
75
POWER SUPPLIES CIRCUIT -- DIAGRAM 11
MPM0754
87679925A - 12 - 2007
76
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 REAR POWER TAKE--OFF CIRCUIT (Diagram 12)
MOD--1/3 TCM transmission control unit C--2 Cab/transmission main connection MOD--27 Instrument SW--80 Hydraulic power take--off switch SW--108 Modulated PTO switch SW--125 Power take--off switch on left--hand mudguard SW--127 Power take--off switch on right--hand mudguard GND--151 Ground on right mudguard SOL--213 PTO solenoid valve SEN--218 PTO speed sensor
87679925A - 12 - 2007
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77
REAR PTO CIRCUIT -- DIAGRAM 12
MPM0755
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
78
GRID HEATER AND ENGINE STARTER CIRCUIT (Diagram 13)
C--1 Cab/engine main connection MOD--27 Instrument MOD--61 Grid heater control unit C--69 Grid heater relay connector (coil) SW--97 Mechanical battery cut--out switch MOD--100 Fuse box and main relay RLY--MR1 Starter motor circuit GND--159 Dashboard ground F--160 Grid Heater mega--fuse RES--174 Inlet Grid Heater RLY--175 Grid heater relay ALT--301/314 Alternator M--302/308 Starter motor C--320 Fuse box protecting memory and safety systems F--320 Fuse protecting memory and safety systems GND--325 Battery ground BAT--500 Battery
87679925A2 - 02 - 2010
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79
GRID HEATER AND ENGINE STARTER CIRCUIT -- DIAGRAM 13
1250 RN 1.0
MPM0756A
87679925A2 - 02 - 2010
1--AQ
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
80
POWER SOCKET AND TRAILER BRAKE CIRCUIT (Diagram 14)
C--2 Cab/transmission main connection C--11 Cab/trailer brake main connection C--21 Transmission/seven--pin socket connection C--21A ISO seven--pin socket C--21B North American seven--pin socket MOD--27 Instrument MOD--100 Fuse box and main relay F--27 (+30 Key) -- Trailer brake circuit RLY--1 Parking Brake RLY--27 Trailer brake circuit RLY--28 Trailer brake circuit GND--136 Transmission ground GND--159 Dashboard ground SEN--196 Actuated trailer brake warning light pressure switch 10 bar (10.13 kg/cm) SOL--197 Trailer brake solenoid valves SEN--198 Trailer brake circuit safety pressure switch 3.5 bar (3.57 kg/cm) SEN--340 Air brake pressure switch
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
81
POWER SOCKET AND TRAILER BRAKE CIRCUIT -- DIAGRAM 14
MPM0757
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
82
WINDSCREEN AND REAR WINDOW WASHER/WIPER CIRCUIT (Diagram 15)
SW--29 Front wiper switch SW--45 Rear wiper switch GND--92 Cab right upright top ground MOD--100 Fuse box and main relay F--19 (+30 Key) -- Rear wiper and washer pump F--21 (+30 Key) -- Front wiper and washer pump M--138 Wiper motor GND--146 Ground on left mudguard M--147 Windscreen wiper pump M--149 Rear wiper motor GND--151 Ground on right mudguard M--163 Rear window wiper pump
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
83
WIPER/WASHER CIRCUIT -- DIAGRAM 15
MPM0758
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
84
WORK LAMP CIRCUIT (Diagram 16)
C--1 Cab/engine main connection LMP--26 Work light on right handrail LMP--28 Work light on left handrail C--33 Engine/front lights connector LMP--49 Front right work light on cab (outside) LMP--66B Right rear work light GND--92 Cab right upright top ground MOD--100 Fuse box and main relay F--25 (+12V MF4 -- 50A) -- Cab front work lights (inside) F--36 (+12V MF4 -- 50A) -- Front swivel work lights F--37 (+12V MF4 -- 50A) -- Cab front work lights F--38 (+12V MF4 -- 50A) -- Front work lights on grab handles F--40 (+12V MF4 -- 50A) -- Cab rear work lights RLY--6 Front swivel lights circuit RLY--11 Cab front work lights circuit RLY--15 Cab front work lights circuit (inside) RLY--12 Front work lights circuit on grab handle RLY--14 Cab rear lights circuit LMP--139 Front left work light on cab (outside) GND--146 Ground on left mudguard LMP--148B Rear left work light on cab roof GND--151 Ground on right mudguard GND--159 Dashboard ground AUD--169 Audible beep LMP--170 Left grille work light LMP--171 Right grille work light SW--178 Front work lights switch SW--179 Rear work lights switch
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
85
WORK LAMP CIRCUIT -- DIAGRAM 16
MPM1210A
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
86
POWER SHUTTLE CIRCUIT (Diagram 17)
PS PS PS 12X12* 20X20** 24X24* MOD--1/3
YES
YES
YES
TCM transmission control unit
C--2
YES
YES
YES
Cab/transmission main connection
SW--13
YES
YES
YES
Gear lever switch
SW--35
YES
YES
YES
Clutch pedal switch
SW--79
YES
YES
YES
Shuttle lever switch
MOD--100
YES
YES
YES
Fuse box and main relay F--23 (+30 Key) -- Transmission control unit F--24 (+30 Key) -- Power Shuttle lever F--28 (+30 Key) -- Starter safety circuit
RES--156
YES
YES
YES
Clutch pedal potentiometer
GND--159
YES
YES
YES
Dashboard ground
SEN--201
YES
YES
YES
Transmission oil temperature sensor
SOL--202
YES
YES
YES
Clutch A solenoid valve
SOL--203
YES
YES
YES
Clutch B solenoid valve
SOL--204
YES
YES
YES
Clutch C solenoid valve (dump Vers. PS 12X12 and 20X20)
SOL--205
NO
NO
YES
Clutch D solenoid valve
SEN--206
NO
NO
YES
Safety pressure switch clutch A
SEN--207
NO
NO
YES
Safety pressure switch clutch B
SW--209
YES
YES
YES
G gear lever status switch
SW--210
YES
YES
YES
R1 range lever status switch
SW--211
YES
YES
YES
R2 range lever status switch
SEN--217
YES
NO
YES
Theoretical wheel speed sensor (Vers. PS 12X12 and 24X24)
SEN--217B
NO
YES
NO
Theoretical wheel speed sensor (Vers. PS 20X20)
SW--296
NO
YES
NO
Creeper unit lever status switch
*
On the Power Shuttle 12X12 and 24X24 version you fit the same cable as the transmission, it is identical.
** On the Power Shuttle 20X20 version you fit a specific transmission cable. Y
On the Power Shuttle version with Creeper Unit 20X20 there is no line 20F on node SA41.
YY
On the Power Shuttle version with Creeper Unit 20X20 line 261 is added to node SA93.
YYY
On the Power Shuttle version with Creeper Unit 20X20, in the diagram, there is line 4M, otherwise, for the other versions, there is line 4C.
YYYY
On all the versions when there is no EDC there are no calls to table 18.
YYYYY On the Power Shuttle version with Creeper Unit 20X20 connect the line of sensor SEN--217B, otherwise connect the line of sensor SEN--217. 87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
87
POWER SHUTTLE CIRCUIT -- DIAGRAM 17
MMP0356A
87679925A2 - 02 - 2010
88
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 ELECTRONIC LIFT CIRCUIT (EDC)
(Diagram 18)
MOD--1/3 TCM transmission control unit C--2 Cab/transmission main connection MOD--53 EDC Potentiometers panel MOD--54 EDC Mouse MOD--55 EDC LED panel MOD--100 Fuse box and main relay F--4 (+15 Key) -- Electronic lift circuit (EDC) GND--136 Transmission ground GND--151 Ground on right mudguard GND--159 Dashboard ground LMP--162 EDC Potentiometer backlighting SW--184 Raise and lower switch on right--hand mudguard EDC SW--187 Raise and lower switch on left--hand mudguard EDC SEN--221 RH draft sensor SOL--222 Lifting solenoid valve SOL--223 Lowering solenoid valve SEN--224 Arms position sensor SEN--225 LH draft sensor SEN--227 Radar
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
89
ELECTRONIC LIFT CIRCUIT (EDC) -- DIAGRAM 18
MPM0761
87679925A - 12 - 2007
90
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
91
VERSION 2 STANDARD VERSION -- (Cab version)
Description
Wiring diagram circuits
Page
Diagram 1
Battery cut--out and handbrake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Diagram 2
CAN line circuit and fault diagnosis connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Diagram 3
Radio and auxiliary functions circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Diagram 4
Brakes and differential lock circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Diagram 5
Engine, sensors and transmitters circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Diagram 6
Front loader and 80 litre combined valve circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Diagram 7
Cab ventilation and air--conditioning circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Diagram 8
Instrument circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Diagram 9
Direction indicator and hazard lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Diagram 10
External lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Diagram 11
Power supplies circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Diagram 12
Rear PTO circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Diagram 13
Grid heater and engine starter circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Diagram 14
Power sockets and trailer brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Diagram 15
Windscreen and rear window washer/wiper circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Diagram 16
Work lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
92
ELECTRICAL CIRCUITS COMPONENTS VERSION 2
COMPONENT
NUMBER DIAGRAM
DESCRIPTION
C--1
1, 4, 5, 7, 10, 11, 13, 16
Cab/engine main connection
C--2
4, 5, 12, 13, 14
Cab/transmission main connection
C--8
6
Cab/front loader main connection
CB--8A
6
Jumper on front loader connection
C--11
14
Cab/trailer brake main connection
C--12
7
Cab/air--conditioning main connection
LMP--17
9
Front LH light
SW--18
9
Emergency switch
C--21
14
Transmission/seven--pin socket connection
C--21A
14
ISO seven--pin socket
C--21B
14
North American seven--pin socket
C--23
12, 13
Connection for switch of indicator light/mechanical power take--off safety device
SW--23
12, 13
Safety switch / mechanical power take--off indicator light
LMP--26
16
Work light on right handrail
MOD--27 1, 2, 4, 5, 8, 9, 12, 13, Instrument 14 LMP--28
16
Work light on left handrail
SW--29
15
Front Windshield Wiper Switch
F--30/31
11
Mega--fuse box
C--33
10, 16
C--34
11
ISO rear power socket connector/North America
SW--35
13
Clutch pedal switch
C--37
8
Extension connector ISO 11786
SW--44
3
Rotating beacon switch
SW--45
15
Rear wiper switch
C--46
1
Cab / battery cut--off cable connector
LMP--49
16
Front right work light
MOD--56
3
Radio
C--57
11
Pneumatic seat supply connector
C--58
8
Connector of fitting for ISO 11786 power socket
SW--59
8
Operator present switch
MOD--61
13
Grid heater control unit
AUD--63
3
LH speaker
SW--64
8
Lift--O--Matic switch
87679925A2 - 02 - 2010
Engine/front lights connector
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
93
LMP--66A
10
Rear right direction indicator on cab roof
LMP--66B
16
Right rear work light
LMP--68
3
Overhead lighting
C--69
13
Grid heater relay connector (coil)
MOD--70
9
Flasher
SW--71
9
Lights switch
SW--73
1
Hand brake switch
C--75
11
Ignition switch connection
C--76
11
Ignition switch connection
C--77
11
Ignition switch connection
C--78
11
Ignition switch connection
SW--75/76/77/78
11
Key--start ignition switch
SW--80
12
Hydraulic power take--off switch
C--81
6
Connector with 3 additional electro--hydraulic functions
C--81A
6
Extension with 8 Amp socket for additional electro--hydraulic functions
SW--82/83
6
Front loader joystick
C--88
3
Cigar/Cigarette Lighter
C--89
6
Connection of fitting for 80 litre pump variant
GND--92
3, 7, 10, 15, 16
Cab right upright top ground
LMP--95
16
Front right work light on cab (inside)
LMP--96
16
Front left work light on cab (inside)
SW--97
13
Mechanical battery cut--out switch
LMP--98
3
Right--hand rotating beacon
LMP--99
3
Left--hand rotating beacon
1, 3, 4, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16
Fuse box and main relay
SW--104
4
Four--wheel drive switch
SW--115
4
Differential lock switch
SW--116
6
Cab dipped beam headlights switch
MOD--100
C--117
2, 8
Diagnostic socket
LMP--121
9
RH number plate light
SW--122
8
CAL/SEL Switch
LMP--123
9
RH tail light
LMP--124
9
LH number plate light
LMP--126
9
Front RH light
D--130
6
Diode for circuit of main beam headlights on handrail lights
RLY--131
6
Front loader RL1 relay
RLY--132
6
Front loader RL2 relay
RLY--133
6
Front loader RL3 relay
RLY--134
6
Front loader RL4 relay (high beam headlights)
RLY--135
6
Front loader RL5 relay (high beam headlights)
GND--136
4, 12, 14
Transmission ground
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
94 M--138
15
Wiper Motor
LMP--139
16
Front left work light on cab (outside)
C--142
3
8A auxiliary power socket
C--143
3
Right--hand rotating beacon socket
C--144
3
Left--hand rotating beacon socket
SW--145
3
Door light switch
GND--146
3, 9, 15, 16
Ground on left mudguard
M--147
15
Windscreen wiper pump
LMP--148A
10
Rear left direction indicator on cab roof
LMP--148B
16
Rear left work light on cab roof
M--149
15
Rear wiper motor
AUD--150
3
RH speaker
GND--151
3, 4, 9, 15, 16
LMP--152
9
LH tail light
SW--158
8
Brake pedals not connected switch
GND--159
1, 2, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 16
Ground on right mudguard
Dashboard ground
F--160
13
Grid Heater mega--fuse
LMP--161
3
Cab upright red light
M--163
15
Rear window wiper pump
SW--165A
7
Electric fan switch
SW--165C
7
Air conditioner switch
MOD--166
2
Key Pad (keypad)
AUD--169
16
Audible beep
LMP--170
16
Left grille work light
LMP--171
16
Right grille work light
LMP--172
10
Left--hand light
LMP--173
10
Right--hand light
RES--174
13
Inlet Grid Heater
RLY--175
13
Grid heater relay
SW--178
16
Front work lights switch
SW--179
16
Rear work lights switch
LMP--180
6
Left--hand light on handrail
LMP--181
6
Right--hand light on handrail
M--188A
7
Electric fan 1
M--188B
7
Electric fan 2
SEN--190
7
Electronic thermostat
SEN--196
14
Actuated trailer brake warning light pressure switch 10 bar (10.13 kg/cm)
SOL--197
14
Trailer brake solenoid valves
SEN--198
14
Trailer brake circuit safety pressure switch 3.5 bar (3.57 kg/cm)
SEN--212
5
Fuel level sensor
SOL--213
12
Power take--off solenoid valve
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
95
SOL--214
4
Four--wheel drive solenoid valve
SOL--215
4
Differential lock solenoid valve
SW--216
4
Differential lock warning light switch
SEN--217
5
Theoretical wheel speed sensor
SEN--218
12
PTO speed sensor
ALT--301/314
13
Alternator
M--302/308
13
Starter motor
SW--303
5
Air filter clogged switch
M--304
7
Air conditioning compressor
SEN--305
5
Sediment filter
SEN--306
5
Coolant temperature sensor
SOL--307
11
Engine shut--down solenoid valve
SEN--309
5
Thermometric sensor
MOD--310
5
Injection pump advance device
SEN--311
5
Gearbox oil pressure switch
SW--312
5
Brake oil level switch
SEN--313
5
Engine oil pressure switch
SEN--315
5
Engine rpm sensor
SW--316
4
Left brake switch
SEN--317
7
Air drier filter
SW--318
4
Right brake switch
C--319
1
Control unit memory connector
C--320
13
Fuse box protecting memory and safety systems
F--320
13
Fuse protecting memory and safety systems
GND--325
13
Battery ground
SOL--330
6
80 litre supplement solenoid valve
SW--331
6
80 litre switch
SEN--340
14
Air brake pressure switch
BAT--500
13
Battery
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
96
BATTERY CUT--OUT AND HANDBRAKE CIRCUIT (Diagram 1)
C--1 Cab/engine main connection MOD--27 Instrument C--46 Cab/battery cut--off connector SW--73 Hand brake switch MOD--100 Fuse box and main relay F--12 (+12V MF2 -- 70A) -- Control unit for transmission, instrument, handbrake indicator light, fault diagnosis socket, car radio GND--159 Dashboard ground C--319 Control unit memory connector
* **
Jumper valid on model without mechanical battery cut--out. For version with electronic battery cut--off refer to the circuit on page 247.
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
97
BATTERY CUT--OUT AND HANDBRAKE CIRCUIT -- DIAGRAM 1
** ** *
MPM0729A
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
98
DIAGNOSTICS CONNECTION AND CAN LINE CIRCUIT (Diagram 2)
MOD--27 Instrument C--117 Diagnostic socket GND--159 Dashboard ground MOD--166 Key Pad (keypad)
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
99
DIAGNOSTICS CONNECTION AND CAN LINE CIRCUIT -- DIAGRAM 2
MPM0730
87679925A1 - 02 - 2008
100
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 RADIO AND AUXILIARY FUNCTIONS CIRCUIT (Diagram 3)
SW--44 Rotating beacon switch MOD--56 Radio AUD--63 LH speaker LMP--68 Overhead lighting C--88 Cigar/Cigarette Lighter GND--92 Cab right upright top ground LMP--98 Right--hand rotating beacon LMP--99 Left--hand rotating beacon MOD--100 Fuse box and main relay F--8 (+12V MF2 -- 70A) -- Rotating beacon, overhead lighting F--9 (+12V MF2 -- 70A) -- Horn, 8A power socket, cigar lighter C--142 8A auxiliary power socket C--143 Right--hand rotating beacon socket C--144 Left--hand rotating beacon socket SW--145 Door light switch GND--146 Ground on left mudguard AUD--150 RH speaker GND--151 Ground on right mudguard LMP161 Cab upright red light
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
101
RADIO AND AUXILIARY FUNCTIONS CIRCUIT -- DIAGRAM 3
MPM1211A
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
102
BRAKES AND DIFFERENTIAL LOCK CIRCUIT (Diagram 4)
C--1 Cab/engine main connection C--2 Cab/transmission main connection MOD--27 Instrument MOD--100 Fuse box and main relay F--3 (+30 Key) -- Brake pressure switches F--20 (+30 Key) -- Four--wheel drive and differential lock circuit RLY--17 4WD, differential lock circuit RLY--18 Differential lock circuit RLY--19 Differential lock circuit RLY--20 4WD circuit SW--104 Four--wheel drive switch SW--115 Differential lock switch GND--136 Transmission ground GND--151 Ground on right mudguard GND--159 Dashboard ground SOL--214 Four--wheel drive solenoid valve SOL--215 Differential lock solenoid valve SW--216 Differential lock warning light switch SW--316 Left brake switch SW--318 Right brake switch
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
103
BRAKES AND DIFFERENTIAL LOCK CIRCUIT -- DIAGRAM 4
MPM0732
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
104
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT (Diagram 5)
C--1 Cab/engine main connection C--2 Cab/transmission main connection MOD--27 Instrument GND--159 Dashboard ground SEN--212 Fuel level sensor SEN--217 Theoretical wheel speed sensor SW--303 Air filter clogged switch SEN--305 Sediment filter SEN--306 Coolant temperature sensor SEN--309 Thermometric sensor MOD--310 Injection pump advance device SEN--311 Gearbox oil pressure switch SW--312 Brake fluid level switch SEN--313 Engine oil pressure switch SEN--315 Engine rpm sensor
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
105
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT -- DIAGRAM 5
1073 N 1.0
MPM0733A
87679925A2 - 02 - 2010
7--AN
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
106
FRONT LOADER AND 80 LITRE COMBINED VALVE CIRCUIT
(Diagram 6)
C--8 Cab/front loader main connection CB--8A Jumper on front loader connection (to be inserted if there is no front loader) C--81 Connector with 3 additional electro--hydraulic functions. SOL--81A Extension with 8 Amp socket for additional electro--hydraulic functions. SW--82/83 Front loader joystick C--89 Connection of fitting for 80 litre pump variant MOD--100 Fuse box and main relay F--15 (+30 Key)-- Front loader circuit SW--116 Cab dipped beam headlights switch D--130 Diode for circuit of main beam headlights on handrail lights RLY--131 Front loader RL1 relay RLY--132 Front loader RL2 relay RLY--133 Front loader RL3 relay RLY--134 Front loader RL4 relay (high beam headlights) RLY--135 Front loader RL5 relay (high beam headlights) GND--159 Dashboard ground LMP--180 Left--hand light on handrail LMP--181 Right--hand light on handrail SOL--330 80 litre supplement solenoid valve SW--331 80 litre switch
* Jumper to be inserted when there is no front loader. *** For version with new front loader TL series (from chassis frame no. Z9JH18085), please refer to the circuit on page 245.
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
107
FRONT LOADER AND 80 LITRE COMBINED VALVE CIRCUIT -- DIAGRAM 6
1086 N 1.0 1
1080 N 1.5
3
17 V 1.5
2
134B LR 1.5
D--130 134A GN 1.5 130B-1
130A-1
1085 N 0.5
*
823B RN 1.0
5
13 H 1.5
4
144 HV 1.5
1087 N 1.0 823A RN 1.0
823 RN 1.5 1084 N 0.5
** *
166H ZB 0.5
805A BR 0.5
805 ZR 0.5 813 Z 0.5
6
166C ZB 0.5
166A ZB 1.0 166F ZB 1.0 1083 N 0.5
814 BN 0.5
166E ZB 1.0 1082 N 0.5
166D ZB 0.5
166C ZB 1.0 1081 N 0.5
812 ZN 0.5
L 1.0
809 L 1.0 163 Z 1.0
810 H 1.0
H 1.0
811 V 1.0
V 1.0
C--81
MPM0734A
87679925A2 - 02 - 2010
C--81A
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
108
CAB VENTILATION AND AIR--CONDITIONING CIRCUIT (Diagram 7)
C--1 Cab/engine main connection C--12 Cab/air--conditioning main connection GND--92 Cab right upright top ground MOD--100 Fuse box and main relay F--6 (+12V MF2 -- 70A) --Air--conditioner compressor circuit RLY--9 Air conditioner compressor RLY--10 Air--conditioner circuit GND--159 Dashboard ground SW--165A Electric fan switch SW--165C Air conditioner switch M--188A Electric fan 1 M--188B Electric fan 2 SEN--190 Electronic thermostat M--304 Air conditioning compressor SEN--317 Air drier filter
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
109
CAB VENTILATION AND AIR--CONDITIONING CIRCUIT -- DIAGRAM 7
1073 N 1.0
MPM0735A
87679925A2 - 02 - 2010
5--AN
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
110
INSTRUMENT CIRCUIT (Diagram 8)
MOD--27 Instrument C--37 Extension connector ISO 11786 C--58 Connector of fitting for ISO 11786 power socket SW--59 Operator present switch SW--64 Lift--O--Matic switch MOD--100 Fuse box and main relay F--17 (+30 Key)-- ISO 11786 power socket C--117 Diagnostic socket SW--122 CAL/SEL Switch SW--158 Brake pedals not connected switch GND--159 Dashboard ground
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
111
INSTRUMENT CIRCUIT -- DIAGRAM 8
MPM0736
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
112
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (Diagram 9)
LMP--17 Front LH light SW--18 Emergency switch MOD--27 Instrument MOD--70 Flasher SW--71 Lights switch MOD--100 Fuse box and main relay F--7 (+12V MF2 -- 70A) -- Direction indicator and hazard lights F--16 (+12V MF2 -- 70A) -- Front right--hand and rear left--hand side lights, cigar lighter indicator light F--29 (+12V MF2 -- 70A) -- Side lights, controls lighting F--30 (+12V MF2 -- 70A) -- Front left--hand and rear right--hand side lights, controls and instruments lighting RLY--2 Side lights circuit RLY--5 Brake lights circuit LMP--121 RH number plate light LMP--123 RH tail light LMP--124 LH number plate light LMP--126 Front RH light GND--146 Ground on left mudguard GND--151 Ground on right mudguard LMP--152 LH tail light GND--159 Dashboard ground
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
113
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT -- DIAGRAM 9
MPM0737
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
114
EXTERNAL LIGHTS CIRCUIT (Diagram 10)
C--1 Cab/engine main connection C--33 Engine/front lights connector GND--92 Cab right upright top ground MOD--100 Fuse box and main relay F--33 (+12V MF2 -- 70A) -- Full beam headlights F--34 (+12V MF2 -- 70A) -- Dipped beam headlights RLY--3 Full beam headlight circuit RLY--4 Dipped beam headlight circuit LMP--148A Rear left direction indicator on cab roof GND--159 Dashboard ground LMP--172 Left--hand light LMP--173 Right--hand light
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
115
EXTERNAL LIGHTS CIRCUIT -- DIAGRAM 10
MPM1212A
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
116
POWER SUPPLIES CIRCUIT (Diagram 11)
C--1 Cab/engine main connection F--30/31 Mega--fuse box F--1 25A (ISO) / 40A (North America) power socket F--2 Power supply fuses No. 6 -- 7 -- 8 -- 9 -- 12 -- 33 -- 34, side lights relay (fuses 16 -- 29 -- 30) F--3 Power supply +30 starter switch (fuses no. 1 -- 3 -- 5 -- 15 -- 17 -- 18 -- 19 -20 -- 21 -- 22 -- 26 -- 27 -- 28 -- 35) and +30 starter relay F--4 Power supply fuses No. 36 -- 37 -- 38 -- 40 C--34 ISO rear power socket connector/North America C--57 Pneumatic seat supply connector C--75 Ignition switch connection C--76 Ignition switch connection C--77 Ignition switch connection C--78 Ignition switch connection SW--75/76/77/78 Key--start ignition switch MOD--100 Fuse box and main relay F--1 (+30 Key) -- Instrument (ADIC) F--5 (+30 Key) -- Engine stop circuit F--18 (+30 Key) -- Engine and transmission services F--22 (+30 Key) -- Ventilation/air--conditioning unit, radio F--35 (+30 Key) -- Brake lights, seat GND--159 Dashboard ground SOL--307 Engine shut--down solenoid valve
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
117
POWER SUPPLIES CIRCUIT -- DIAGRAM 11
MPM0739
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
118
REAR POWER TAKE--OFF CIRCUIT (Diagram 12)
C--2 Cab/transmission main connection C--23 Connection for switch of indicator light/mechanical power take--off safety device SW--23 Safety switch / mechanical power take--off indicator light MOD--27 Instrument SW--80 Hydraulic power take--off switch MOD--100 Fuse box and main relay F--26 (+30 Key) -- Rear power take--off circuit RLY--23 Rear PTO circuit RLY--24 Rear PTO circuit GND--136 Transmission ground GND--159 Dashboard ground SOL--213 PTO solenoid valve SEN--218 PTO speed sensor
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
119
REAR PTO CIRCUIT -- DIAGRAM 12
MPM0740
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
120
GRID HEATER AND ENGINE STARTER CIRCUIT (Diagram 13)
C--1 Cab/engine main connection C--2 Cab/transmission main connection C--23 Connection for switch of indicator light/mechanical power take--off safety device SW--23 Safety switch / mechanical power take--off indicator light MOD--27 Instrument SW--35 Clutch pedal switch MOD--61 Grid heater control unit C--69 Grid heater relay connector (coil) SW--97 Mechanical battery cut--out switch MOD--100 Fuse box and main relay F--28 (+30 Key) -- Starter safety circuit RLY--MR1 Starter motor circuit GND--159 Dashboard ground F--160 Grid Heater mega--fuse RES--174 Inlet Grid Heater RLY--175 Grid heater relay ALT--301/314 Alternator M--302/308 Starter motor C--320 Fuse box protecting memory and safety systems F--320 Fuse protecting memory and safety systems GND--325 Battery ground BAT--500 Battery
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
121
GRID HEATER AND ENGINE STARTER CIRCUIT -- DIAGRAM 13
1250 RN 1.0
MPM0741A
87679925A2 - 02 - 2010
1--AQ
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
122
POWER SOCKET AND TRAILER BRAKE CIRCUIT (Diagram 14)
C--2 Cab/transmission main connection C--11 Cab/trailer brake main connection C--21 Transmission/seven--pin socket connection C--21A ISO seven--pin socket C--21B North American seven--pin socket MOD--27 Instrument MOD--100 Fuse box and main relay F--27 (+30 Key) -- Trailer brake circuit RLY--1 Parking Brake RLY--27 Trailer brake circuit RLY--28 Trailer brake circuit GND--136 Transmission ground GND--159 Dashboard ground SEN--196 Actuated trailer brake warning light pressure switch 10 bar (10.13 kg/cm) SOL--197 Trailer brake solenoid valves SEN--198 Trailer brake circuit safety pressure switch 3.5 bar (3.57 kg/cm) SEN--340 Air brake pressure switch
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
123
POWER SOCKET AND TRAILER BRAKE CIRCUIT -- DIAGRAM 14
MPM0742
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
124
WINDSCREEN AND REAR WINDOW WASHER/WIPER CIRCUIT (Diagram 15)
SW--29 Front wiper switch SW--45 Rear wiper switch GND--92 Cab right upright top ground MOD--100 Fuse box and main relay F--19 (+30 Key) -- Rear wiper and washer pump F--21 (+30 Key) -- Front wiper and washer pump M--138 Wiper motor GND--146 Ground on left mudguard M--147 Windscreen wiper pump M--149 Rear wiper motor GND--151 Ground on right mudguard M--163 Rear window wiper pump
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
125
WIPER/WASHER CIRCUIT -- DIAGRAM 15
MPM0743
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
126
WORK LAMP CIRCUIT (Diagram 16)
C--1 Cab/engine main connection LMP--26 Work light on right handrail LMP--28 Work light on left handrail C--33 Engine/front lights connector LMP--49 Front right work light on cab (outside) LMP--66B Right rear work light GND--92 Cab right upright top ground MOD--100 Fuse box and main relay F--25 (+12V MF4 -- 50A) -- Cab front work lights (inside) F--36 (+12V MF4 -- 50A) -- Front swivel work lights F--37 (+12V MF4 -- 50A) -- Cab front work lights F--38 (+12V MF4 -- 50A) -- Front work lights on grab handles F--40 (+12V MF4 -- 50A) -- Cab rear work lights RLY--6 Front swivel lights circuit RLY--11 Cab front work lights circuit RLY--15 Cab front work lights circuit (inside) RLY--12 Front work lights circuit on grab handle RLY--14 Cab rear lights circuit LMP--139 Front left work light on cab (outside) GND--146 Ground on left mudguard LMP--148B Rear left work light on cab roof GND--151 Ground on right mudguard GND--159 Dashboard ground AUD--169 Audible beep LMP--170 Left grille work light LMP--171 Right grille work light SW--178 Front work lights switch SW--179 Rear work lights switch
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
127
WORK LAMP CIRCUIT -- DIAGRAM 16
MPM1213A
87679925A1 - 02 - 2008
128
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
129
VERSION 3 VERSION WITH POWER SHUTTLE ISO - (Deck version)
Description
Wiring diagram circuits
Page
Diagram 1
CAN line circuit and fault diagnosis connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Diagram 2
Brakes and differential lock circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Diagram 3
Engine, sensors and transmitters circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Diagram 4
Battery cut--out, handbrake and instrument circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Diagram 5
Direction indicator and hazard lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Diagram 6
External lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Diagram 7
Power supplies circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Diagram 8
Grid heater and engine starter circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Diagram 9
Power sockets and trailer brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Diagram 10
Rear PTO circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Diagram 11
Work lights and auxiliary functions circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Diagram 12
Power Shuttle circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
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ELECTRICAL CIRCUITS COMPONENTS VERSION 3
COMPONENT
C--1
NUMBER DIAGRAM
2, 3, 4, 6, 7, 8, 11
DESCRIPTION
Cab/engine main connection
MOD--1/3
1, 2, 4, 10, 12
TCM transmission control unit
C--2
2, 3, 9, 10, 12
Cab/transmission main connection
C--8
11
Cab/front loader main connection (b)
C--11
9
Cab/trailer brake main connection
SW--13
12
Gear lever switch
LMP--17
5
Front LH light
SW--18
5
Emergency switch
C--21
9
Transmission/seven--pin socket connection
C--21A
9
ISO seven--pin socket
C--21B
9
North American seven--pin socket
MOD--27
1, 2, 3, 4, 5, 6, 8, 9, 10, 11
F--30/31
7
Instrument Mega--fuse box
C--33
6, 11
C--34
7
ISO rear power socket connector
SW--35
12
Clutch pedal switch
C--57
7
Pneumatic seat supply connector
SW--59
4
Operator present switch
MOD--61
8
Grid heater control unit
SW--64
4
Lift--O--Matic switch
C--69
8
Grid heater relay connector (coil)
RLY--70A
5
Flasher relay
SW--71
5
Lights switch
SW--73
9
Hand brake switch
C--75
7
Ignition switch connection
C--76
7
Ignition switch connection
C--77
7
Ignition switch connection
C--78
7
Ignition switch connection
SW--75/76/77/78
7
Key--start ignition switch
SW--79
12
Shuttle lever switch
SW--80
10
Hydraulic power take--off switch
C--89
11
Connection of fitting for 80 litre pump variant
SW--97
8
Mechanical battery cut--out switch
MOD--100
87679925A2 - 02 - 2010
2, 4, 5, 6, 7, 8, 9, 11, 12
Engine/front lights connector
Fuse box and main relay
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
COMPONENT
NUMBER DIAGRAM
DESCRIPTION
SW--104
2
Four--wheel drive switch
SW--112
11
Grille work lights switch
SW--115
2
Differential lock switch
C--117
1, 4
131
Diagnostic socket
LMP--121
5
RH number plate light
SW--122
4
CAL/SEL Switch
LMP--123
5
RH tail light
LMP--124
5
LH number plate light
LMP--126
5
Front RH light
LMP--128
11
Rear work light
GND--136
2, 9
Transmission ground
C--142
11
8A auxiliary power socket
LMP--152
5
LH tail light
RES--156
12
Clutch pedal potentiometer
SW--158
4
Brake pedals not connected switch
GND--159 1, 2, 3, 4, 5, 6, 7, 8, 9, Dashboard ground 11, 12 F--160
8
Grid Heater mega--fuse
MOD--166
1
Key Pad (keypad)
AUD--169
11
Audible beep
LMP--170
11
Left grille work light
LMP--171
11
Right grille work light
LMP--172
6
Left--hand light
LMP--173
6
Right--hand light
RES--174
8
Inlet Grid Heater
RLY--175
8
Grid heater relay
SEN--196
9
Actuated trailer brake warning light pressure switch 10 bar (10.13 kg/cm)
SOL--197
9
Trailer brake solenoid valves
SEN--198
9
Trailer brake circuit safety pressure switch 3.5 bar (3.57 kg/cm)
SEN--201
12
Transmission oil temperature sensor
SOL--202
12
Clutch A solenoid valve
SOL--203
12
Clutch B solenoid valve
SOL--204
12
Clutch C solenoid valve (dump solenoid valve Vers. PS 12X12)
SOL--205
12
Clutch D solenoid valve
SEN--206
12
Safety pressure switch clutch A
SEN--207
12
Safety pressure switch clutch B
SW--209
12
G gear lever status switch
SW--210
12
R1 range lever status switch
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
132
COMPONENT
NUMBER DIAGRAM
DESCRIPTION
SW--211
12
R2 range lever status switch
SEN--212
3
Fuel level sensor
SOL--213
10
Power take--off solenoid valve
SOL--214
2
Four--wheel drive solenoid valve
SOL--215
2
Differential lock solenoid valve
SW--216
2
Differential lock warning light switch
SEN--217
12
Theoretical wheel speed sensor
SEN--218
10
PTO speed sensor
ALT--301/314
8
Alternator
M--302/308
8
Starter motor
SW--303
3
Air filter clogged switch
SEN--305
3
Sediment filter
SEN--306
3
Coolant temperature sensor
SOL--307
7
Engine shut--down solenoid valve
SEN--309
3
Thermometric sensor
MOD--310
3
Injection pump advance device
SEN--311
3
Gearbox oil pressure switch
SW--312
3
Brake oil level switch
SEN--313
3
Engine oil pressure switch
SEN--315
3
Engine rpm sensor
SW--316
2
Left brake switch
SW--318
2
Right brake switch
C--319
4
Connection of fitting for mechanical battery cut--out
C--320
8
Fuse box protecting memory and safety systems
F--320
8
Fuse protecting memory and safety systems
GND--325
8
Battery ground
SOL--330
11
80 litre supplement solenoid valve
SW--331
11
80 litre switch
SEN--340
9
Air brake pressure switch
BAT--500
8
Battery
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
133
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
134
DIAGNOSTICS CONNECTION AND CAN LINE CIRCUIT (Diagram 1)
MOD--1/3 TCM transmission control unit MOD--27 Instrument C--117 Diagnostic socket GND--159 Dashboard ground MOD--166 Key Pad (keypad)
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
135
DIAGNOSTICS CONNECTION AND CAN LINE CIRCUIT -- DIAGRAM 1
MPM1019
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
136
BRAKES AND DIFFERENTIAL LOCK CIRCUIT (Diagram 2)
C--1 Cab/engine main connection MOD--1/3 TCM transmission control unit C--2 Cab/transmission main connection MOD--27 Instrument MOD--100 Fuse box and main relay F--3 (+30 Key) -- Brake pressure switches F--20 (+30 Key) -- Four--wheel drive and differential lock circuit SW--104 Four--wheel drive switch SW--115 Differential lock switch GND--136 Transmission ground GND--159 Dashboard ground SOL--214 Four--wheel drive solenoid valve SOL--215 Differential lock solenoid valve SW--216 Differential lock warning light switch SW--316 Left brake switch SW--318 Right brake switch
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
137
BRAKES AND DIFFERENTIAL LOCK CIRCUIT -- DIAGRAM 2
MPM1020
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
138
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT (Diagram 3)
C--1 Cab/engine main connection C--2 Cab/transmission main connection MOD--27 Instrument GND--159 Dashboard ground SEN--212 Fuel level sensor SW--303 Air filter clogged switch SEN--305 Sediment filter SEN--306 Coolant temperature sensor SEN--309 Thermometric sensor MOD--310 Injection pump advance device SEN--311 Gearbox oil pressure switch SW--312 Brake fluid level switch SEN--313 Engine oil pressure switch SEN--315 Engine rpm sensor
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
139
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT -- DIAGRAM 3
MPM1021
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
140
BATTERY CUT--OUT, HANDBRAKE AND INSTRUMENT CIRCUIT (Diagram 4)
C--1 Cab/engine main connection MOD--1/3 TCM transmission control unit MOD--27 Instrument SW--59 Operator present switch SW--64 Lift--O--Matic switch MOD--100 Fuse box and main relay F--12 (+12V MF2 -- 70A) -- Control unit for transmission, instrument, handbrake indicator light, fault diagnosis socket, car radio C--117 Diagnostic socket SW--122 CAL/SEL Switch SW--158 Brake pedals not connected switch GND--159 Dashboard ground C--319 Connection of fitting for mechanical battery cut--out
*
Jumper valid on version without mechanical battery cut--out.
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
141
BATTERY CUT--OUT, HANDBRAKE AND INSTRUMENT CIRCUIT -- DIAGRAM 4
MPM1022
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
142
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (Diagram 5)
LMP--17 Front LH light SW--18 Emergency switch MOD--27 Instrument RLY--70A Flasher relay SW--71 Lights switch MOD--100 Fuse box and main relay F--7 (+12V MF2 -- 70A) -- Direction indicator and hazard lights F--16 (+12V MF2 -- 70A) -- Front right--hand and rear left--hand side lights, cigar lighter indicator light F--29 (+12V MF2 -- 70A) -- Side lights, controls lighting F--30 (+12V MF2 -- 70A) -- Front left--hand and rear right--hand side lights, controls and instruments lighting RLY--2 Side lights circuit RLY--5 Brake lights circuit LMP--121 RH number plate light LMP--123 RH tail light LMP--124 LH number plate light LMP--126 Front RH light LMP--152 LH tail light GND--159 Dashboard ground
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
143
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT -- DIAGRAM 5
MPM1023
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
144
EXTERNAL LIGHTS CIRCUIT (Diagram 6)
C--1 Cab/engine main connection MOD--27 Instrument C--33 Engine/front lights connector MOD--100 Fuse box and main relay F--33 (+12V MF2 -- 70A) -- Full beam headlights F--34 (+12V MF2 -- 70A) -- Dipped beam headlights RLY--3 Full beam headlight circuit RLY--4 Dipped beam headlight circuit GND--159 Dashboard ground LMP--172 Left--hand light LMP--173 Right--hand light
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
145
EXTERNAL LIGHTS CIRCUIT -- DIAGRAM 6
MPM1024
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
146
POWER SUPPLIES CIRCUIT (Diagram 7)
C--1 Cab/engine main connection F--30/31 Mega--fuse box F--1 25A (ISO) / 40A (North America) power socket F--2 Power supply fuses No. 6 -- 7 -- 8 -- 9 -- 12 -- 33 -- 34, side lights relay (fuses 16 -- 29 -- 30) F--3 Power supply +30 starter switch (fuses no. 1 -- 3 -- 5 -- 15 -- 17 -- 18 -- 19 -20 -- 21 -- 22 -- 26 -- 27 -- 28 -- 35) and +30 starter relay C--34 ISO rear power socket connector/North America C--57 Pneumatic seat supply connector C--75 Ignition switch connection C--76 Ignition switch connection C--77 Ignition switch connection C--78 Ignition switch connection SW--75/76/77/78 Key--start ignition switch MOD--100 Fuse box and main relay F--1 (+30 Key) -- Instrument (ADIC) F--2 (+30 Key) -- Turn indicators, four--wheel drive circuit, differential lock and power take--off F--5 (+30 Key) -- Engine stop circuit F--18 (+30 Key) -- Engine and transmission services F--35 (+30 Key) -- Brake lights, seat GND--159 Dashboard ground SOL--307 Engine shut--down solenoid valve
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
147
POWER SUPPLIES CIRCUIT -- DIAGRAM 7
MPM1025
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
148
GRID HEATER AND ENGINE STARTER CIRCUIT (Diagram 8)
C--1 Cab/engine main connection MOD--27 Instrument MOD--61 Grid heater control unit C--69 Grid heater relay connector (coil) SW--97 Mechanical battery cut--out switch MOD--100 Fuse box and main relay RLY--MR1 Starter motor circuit GND--159 Dashboard ground F--160 Grid Heater mega--fuse RES--174 Inlet Grid Heater RLY--175 Grid heater relay ALT--301/314 Alternator M--302/308 Starter motor C--320 Fuse box protecting memory and safety systems F--320 Fuse protecting memory and safety systems GND--325 Battery ground BAT--500 Battery
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
149
GRID HEATER AND ENGINE STARTER CIRCUIT -- DIAGRAM 8
MPM1026
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
150
POWER SOCKET AND TRAILER BRAKE CIRCUIT (Diagram 9)
C--2 Cab/transmission main connection C--11 Cab/trailer brake main connection C--21 Transmission/seven--pin socket connection C--21A ISO seven--pin socket C--21B North American seven--pin socket MOD--27 Instrument SW--73 Hand brake switch MOD--100 Fuse box and main relay F--27 (+30 Key) -- Trailer brake circuit RLY--1 Parking Brake RLY--27 Trailer brake circuit RLY--28 Trailer brake circuit GND--136 Transmission ground GND--159 Dashboard ground SEN--196 Actuated trailer brake warning light pressure switch 10 bar (10.13 kg/cm) SOL--197 Trailer brake solenoid valves SEN--198 Trailer brake circuit safety pressure switch 3.5 bar (3.57 kg/cm) SEN--340 Air brake pressure switch
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
151
POWER SOCKET AND TRAILER BRAKE CIRCUIT -- DIAGRAM 9
MPM1027
87679925A - 12 - 2007
152
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 REAR POWER TAKE--OFF CIRCUIT (Diagram 10)
MOD--1/3 TCM transmission control unit C--2 Cab/transmission main connection MOD--27 Instrument SW--80 Hydraulic power take--off switch SOL--213 PTO solenoid valve SEN--218 PTO speed sensor
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
153
REAR POWER TAKE--OFF CIRCUIT -- DIAGRAM 10
MPM1028
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
154
WORK LIGHTS AND AUXILIARY FUNCTIONS CIRCUIT (Diagram 11)
C--1 Cab/engine main connection C--8 Cab/front loader main connection (b) MOD--27 Instrument C--33 Engine/front lights connector C--89 Connection of fitting for 80 litre pump variant MOD--100 Fuse box and main relay F--9 (+12V MF2 -- 70A) -- Horn, 8A power socket, cigar lighter F--14 Rear work light F--15 (+30 Key) -- Front loader circuit F--36 (+12V MF4 -- 50A) -- Front swivel work lights RLY--6 Front swivel lights circuit SW--112 Grille work lights switch LMP--128 Rear work light C--142 8A auxiliary power socket GND--159 Dashboard ground AUD--169 Horn LMP--170 Left grille work light LMP--171 Right grille work light SOL--330 80 litre pump supplement solenoid valve SW--331 80 litre switch
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
155
WORK LIGHTS AND AUXILIARY FUNCTIONS CIRCUIT -- DIAGRAM 11
MPM1029
87679925A - 12 - 2007
156
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 POWER SHUTTLE CIRCUIT (Diagram 12)
MOD--1/3 TCM transmission control unit C--2 Cab/transmission main connection SW--13 Gear lever switch SW--35 Clutch pedal switch SW--79 Shuttle lever switch MOD--100 Fuse box and main relay F--23 (+30 Key) -- Transmission control unit F--24 (+30 Key) -- Power Shuttle lever F--28 (+30 Key) -- Starter safety circuit RES--156 Clutch pedal potentiometer GND--159 Dashboard ground SEN--201 Transmission oil temperature sensor SOL--202 Clutch A solenoid valve SOL--203 Clutch B solenoid valve SOL--204 Clutch C solenoid valve (dump solenoid valve Vers. PS 12X12) SOL--205 Clutch D solenoid valve SEN--206 Safety pressure switch clutch A SEN--207 Safety pressure switch clutch B SW--209 G gear lever status switch SW--210 R1 range lever status switch SW--211 R2 range lever status switch SEN--217 Theoretical wheel speed sensor
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
157
POWER SHUTTLE CIRCUIT -- DIAGRAM 12
MPM1030
87679925A - 12 - 2007
158
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
159
VERSION 4 STANDARD ISO VERSION - (Deck version)
Description
Wiring diagram circuits
Page
Diagram 1
CAN line circuit and fault diagnosis connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Diagram 2
Brakes and differential lock circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Diagram 3
Engine, sensors and transmitters circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Diagram 4
Battery cut--out, handbrake and instrument circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Diagram 5
Direction indicator and hazard lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Diagram 6
External lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Diagram 7
Power supplies circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Diagram 8
Grid heater and engine starter circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Diagram 9
Power sockets and trailer brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Diagram 10
Rear PTO circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Diagram 11
Work lights and auxiliary functions circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
160
ELECTRICAL CIRCUITS COMPONENTS VERSION 4
COMPONENT
NUMBER DIAGRAM
DESCRIPTION
C--1
2, 3, 4, 6, 7, 8, 11
Cab/engine main connection
C--2
2, 3, 8, 9, 10
C--8
11
Cab/front loader main connection (b)
C--11
9
Cab/trailer brake main connection
LMP--17
5
Front LH light
SW--18
5
Emergency switch
C--21
9
Transmission/seven--pin socket connection
C--21A
9
ISO seven--pin socket
C--21B
9
North American seven--pin socket
Cab/transmission main connection
C--23
8, 10
Connection for switch of indicator light/mechanical power take--off safety device
SW--23
8, 10
Safety switch / mechanical power take--off indicator light
MOD--27
1, 2, 3, 4, 5, 6, 8, 9, 10, 11
F--30/31
7
Instrument Mega--fuse box
C--33
6, 11
C--34
7
ISO rear power socket connector
SW--35
8
Clutch pedal switch
C--57
7
Pneumatic seat supply connector
SW--59
4
Operator present switch
MOD--61
8
Grid heater control unit
SW--64
4
Lift--O--Matic switch
C--69
8
Grid heater relay connector (coil)
RLY--70A
5
Flasher relay
SW--71
5
Lights switch
SW--73
9
Hand brake switch
C--75
7
Ignition switch connection
C--76
7
Ignition switch connection
C--77
7
Ignition switch connection
C--78
7
Ignition switch connection
SW--75/76/77/78
7
Key--start ignition switch
SW--80
10
Hydraulic power take--off switch
C--89
11
Connection of fitting for 80 litre pump variant
SW--97
8
Mechanical battery cut--out switch
MOD--100 SW--104 87679925A - 12 - 2007
Engine/front lights connector
2, 4, 5, 6, 7, 8, 9, 10, 11
Fuse box and main relay
2
Four--wheel drive switch
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
COMPONENT
NUMBER DIAGRAM
DESCRIPTION
SW--104
2
Four--wheel drive switch
SW--112
11
Grille work lights switch
SW--115
2
Differential lock switch
C--117
1, 4
161
Diagnostic socket
LMP--121
5
RH number plate light
SW--122
4
CAL/SEL Switch
LMP--123
5
RH tail light
LMP--124
5
LH number plate light
LMP--126
5
Front RH light
LMP--128
11
Rear work light
GND--136
2, 9, 10
Transmission ground
C--142
11
8A auxiliary power socket
LMP--152
5
LH tail light
SW--158
4
Brake pedals not connected switch
GND--159 1, 2, 3, 4, 5, 6, 7, 8, 9, Dashboard ground 10, 11 F--160
8
Grid Heater mega--fuse
MOD--166
1
Key Pad (keypad)
AUD--169
11
Audible beep
LMP--170
11
Left grille work light
LMP--171
11
Right grille work light
LMP--172
6
Left--hand light
LMP--173
6
Right--hand light
RES--174
8
Inlet Grid Heater
RLY--175
8
Grid heater relay
SEN--196
9
Actuated trailer brake warning light pressure switch 10 bar (10.13 kg/cm)
SOL--197
9
Trailer brake solenoid valves
SEN--198
9
Trailer brake circuit safety pressure switch 3.5 bar (3.57 kg/cm)
SEN--212
3
Fuel level sensor
SOL--213
10
Power take--off solenoid valve
SOL--214
2
Four--wheel drive solenoid valve
SOL--215
2
Differential lock solenoid valve
SW--216
2
Differential lock warning light switch
SEN--217
3
Theoretical wheel speed sensor
SEN--218
10
PTO speed sensor
ALT--301/314
8
Alternator
M--302/308
8
Starter motor
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
162
COMPONENT
NUMBER DIAGRAM
DESCRIPTION
SW--303
3
Air filter clogged switch
SEN--305
3
Sediment filter
SEN--306
3
Coolant temperature sensor
SOL--307
7
Engine shut--down solenoid valve
SEN--309
3
Thermometric sensor
MOD--310
3
Injection pump advance device
SEN--311
3
Gearbox oil pressure switch
SW--312
3
Brake oil level switch
SEN--313
3
Engine oil pressure switch
SEN--315
3
Engine rpm sensor
SW--316
2
Left brake switch
SW--318
2
Right brake switch
C--319
4
Connection of fitting for mechanical battery cut--out
C--320
8
Fuse box protecting memory and safety systems
F--320
8
Fuse protecting memory and safety systems
GND--325
8
Battery ground
SOL--330
11
80 litre supplement solenoid valve
SW--331
11
80 litre switch
SEN--340
9
Air brake pressure switch
BAT--500
8
Battery
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
163
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
164
DIAGNOSTICS CONNECTION AND CAN LINE CIRCUIT (Diagram 1)
MOD--27 Instrument C--117 Diagnostic socket GND--159 Dashboard ground MOD--166 Key Pad (keypad)
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
165
DIAGNOSTICS CONNECTION AND CAN LINE CIRCUIT -- DIAGRAM 1
MPM1006
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
166
BRAKES AND DIFFERENTIAL LOCK CIRCUIT (Diagram 2)
C--1
Cab/engine main connection
C--2
Cab/transmission main connection
MOD--27 MOD--100
Instrument Fuse box and main relay F--3 F--20
(+30 Key) -- Brake pressure switches (+30 Key) -- Four--wheel drive and differential lock circuit
RLY--17
4WD, differential lock circuit
RLY--18
Differential lock circuit
RLY--19
Differential lock circuit
RLY--20
4WD circuit
SW--104
Four--wheel drive switch
SW--115
Differential lock switch
GND--136
Transmission ground
GND--159
Dashboard ground
SOL--214
Four--wheel drive solenoid valve
SOL--215
Differential lock solenoid valve
SW--216
Differential lock warning light switch
SW--316
Left brake switch
SW--318
Right brake switch
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
167
BRAKES AND DIFFERENTIAL LOCK CIRCUIT -- DIAGRAM 2
MPM1007
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
168
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT (Diagram 3)
C--1
Cab/engine main connection
C--2
Cab/transmission main connection
MOD--27
Instrument
GND--159
Dashboard ground
SEN--212
Fuel level sensor
SEN--217
Theoretical wheel speed sensor
SW--303
Air filter clogged switch
SEN--305
Sediment filter
SEN--306
Coolant temperature sensor
SEN--309
Thermometric sensor
MOD--310
Injection pump advance device
SEN--311 SW--312
Gearbox oil pressure switch Brake fluid level switch
SEN--313
Engine oil pressure switch
SEN--315
Engine rpm sensor
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
169
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT -- DIAGRAM 3
MPM1008
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
170
BATTERY CUT--OUT, HANDBRAKE AND INSTRUMENT CIRCUIT (Diagram 4)
C--1 MOD--27
Cab/engine main connection Instrument
SW--59
Operator present switch
SW--64
Lift--O--Matic switch
MOD--100
Fuse box and main relay F--12
C--117
Diagnostic socket
SW--122
CAL/SEL Switch
SW--158
Brake pedals not connected switch
GND--159 C--319
*
(+12V MF2 -- 70A) -- Control unit for transmission, instrument, handbrake indicator light, fault diagnosis socket, car radio
Dashboard ground Connection of fitting for mechanical battery cut--out
Jumper valid on version without mechanical battery cut--out.
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
171
BATTERY CUT--OUT, HANDBRAKE AND INSTRUMENT CIRCUIT -- DIAGRAM 4
MPM1009
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
172
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (Diagram 5)
LMP--17 SW--18
Front LH light Emergency switch
MOD--27
Instrument
RLY--70A
Flasher relay
SW--71
Lights switch
MOD--100
Fuse box and main relay F--7
(+12V MF2 -- 70A) -- Direction indicator and hazard lights
F--16
(+12V MF2 -- 70A) -- Front right--hand and rear left--hand side lights, cigar lighter indicator light
F--29
(+12V MF2 -- 70A) -- Side lights, controls lighting
F--30
(+12V MF2 -- 70A) -- Front left--hand and rear right--hand side lights, controls and instruments lighting
RLY--2
Side lights circuit
RLY--5
Brake lights circuit
LMP--121
RH number plate light
LMP--123
RH tail light
LMP--124
LH number plate light
LMP--126
Front RH light
LMP--152
LH tail light
GND--159
Dashboard ground
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
173
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT -- DIAGRAM 5
MPM1010
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
174
EXTERNAL LIGHTS CIRCUIT (Diagram 6)
C--1 MOD--27 C--33 MOD--100
Cab/engine main connection Instrument Engine/front lights connector Fuse box and main relay F--33
(+12V MF2 -- 70A) -- Full beam headlights
F--34
(+12V MF2 -- 70A) -- Dipped beam headlights
RLY--3
Full beam headlight circuit
RLY--4
Dipped beam headlight circuit
GND--159
Dashboard ground
LMP--172
Left--hand light
LMP--173
Right--hand light
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
175
EXTERNAL LIGHTS CIRCUIT -- DIAGRAM 6
MPM1011
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
176
POWER SUPPLIES CIRCUIT (Diagram 7)
C--1 F--30/31
Cab/engine main connection Mega--fuse box F--1
25A power socket
F--2
Power supply fuses No. 7 -- 9 -- 12 -- 33 -- 34 -- 36, side lights relay (fuses 16 -- 29 -- 30)
F--3
Power supply +30 starter switch (fuses no. 1 -- 3 -- 5 -- 14 -- 15 -- 18 -- 20 -- 26 -- 27 -- 28 -- 35) and +30 starter relay
C--34
ISO rear power socket connector
C--57
Pneumatic seat supply connector
C--75
Ignition switch connection
C--76
Ignition switch connection
C--77
Ignition switch connection
C--78
Ignition switch connection
SW--75/76/77/78
Key--start ignition switch
MOD--100
Fuse box and main relay F--1
(+30 Key) -- Instrument (ADIC)
F--5
(+30 Key) -- Engine stop circuit
F--18
(+30 Key) -- Engine and transmission services
F--35
(+30 Key) -- Brake lights, seat
GND--159
Dashboard ground
SOL--307
Engine shut--down solenoid valve
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
177
POWER SUPPLIES CIRCUIT -- DIAGRAM 7
MPM1012
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
178
GRID HEATER AND ENGINE STARTER CIRCUIT (Diagram 8)
C--1
Cab/engine main connection
C--2
Cab/transmission main connection
C--23 SW--23 MOD--27 SW--35 MOD--61
Connection for switch of indicator light/mechanical power take--off safety device Safety switch / mechanical power take--off indicator light Instrument Clutch pedal switch Grid heater control unit
C--69
Grid heater relay connector (coil)
SW--97
Mechanical battery cut--out switch
MOD--100
Fuse box and main relay F--28 RLY--MR 1
GND--159 F--160
(+30 Key) -- Starter safety circuit Starter motor circuit
Dashboard ground Grid Heater mega--fuse
RES--174
Inlet Grid Heater
RLY--175
Grid heater relay
ALT--301/314 M--302/308
Alternator Starter motor
C--320 Fuse box protecting memory and safety systems F--320 Fuse protecting memory and safety systems GND--325
Battery ground
BAT--500
Battery
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
179
GRID HEATER AND ENGINE STARTER CIRCUIT -- DIAGRAM 8
MPM1013
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
180
POWER SOCKET AND TRAILER BRAKE CIRCUIT (Diagram 9)
C--2
Cab/transmission main connection
C--11
Cab/trailer brake main connection
C--21
Transmission/seven--pin socket connection
C--21A
ISO seven--pin socket
C--21B
North American seven--pin socket
MOD--27 SW--73 MOD--10 0
Instrument Hand brake switch Fuse box and main relay F--27 RLY--1
(+30 Key) -- Trailer brake circuit Parking Brake
RLY--27
Trailer brake circuit
RLY--28
Trailer brake circuit
GND--13 6
Transmission ground
GND--15 9
Dashboard ground
SEN--196
Actuated trailer brake warning light pressure switch 10 bar (10.13 kg/cm)
SOL--197
Trailer brake solenoid valves
SEN--198
Trailer brake circuit safety pressure switch 3.5 bar (3.57 kg/cm)
SEN--340
Air brake pressure switch
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
181
POWER SOCKET AND TRAILER BRAKE CIRCUIT -- DIAGRAM 9
MPM1014
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
182
REAR POWER TAKE--OFF CIRCUIT (Diagram 10)
C--2 C--23 SW--23 MOD--27 SW--80 MOD--100
Cab/transmission main connection Connection for switch of indicator light/mechanical power take--off safety device Safety switch / mechanical power take--off indicator light Instrument Hydraulic power take--off switch Fuse box and main relay F--26
(+30 Key) -- Rear power take--off circuit
RLY--23
Rear PTO circuit
RLY--24
Rear PTO circuit
GND--136
Transmission ground
GND--159
Dashboard ground
SOL--213
PTO solenoid valve
SEN--218
PTO speed sensor
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
183
REAR POWER TAKE--OFF CIRCUIT -- DIAGRAM 10
MPM1015
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
184
WORK LIGHTS AND AUXILIARY FUNCTIONS CIRCUIT (Diagram 11)
C--1
Cab/engine main connection
C--8
Cab/front loader main connection (b)
MOD--27
Instrument
C--33
Engine/front lights connector
C--89
Connection of fitting for 80 litre pump variant
MOD--100
Fuse box and main relay F--9 F--14
Rear work light
F--15
(+30 Key) -- Front loader circuit
F--36
(+12V MF4 -- 50A) -- Front swivel work lights
RLY--6 SW--112 LMP--128 C--142
(+12V MF2 -- 70A) -- Horn, 8A power socket, cigar lighter
Front swivel lights circuit
Grille work lights switch Rear work light 8A auxiliary power socket
GND--159
Dashboard ground
AUD--169
Horn
LMP--170
Left grille work light
LMP--171
Right grille work light
SOL--330
80 litre pump supplement solenoid valve
SW--331
80 litre switch
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
185
WORK LIGHTS AND AUXILIARY FUNCTIONS CIRCUIT -- DIAGRAM 11
MPM1016
87679925A - 12 - 2007
186
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
187
VERSION 5 VERSION WITH POWER SHUTTLE NORTH AMERICA - (Deck version)
Description
Wiring diagram circuits
Page
Diagram 1
CAN line circuit and fault diagnosis connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Diagram 2
Brakes and differential lock circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Diagram 3
Engine, sensors and transmitters circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Diagram 4
Battery cut--out, handbrake and instrument circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Diagram 5
Direction indicator and hazard lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Diagram 6
External lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Diagram 7
Power supplies circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Diagram 8
Grid heater and engine starter circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Diagram 9
Power sockets and trailer brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Diagram 10
Rear PTO circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Diagram 11
Work lights and auxiliary functions circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Diagram 12
Power Shuttle circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
188
ELECTRICAL CIRCUITS COMPONENTS VERSION 5
COMPONENT
C--1
NUMBER DIAGRAM
2, 3, 4, 6, 7, 8, 11
DESCRIPTION
Cab/engine main connection
MOD--1/3
1, 2, 4, 10, 12
TCM transmission control unit
C--2
2, 3, 9, 10, 12
Cab/transmission main connection
C--8
11
Cab/front loader main connection (b)
C--11
9
Cab/trailer brake main connection
SW--13
12
Gear lever switch
SW--18
5
Emergency switch
C--21
9
Transmission/seven--pin socket connection
C--21A
9
ISO seven--pin socket
C--21B
9
North American seven--pin socket
MOD--27
1, 2, 3, 4, 5, 6, 8, 9, 10, 11
F--30/31
7
Instrument Mega--fuse box
C--33
6, 11
C--34
7
ISO rear power socket connector/North America
SW--35
12
Clutch pedal switch
C--57
7
Pneumatic seat supply connector
SW--59
4
Operator present switch
MOD--61
8
Grid heater control unit
SW--64
4
Lift--O--Matic switch
C--69
8
Grid heater relay connector (coil)
MOD--70
5
Flasher
SW--71
5
Lights switch
LMP--72
5
LH two--faced headlight
SW--73
9
Hand brake switch
LMP--74
5
RH two--faced headlight
C--75
7
Ignition switch connection
C--76
7
Ignition switch connection
C--77
7
Ignition switch connection
C--78
7
Ignition switch connection
SW--75/76/77/78
7
Key--start ignition switch
SW--79
12
Shuttle lever switch
SW--80
10
Hydraulic power take--off switch
C--89
11
Connection of fitting for 80 litre pump variant
SW--97
8
Mechanical battery cut--out switch
87679925A - 12 - 2007
Engine/front lights connector
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
COMPONENT
NUMBER DIAGRAM
DESCRIPTION
2, 4, 5, 6, 7, 8, 9, 11, 12
Fuse box and main relay
SW--104
2
Four--wheel drive switch
SW--112
11
Grille work lights switch
SW--115
2
Differential lock switch
MOD--100
1, 4
Diagnostic socket
SW--122
4
CAL/SEL Switch
LMP--128
11
Rear work light
GND--136
2, 9
C--117
189
Transmission ground
C--142
11
8A auxiliary power socket
RES--156
12
Clutch pedal potentiometer
SW--158
4
Brake pedals not connected switch
GND--159
2, 3, 4, 5, 6, 7, 8, 9, 11, 12
Dashboard ground
F--160
8
Grid Heater mega--fuse
MOD--166
1
Key Pad (keypad)
AUD--169
11
Audible beep
LMP--170
11
Left grille work light
LMP--171
11
Right grille work light
LMP--172
6
Left--hand light
LMP--173
6
Right--hand light
RES--174
8
Inlet Grid Heater
RLY--175
8
Grid heater relay
SEN--196
9
Actuated trailer brake warning light pressure switch 10 bar (10.13 kg/cm)
SOL--197
9
Trailer brake solenoid valves
SEN--198
9
Trailer brake circuit safety pressure switch 3.5 bar (3.57 kg/cm)
SEN--201
12
Transmission oil temperature sensor
SOL--202
12
Clutch A solenoid valve
SOL--203
12
Clutch B solenoid valve
SOL--204
12
Clutch C solenoid valve (dump solenoid valve Vers. PS 12X12)
SOL--205
12
Clutch D solenoid valve
SEN--206
12
Safety pressure switch clutch A
SEN--207
12
Safety pressure switch clutch B
SW--209
12
G gear lever status switch
SW--210
12
R1 range lever status switch
SW--211
12
R2 range lever status switch
SEN--212
3
Fuel level sensor
SOL--213
10
Power take--off solenoid valve
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
190
COMPONENT
NUMBER DIAGRAM
DESCRIPTION
SOL--214
2
Four--wheel drive solenoid valve
SOL--215
2
Differential lock solenoid valve
SW--216
2
Differential lock warning light switch
SEN--217
12
Theoretical wheel speed sensor
SEN--218
10
PTO speed sensor
ALT--301/314
8
Alternator
M--302/308
8
Starter motor
SW--303
3
Air filter clogged switch
SEN--305
3
Sediment filter
SEN--306
3
Coolant temperature sensor
SOL--307
7
Engine shut--down solenoid valve
SEN--309
3
Thermometric sensor
MOD--310
3
Injection pump advance device
SEN--311
3
Gearbox oil pressure switch
SW--312
3
Brake oil level switch
SEN--313
3
Engine oil pressure switch
SEN--315
3
Engine rpm sensor
SW--316
2
Left brake switch
SW--318
2
Right brake switch
C--319
4
Connection of fitting for mechanical battery cut--out
C--320
8
Fuse box protecting memory and safety systems
F--320
8
Fuse protecting memory and safety systems
GND--325
8
Battery ground
SOL--330
11
80 litre supplement solenoid valve
SW--331
11
80 litre switch
SEN--340
9
Air brake pressure switch
BAT--500
8
Battery
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
191
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
192
DIAGNOSTICS CONNECTION AND CAN LINE CIRCUIT (Diagram 1)
MOD--1/3 TCM transmission control unit MOD--27 Instrument C--117 Diagnostic socket MOD--166 Key Pad (keypad)
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
193
DIAGNOSTICS CONNECTION AND CAN LINE CIRCUIT -- DIAGRAM 1
MPM1042
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
194
BRAKES AND DIFFERENTIAL LOCK CIRCUIT (Diagram 2)
C--1 Cab/engine main connection MOD--1/3 TCM transmission control unit C--2 Cab/transmission main connection MOD--27 Instrument MOD--100 Fuse box and main relay F--3 (+30 Key) -- Brake pressure switches SW--104 Four--wheel drive switch SW--115 Differential lock switch GND--136 Transmission ground GND--159 Dashboard ground SOL--214 Four--wheel drive solenoid valve SOL--215 Differential lock solenoid valve SW--216 Differential lock warning light switch SW--316 Left brake switch SW--318 Right brake switch
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
195
BRAKES AND DIFFERENTIAL LOCK CIRCUIT -- DIAGRAM 2
MPM1043
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
196
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT (Diagram 3)
C--1 Cab/engine main connection C--2 Cab/transmission main connection MOD--27 Instrument GND--159 Dashboard ground SEN--212 Fuel level sensor SW--303 Air filter clogged switch SEN--305 Sediment filter SEN--306 Coolant temperature sensor SEN--309 Thermometric sensor MOD--310 Injection pump advance device SEN--311 Gearbox oil pressure switch SW--312 Brake fluid level switch SEN--313 Engine oil pressure switch SEN--315 Engine rpm sensor
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
197
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT -- DIAGRAM 3
MPM1044
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
198
BATTERY CUT--OUT, HANDBRAKE AND INSTRUMENT CIRCUIT (Diagram 4)
C--1 Cab/engine main connection MOD--1/3 TCM transmission control unit MOD--27 Instrument SW--59 Operator present switch SW--64 Lift--O--Matic switch MOD--100 Fuse box and main relay F--12 (+12V MF2 -- 70A) -- Control unit for transmission, instrument, handbrake indicator light, fault diagnosis socket, car radio C--117 Diagnostic socket SW--122 CAL/SEL Switch SW--158 Brake pedals not connected switch GND--159 Dashboard ground C--319 Connection of fitting for mechanical battery cut--out
*
Jumper valid on version without mechanical battery cut--out.
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
199
BATTERY CUT--OUT, HANDBRAKE AND INSTRUMENT CIRCUIT -- DIAGRAM 4
MPM1045
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
200
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (Diagram 5)
SW--18 Emergency switch MOD--27 Instrument MOD--70 Flasher SW--71 Lights switch LMP--72 LH two--faced headlight LMP--74 RH two--faced headlight MOD--100 Fuse box and main relay F--7 (+12V MF2 -- 70A) -- Direction indicator and hazard lights F--16 (+12V MF2 -- 70A) -- Front right--hand and rear left--hand side lights, cigar lighter indicator light F--29 (+12V MF2 -- 70A) -- Side lights, controls lighting F--30 (+12V MF2 -- 70A) -- Front left--hand and rear right--hand side lights, controls and instruments lighting RLY--2 Side lights circuit RLY--5 Brake lights circuit GND--159 Dashboard ground
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
201
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT -- DIAGRAM 5
MPM1046
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
202
EXTERNAL LIGHTS CIRCUIT (Diagram 6)
C--1 Cab/engine main connection MOD--27 Instrument C--33 Engine/front lights connector MOD--100 Fuse box and main relay F--33 (+12V MF2 -- 70A) -- Full beam headlights F--34 (+12V MF2 -- 70A) -- Dipped beam headlights RLY--3 Full beam headlight circuit RLY--4 Dipped beam headlight circuit GND--159 Dashboard ground LMP--172 Left--hand light LMP--173 Right--hand light
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
203
EXTERNAL LIGHTS CIRCUIT -- DIAGRAM 6
MPM1047
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
204
POWER SUPPLIES CIRCUIT (Diagram 7)
C--1 Cab/engine main connection F--30/31 Mega--fuse box F--1 40A power socket (North America) F--2 Power supply fuses No. 7 -- 9 -- 12 -- 33 -- 34 -- 36, side lights relay (fuses 16 -- 29 -- 30) F--3 Power supply +30 starter switch (fuses no. 1 -- 2 -- 3 -- 5 -- 14 -- 15 -- 18 -- 23 -- 24 -- 27 -- 28 -- 35) and +30 starter relay C--34 ISO rear power socket connector/North America C--57 Pneumatic seat supply connector C--75 Ignition switch connection C--76 Ignition switch connection C--77 Ignition switch connection C--78 Ignition switch connection SW--75/76/77/78 Key--start ignition switch MOD--100 Fuse box and main relay F--1 (+30 Key) -- Instrument (ADIC) F--2 (+30 Key) -- Turn indicators, four--wheel drive circuit, differential lock and power take--off F--5 (+30 Key) -- Engine stop circuit F--18 (+30 Key) -- Engine and transmission services F--35 (+30 Key) -- Brake lights, seat GND--159 Dashboard ground SOL--307 Engine shut--down solenoid valve
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
205
POWER SUPPLIES CIRCUIT -- DIAGRAM 7
MPM1048
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
206
GRID HEATER AND ENGINE STARTER CIRCUIT (Diagram 8)
C--1 Cab/engine main connection MOD--27 Instrument MOD--61 Grid heater control unit C--69 Grid heater relay connector (coil) SW--97 Mechanical battery cut--out switch MOD--100 Fuse box and main relay RLY--MR1 Starter motor circuit GND--159 Dashboard ground F--160 Grid Heater mega--fuse RES--174 Inlet Grid Heater RLY--175 Grid heater relay ALT--301/314 Alternator M--302/308 Starter motor C--320 Fuse box protecting memory and safety systems F--320 Fuse protecting memory and safety systems GND--325 Battery ground BAT--500 Battery
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
207
GRID HEATER AND ENGINE STARTER CIRCUIT -- DIAGRAM 8
MPM1049
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
208
POWER SOCKET AND TRAILER BRAKE CIRCUIT (Diagram 9)
C--2 Cab/transmission main connection C--11 Cab/trailer brake main connection C--21 Transmission/seven--pin socket connection C--21A ISO seven--pin socket C--21B North American seven--pin socket MOD--27 Instrument SW--73 Hand brake switch MOD--100 Fuse box and main relay F--27 (+30 Key) -- Trailer brake circuit RLY--1 Parking Brake RLY--27 Trailer brake circuit RLY--28 Trailer brake circuit GND--136 Transmission ground GND--159 Dashboard ground SEN--196 Actuated trailer brake warning light pressure switch 10 bar (10.13 kg/cm) SOL--197 Trailer brake solenoid valves SEN--198 Trailer brake circuit safety pressure switch 3.5 bar (3.57 kg/cm) SEN--340 Air brake pressure switch
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
209
POWER SOCKET AND TRAILER BRAKE CIRCUIT -- DIAGRAM 9
MPM1050
87679925A - 12 - 2007
210
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 REAR POWER TAKE--OFF CIRCUIT (Diagram 10)
MOD--1/3 TCM transmission control unit C--2 Cab/transmission main connection MOD--27 Instrument SW--80 Hydraulic power take--off switch SOL--213 PTO solenoid valve SEN--218 PTO speed sensor
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
211
REAR POWER TAKE--OFF CIRCUIT -- DIAGRAM 10
MPM1051
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
212
WORK LIGHTS AND AUXILIARY FUNCTIONS CIRCUIT (Diagram 11)
C--1 Cab/engine main connection C--8 Cab/front loader main connection (b) MOD--27 Instrument C--33 Engine/front lights connector C--89 Connection of fitting for 80 litre pump variant MOD--100 Fuse box and main relay F--9 (+12V MF2 -- 70A) -- Horn, 8A power socket, cigar lighter F--14 Rear work light F--15 (+30 Key) -- Front loader circuit F--36 (+12V MF4 -- 50A) -- Front swivel work lights RLY--6 Front swivel lights circuit SW--112 Grille work lights switch LMP--128 Rear work light C--142 8A auxiliary power socket GND--159 Dashboard ground AUD--169 Horn LMP--170 Left grille work light LMP--171 Right grille work light SOL--330 80 litre pump supplement solenoid valve SW--331 80 litre switch
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
213
WORK LIGHTS AND AUXILIARY FUNCTIONS CIRCUIT -- DIAGRAM 11
MPM1052
87679925A - 12 - 2007
214
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 POWER SHUTTLE CIRCUIT (Diagram 12)
MOD--1/3 TCM transmission control unit C--2 Cab/transmission main connection SW--13 Gear lever switch SW--35 Clutch pedal switch SW--79 Shuttle lever switch MOD--100 Fuse box and main relay F--23 (+30 Key) -- Transmission control unit F--24 (+30 Key) -- Power Shuttle lever F--28 (+30 Key) -- Starter safety circuit RES--156 Clutch pedal potentiometer GND--159 Dashboard ground SEN--201 Transmission oil temperature sensor SOL--202 Clutch A solenoid valve SOL--203 Clutch B solenoid valve SOL--204 Clutch C solenoid valve (dump solenoid valve Vers. PS 12X12) SOL--205 Clutch D solenoid valve SEN--206 Safety pressure switch clutch A SEN--207 Safety pressure switch clutch B SW--209 G gear lever status switch SW--210 R1 range lever status switch SW--211 R2 range lever status switch SEN--217 Theoretical wheel speed sensor
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
215
POWER SHUTTLE CIRCUIT -- DIAGRAM 12
MPM1053
87679925A - 12 - 2007
216
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
217
VERSION 6 STANDARD VERSION FOR NORTH AMERICA - (Deck version)
Description
Wiring diagram circuits
Page
Diagram 1
CAN line circuit and fault diagnosis connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Diagram 2
Brakes and differential lock circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Diagram 3
Engine, sensors and transmitters circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Diagram 4
Battery cut--out, handbrake and instrument circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Diagram 5
Direction indicator and hazard lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Diagram 6
External lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Diagram 7
Power supplies circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Diagram 8
Grid heater and engine starter circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Diagram 9
Power sockets and trailer brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Diagram 10
Rear PTO circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Diagram 11
Work lights and auxiliary functions circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
218
ELECTRICAL CIRCUITS COMPONENTS VERSION 6
COMPONENT
NUMBER DIAGRAM
DESCRIPTION
C--1
2, 3, 4, 6, 7, 8, 11
Cab/engine main connection
C--2
2, 3, 8, 9, 10
C--8
11
Cab/front loader main connection (b)
C--11
9
Cab/trailer brake main connection
SW--18
5
Emergency switch
C--21
9
Transmission/seven--pin socket connection
C--21A
9
ISO seven--pin socket
C--21B
9
North American seven--pin socket
Cab/transmission main connection
C--23
8, 10
Connection for switch of indicator light/mechanical power take--off safety device
SW--23
8, 10
Safety switch / mechanical power take--off indicator light
MOD--27
1, 2, 3, 4, 5, 6, 8, 9, 10, 11
F--30/31
7
Instrument Mega--fuse box
C--33
6, 11
C--34
7
North America rear power socket connector
SW--35
8
Clutch pedal switch
C--57
7
Pneumatic seat supply connector
SW--59
4
Operator present switch
MOD--61
8
Grid heater control unit
SW--64
4
Lift--O--Matic switch
C--69
8
Grid heater relay connector (coil)
MOD--70
5
Flasher
SW--71
5
Lights switch
LMP--72
5
LH two--faced headlight
SW--73
9
Hand brake switch
LMP--74
5
RH two--faced headlight
C--75
7
Ignition switch connection
C--76
7
Ignition switch connection
C--77
7
Ignition switch connection
C--78
7
Ignition switch connection
SW--75/76/77/78
7
Key--start ignition switch
SW--80
10
Hydraulic power take--off switch
C--89
11
Connection of fitting for 80 litre pump variant
SW--97
8
Mechanical battery cut--out switch
MOD--100
87679925A - 12 - 2007
2, 4, 5, 6, 7, 8, 9, 10, 11
Engine/front lights connector
Fuse box and main relay
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
COMPONENT
NUMBER DIAGRAM
DESCRIPTION
2, 4, 5, 6, 7, 8, 9, 10, 11
Fuse box and main relay
SW--104
2
Four--wheel drive switch
SW--112
11
Grille work lights switch
SW--115
2
Differential lock switch
MOD--100
1, 4
Diagnostic socket
SW--122
4
CAL/SEL Switch
LMP--128
11
Rear work light
GND--136
2, 9, 10
C--117
219
Transmission ground
C--142
11
8A auxiliary power socket
SW--158
4
Brake pedals not connected switch
GND--159 1, 2, 3, 4, 5, 6, 7, 8, 9, Dashboard ground 10, 11 F--160
8
Grid Heater mega--fuse
MOD--166
1
Key Pad (keypad)
AUD--169
11
Audible beep
LMP--170
11
Left grille work light
LMP--171
11
Right grille work light
LMP--172
6
Left--hand light
LMP--173
6
Right--hand light
RES--174
8
Inlet Grid Heater
RLY--175
8
Grid heater relay
SEN--196
9
Actuated trailer brake warning light pressure switch 10 bar (10.13 kg/cm)
SOL--197
9
Trailer brake solenoid valves
SEN--198
9
Trailer brake circuit safety pressure switch 3.5 bar (3.57 kg/cm)
SEN--212
3
Fuel level sensor
SOL--213
10
Power take--off solenoid valve
SOL--214
2
Four--wheel drive solenoid valve
SOL--215
2
Differential lock solenoid valve
SW--216
2
Differential lock warning light switch
SEN--217
3
Theoretical wheel speed sensor
SEN--218
10
PTO speed sensor
ALT--301/314
8
Alternator
M--302/308
8
Starter motor
SW--303
3
Air filter clogged switch
SEN--305
3
Sediment filter
SEN--306
3
Coolant temperature sensor
SOL--307
7
Engine shut--down solenoid valve
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
220
COMPONENT
NUMBER DIAGRAM
DESCRIPTION
SEN--309
3
Thermometric sensor
MOD--310
3
Injection pump advance device
SEN--311
3
Gearbox oil pressure switch
SW--312
3
Brake oil level switch
SEN--313
3
Engine oil pressure switch
SEN--315
3
Engine rpm sensor
SW--316
2
Left brake switch
SW--318
2
Right brake switch
C--319
4
Connection of fitting for mechanical battery cut--out
C--320
8
Fuse box protecting memory and safety systems
F--320
8
Fuse protecting memory and safety systems
GND--325
8
Battery ground
SOL--330
11
80 litre supplement solenoid valve
SW--331
11
80 litre switch
SEN--340
9
Air brake pressure switch
BAT--500
8
Battery
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
221
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
222
DIAGNOSTICS CONNECTION AND CAN LINE CIRCUIT (Diagram 1)
MOD--27 Instrument C--117 Diagnostic socket GND--159 Dashboard ground MOD--166 Key Pad (keypad)
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
223
DIAGNOSTICS CONNECTION AND CAN LINE CIRCUIT -- DIAGRAM 1
MPM1031
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
224
BRAKES AND DIFFERENTIAL LOCK CIRCUIT (Diagram 2)
C--1 Cab/engine main connection C--2 Cab/transmission main connection MOD--27 Instrument MOD--100 Fuse box and main relay F--3 (+30 Key) -- Brake pressure switches F--20 (+30 Key) -- Four--wheel drive and differential lock circuit RLY--17 4WD, differential lock circuit RLY--18 Differential lock circuit RLY--19 Differential lock circuit RLY--20 4WD circuit SW--104 Four--wheel drive switch SW--115 Differential lock switch GND--136 Transmission ground GND--159 Dashboard ground SOL--214 Four--wheel drive solenoid valve SOL--215 Differential lock solenoid valve SW--216 Differential lock warning light switch SW--316 Left brake switch SW--318 Right brake switch
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
225
BRAKES AND DIFFERENTIAL LOCK CIRCUIT -- DIAGRAM 2
MPM1032
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
226
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT (Diagram 3)
C--1 Cab/engine main connection C--2 Cab/transmission main connection MOD--27 Instrument GND--159 Dashboard ground SEN--212 Fuel level sensor SEN--217 Theoretical wheel speed sensor SW--303 Air filter clogged switch SEN--305 Sediment filter SEN--306 Coolant temperature sensor SEN--309 Thermometric sensor MOD--310 Injection pump advance device SEN--311 Gearbox oil pressure switch SW--312 Brake fluid level switch SEN--313 Engine oil pressure switch SEN--315 Engine rpm sensor
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
227
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT -- DIAGRAM 3
MPM1033
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
228
BATTERY CUT--OUT, HANDBRAKE AND INSTRUMENT CIRCUIT (Diagram 4)
C--1 Cab/engine main connection MOD--27 Instrument SW--59 Operator present switch SW--64 Lift--O--Matic switch MOD--100 Fuse box and main relay F--12 (+12V MF2 -- 70A) -- Control unit for transmission, instrument, handbrake indicator light, fault diagnosis socket, car radio C--117 Diagnostic socket SW--122 CAL/SEL Switch SW--158 Brake pedals not connected switch C--319 Connection of fitting for mechanical battery cut--out
*
Jumper valid on version without mechanical battery cut--out.
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
229
BATTERY CUT--OUT, HANDBRAKE AND INSTRUMENT CIRCUIT -- DIAGRAM 4
MPM1034
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
230
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT (Diagram 5)
SW--18 Emergency switch MOD--27 Instrument MOD--70 Flasher SW--71 Lights switch LMP--72 LH two--faced headlight LMP--74 RH two--faced headlight MOD--100 Fuse box and main relay F--7 (+12V MF2 -- 70A) -- Direction indicator and hazard lights F--16 (+12V MF2 -- 70A) -- Front right--hand and rear left--hand side lights, cigar lighter indicator light F--29 (+12V MF2 -- 70A) -- Side lights, controls lighting F--30 (+12V MF2 -- 70A) -- Front left--hand and rear right--hand side lights, controls and instruments lighting RLY--2 Side lights circuit RLY--5 Brake lights circuit GND--159 Dashboard ground
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
231
DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT -- DIAGRAM 5
MPM1035
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
232
EXTERNAL LIGHTS CIRCUIT (Diagram 6)
C--1 Cab/engine main connection MOD--27 Instrument C--33 Engine/front lights connector MOD--100 Fuse box and main relay F--33 (+12V MF2 -- 70A) -- Full beam headlights F--34 (+12V MF2 -- 70A) -- Dipped beam headlights RLY--3 Full beam headlight circuit RLY--4 Dipped beam headlight circuit GND--159 Dashboard ground LMP--172 Left--hand light LMP--173 Right--hand light
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
233
EXTERNAL LIGHTS CIRCUIT -- DIAGRAM 6
MPM1036
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
234
POWER SUPPLIES CIRCUIT (Diagram 7)
C--1 Cab/engine main connection F--30/31 Mega--fuse box F--1 40A power socket F--2 Power supply fuses No. 7 -- 9 -- 12 -- 33 -- 34 -- 36, side lights relay (fuses 16 -- 29 -- 30) F--3 Power supply +30 starter switch (fuses no. 1 -- 3 -- 5 -- 14 -- 15 -- 18 -- 20 -26 -- 27 -- 28 -- 35) and +30 starter relay C--34 ISO rear power socket connector/North America C--57 Pneumatic seat supply connector C--75 Ignition switch connection C--76 Ignition switch connection C--77 Ignition switch connection C--78 Ignition switch connection SW--75/76/77/78 Key--start ignition switch MOD--100 Fuse box and main relay F--1 (+30 Key) -- Instrument (ADIC) F--5 (+30 Key) -- Engine stop circuit F--18 (+30 Key) -- Engine and transmission services F--35 (+30 Key) -- Brake lights, seat GND--159 Dashboard ground SOL--307 Engine shut--down solenoid valve
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
235
POWER SUPPLIES CIRCUIT -- DIAGRAM 7
MPM1037
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
236
GRID HEATER AND ENGINE STARTER CIRCUIT (Diagram 8)
C--1 Cab/engine main connection C--2 Cab/transmission main connection C--23 Connection for switch of indicator light/mechanical power take--off safety device SW--23 Safety switch / mechanical power take--off indicator light MOD--27 Instrument SW--35 Clutch pedal switch MOD--61 Grid heater control unit C--69 Grid heater relay connector (coil) SW--97 Mechanical battery cut--out switch MOD--100 Fuse box and main relay F--28 (+30 Key) -- Starter safety circuit RLY--MR1 Starter motor circuit GND--159 Dashboard ground F--160 Grid Heater mega--fuse RES--174 Inlet Grid Heater RLY--175 Grid heater relay ALT--301/314 Alternator M--302/308 Starter motor C--320 Fuse box protecting memory and safety systems F--320 Fuse protecting memory and safety systems GND--325 Battery ground BAT--500 Battery
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
237
GRID HEATER AND ENGINE STARTER CIRCUIT -- DIAGRAM 8
MPM1038
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
238
POWER SOCKET AND TRAILER BRAKE CIRCUIT (Diagram 9)
C--2 Cab/transmission main connection C--11 Cab/trailer brake main connection C--21 Transmission/seven--pin socket connection C--21A ISO seven--pin socket C--21B North American seven--pin socket MOD--27 Instrument SW--73 Hand brake switch MOD--100 Fuse box and main relay F--27 (+30 Key) -- Trailer brake circuit RLY--1 Parking Brake RLY--27 Trailer brake circuit RLY--28 Trailer brake circuit GND--136 Transmission ground GND--159 Dashboard ground SEN--196 Actuated trailer brake warning light pressure switch 10 bar (10.13 kg/cm) SOL--197 Trailer brake solenoid valves SEN--198 Trailer brake circuit safety pressure switch 3.5 bar (3.57 kg/cm) SEN--340 Air brake pressure switch
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
239
POWER SOCKET AND TRAILER BRAKE CIRCUIT -- DIAGRAM 9
MPM1039
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
240
REAR POWER TAKE--OFF CIRCUIT (Diagram 10)
C--2 Cab/transmission main connection C--23 Connection for switch of indicator light/mechanical power take--off safety device SW--23 Safety switch / mechanical power take--off indicator light MOD--27 Instrument SW--80 Hydraulic power take--off switch MOD--100 Fuse box and main relay F--26 (+30 Key) -- Rear power take--off circuit RLY--23 Rear PTO circuit RLY--24 Rear PTO circuit GND--136 Transmission ground GND--159 Dashboard ground SOL--213 PTO solenoid valve SEN--218 PTO speed sensor
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
241
REAR POWER TAKE--OFF CIRCUIT -- DIAGRAM 10
MPM1040
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
242
WORK LIGHTS AND AUXILIARY FUNCTIONS CIRCUIT (Diagram 11)
C--1 Cab/engine main connection C--8 Cab/front loader main connection (b) MOD--27 Instrument C--33 Engine/front lights connector C--89 Connection of fitting for 80 litre pump variant MOD--100 Fuse box and main relay F--9 (+12V MF2 -- 70A) -- Horn, 8A power socket, cigar lighter F--14 Rear work light F--15 (+30 Key) -- Front loader circuit F--36 (+12V MF4 -- 50A) -- Front swivel work lights RLY--6 Front swivel lights circuit SW--112 Grille work lights switch LMP--128 Rear work light C--142 8A auxiliary power socket GND--159 Dashboard ground AUD--169 Horn LMP--170 Left grille work light LMP--171 Right grille work light SOL--330 80 litre pump supplement solenoid valve SW--331 80 litre switch
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
243
WORK LIGHTS AND AUXILIARY FUNCTIONS CIRCUIT -- DIAGRAM 11
MPM1041
87679925A2 - 02 - 2010
244
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 VERSION A
FRONT LOADER CIRCUIT TL SERIES
C--8 Cab/front loader main connection C--50 Front loader prearrangement connector CB--50A Jumper on front loader arrangement connector D--50B Front loader arrangement connector jumper diode C--60 Implement locking switch arrangement connector C--60A Antidumping switch arrangement connector C--84 Connector with 6 additional electro--hydraulic functions. C--84A Extension with 7--pole socket for additional electro--hydraulic functions. SW--82/83 Front loader joystick SW--116A Cab dipped beam headlights switch RLY--131 Front loader RL1 relay RLY--132 Front loader RL2 relay RLY--133 Front loader RL3 relay RLY--134 Front loader RL4 relay (high beam headlights) RLY--135 Front loader RL5 relay (high beam headlights) LMP--180 Left--hand light on handrail LMP--181 Right--hand light on handrail
*** The variant with new front loader TL series (from chassis frame no. Z9JH18085), insert the circuit: A) -- on tractor with power shuttle and EDC in the diagram on page 65 B) -- on tractor with manual transmission in the diagram on page 107
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
245
FRONT LOADER CIRCUIT TL SERIES
1086 N 1087 N
C--8 1080
N
1.50
1.00 1.00
RLY--135 134B UR
1.50
** *
17 V
1.50
134A GN
1.50
134 GN
0.50
1.50
13 H
1.50
144A HV
1.50
144B HV
0.50
1084
166A ZB
CB--50A 1.00
7
V
9 VR 1.00
166F 8B L
1.00
1 V
1.00
3 R
1.00
2 V
1.00
1083
N
1.00
1
V
1.00
3
R
1.00
4
H
1.00
5
G
1.00
6
M
1.00
8A L
1.00
5 A 6 M
C--60
C--60A
MMP0357A
87679925A2 - 02 - 2010
1.00 1.00
1082
805 BR
0.50
166D ZB
0.50
166C ZB
0.50
ZB
1.00
N
0.50
ZB
1.00
N
0.50
166G ZB N
1.00 0.50
1.00
SW--82/83
8 L
1.00 814 BN
0.50
4 H
813 Z
0.50
812 ZN
0.50
1.00
RLY--131
1081 1.00
L
166E
ZB
8A
0.50
SW--116A
0.50
166L
C--84
1.00 1.00
1.00
C--84A
823B R
1.50
RLY--132
166M ZB 1089 N
1.00
N
0.50
823 R 805A BR
RLY--133
C--50
1.00
N
RLY--134
1.00
1088
7A V
1.00
LMP--181
1085
7B V
LMP--180
1.50
823 R
144 HV
D--50B
823C RN
2 V
1.00
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
246
VERSION B
ELECTRONIC BATTERY CUT--OFF CIRCUIT
MOD--40/41 Electronic battery cut--off relay module RLY--40 Safety relay * RLY--41 Timed relay *(!) C--40A Connector for positive cable on motor / alternator side C--40B Connector for positive cable on battery side MOD--43 Battery cut--off module *(@) C--46 Connector for cab/battery cut--off cable D--47 Starter circuit diode SW--97A Electronic battery cut--off switch M--302/308 Starter motor C--319 Control unit memory connector GND--325 Battery ground C--351 Battery cut--off module cable connector BAT--500 Battery * With key ON it prevents battery cut--off *(!) on engaging battery cut--off immediately after turning the key OFF let the necessary time pass before switching over for the safety warnings (for example: sound the buzzer on leaving the vehicle without having engaged the parking brake). *(@) This module contains a relay with a twin coil, powering it on pin: 43--3 ground 43--1 opens contact 43--2 ground 43--4 closes the contact.
**
The variant with electronic battery cut--off, insert the circuit: A) -- on tractor with power shuttle and EDC in the diagram on page 55 B) -- on tractor with manual transmission in the diagram on page 97
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
247
ELECTRONIC BATTERY CUT--OUT CIRCUIT
**
MMP0358A
87679925A2 - 02 - 2010
248
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
INPUT/OUTPUT WIRING DIAGRAM FOR THE TRANSMISSION ELECTRONIC CONTROL UNIT (TCM) -- POWER SHUTTLE AND CREEPER VERSION (12X12 AND 20X20) 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. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52.
Raise and lower switches on mudguards. Position, draft and Lift o matic control turret, located on the right mudguard. Power supply to the potentiometers (+5Volt from CN1B_17). Lift o matic and fast ground entry button. Lift arms position sensor. Work control potentiometer in position. Draught Potentiometer. Height limit control potentiometer. Lift potentiometer setting panel. Slip limit control potentiometer. Draft sensing pins. Drop rate control potentiometer. Sensitivity control potentiometer. Radar. Lift status indicator light (on / off). Slip limit warning light. Lift raise and lower indicator lights. Lifting solenoid valve. Lowering solenoid valve. Line through which the dashboard control unit (ADIC) and the grid heater detect ignition. Start Relay. Clutch pedal switch (pedal pressed). Shuttle lever diagram. Forward and reverse gear clutch discharge solenoid valve C. Clutch pedal potentiometer. Gear lever status switches (GN). Range lever status switches (R1 and R2). Transmission oil temperature sensor. Theoretical wheel speed sensor only for Power Shuttle version (12X12). Power supply from the clutch pedal switch to the control unit to operate the solenoid valves A and B. Power supply from fuse F23 (5A) to activate solenoid valve C closing it and sending the oil to the solenoid valves A or B. Forward gear solenoid valve A. Reverse gear solenoid valve B. Rear electro--hydraulic PTO engagement switch. PTO modulation cut--in switch. PTO engagement switches on the mudguards. Brake pedal switches (switches on with brakes at rest). Differential lock engagement switch. Four--wheel drive disengagement switch. Four--wheel drive disengagement solenoid valve. Diagram of behaviour of range lever status switches (R1 and R2). Differential lock engagement solenoid valve. Rear power take--off engagement solenoid valve. Control unit grounds. Potentiometers and sensors common ground. Electrostatic ground. Connector layout on control unit, Control unit connectors. CAN BUS line terminator. CAN BUS line external terminator (for manual transmissions). Creeper unit status switches. Theoretical wheel speed sensor only for Power Shuttle and creeper unit version (20X20).
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
249
INPUT/OUTPUT WIRING DIAGRAM FOR THE TRANSMISSION ELECTRONIC CONTROL UNIT (TCM) -- POWER SHUTTLE AND CREEPER VERSION (12X12 AND 20X20) MF3 -- 50A
F1 -- 5A
F1 -- 5A F2 -- 5A
+30 +50a
F2 -- 5A
F3 -- 5A
F3 -- 5A
F4 -- 5 A +15/1
MF2 -- 70A
F4 -- 5 A F18 -- 10A
F18 -- 10A
+15
F23 -- 5A F24 -- 5A F17 -- 10A
F23 -- 5A F24 -- 5A F17 -- 10A
F28 -- 5A
F31 -- 30A
F28 -- 5A F12 -- 5A
F12 -- 5A
F18
F24
20 21 22
23
30
31
39 33
3
15
40
1 16
2
32
5
4
6
3
25 26
8 9 10
560 SEE CREEPER 560 off
Power socket (Polarity 3)
51
19
13
TYCO 26 way Power socket (Polarity 4)
GN 2000 R1 2000 R2 2000 2000
12
CN1a TYCO 26 way
CN2
560
27
18
37 560
11
Power socket (Polarity 2)
HALL
52
36 Only for 20X20
35
29
CN3b TYCO 34 way Power socket (Polarity 1)
Only for 12X12
(POWER SHUTTLE 12X12) (P.S. WITH CREEPER 20X20)
Power socket (Polarity 1)
CN1b CN1a CN2 MPM0368A
CN3a CN3b
34 CAN TERMINATOR
120 Ohm
49
B2
CRANK DETECT
20 47
43
28
14
CN3a TYCO 26 way
42
38
24
17
7
CN1b TYCO 34 way
41
44
46 45 CRANK DETECT
VIEW OF TCM MODULE 9
1 10 18
7
1
17
8
25
14
13
1
7 8
13
14
34
26
CN1b
9
1 10
17
8
18
25
14
26
CN1a
CN2
87679925A2 - 02 - 2010
7
1
13
34
CN3b
CN3a
48
250
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
INPUT/OUTPUT WIRING DIAGRAM FOR THE TRANSMISSION ELECTRONIC CONTROL UNIT (TCM) -- POWER SHUTTLE 24X24 VERSION 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. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50.
Raise and lower switches on mudguards. Position, draft and Lift o matic control turret, located on the right mudguard. Power supply to the potentiometers (+5 Volt from CN1B_17). Lift o matic and fast ground entry button. Lift arms position sensor. Work control potentiometer in position. Draught Potentiometer. Height limit control potentiometer. Lift potentiometer setting panel. Slip limit control potentiometer. Draft sensing pins. Drop rate control potentiometer. Sensitivity control potentiometer. Radar. Lift status indicator light (on / off). Slip limit warning light. Lift raise and lower indicator lights. Lifting solenoid valve. Lowering solenoid valve. Line through which the dashboard control unit (ADIC) and the grid heater detect ignition. Start Relay. Clutch pedal switch (pedal pressed). Shuttle lever diagram. Gear lever buttons (Dual Command (2 Speed Power Shift) and clutch cut--out). Clutch pedal potentiometer. Gear lever (GN) and range lever (R1 and R2) status switches. Clutch A and B safety switches. Transmission oil temperature sensor. Theoretical wheel speed sensor. Clutch D solenoid valve. Clutch Solenoid C. Reverse gear solenoid valve B (supplied from the clutch pedal switch). Forward gear solenoid valve A (supplied from the clutch pedal switch). Rear electro--hydraulic PTO engagement switch. PTO modulation cut--in switch. PTO engagement switches on the mudguards. Brake pedal switches (switches on with brakes at rest). Differential lock engagement switch. Four--wheel drive disengagement switch. Four--wheel drive disengagement solenoid valve. Diagram of behaviour of range lever status switches (R1 and R2). Differential lock engagement solenoid valve. Rear power take--off engagement solenoid valve. Control unit grounds. Potentiometers and sensors common ground. Electrostatic ground. Connector layout on control unit, Control unit connectors. CAN BUS line terminator. CAN BUS line external terminator (for manual transmissions).
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
251
INPUT/OUTPUT WIRING DIAGRAM FOR THE TRANSMISSION ELECTRONIC CONTROL UNIT (TCM) POWER SHUTTLE 24X24 VERSION
CN3a CN3b
CN2 CN1a CN1b
MPM0369A
87679925A2 - 02 - 2010
252
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
INPUT/OUTPUT WIRING DIAGRAM FOR THE ELECTRONIC CONTROL UNIT OF THE INSTRUMENT PANEL (ADIC) 1. 2.
Line through which the dashboard control unit (ADIC) and the grid heater detect ignition. Fuel level sensor.
3. 4. 5. 6. 7.
Lift status switch (without electronic lift and keypad). Brake fluid reservoir level switch. Work lights indicator lights. Power supply from the mechanical clutch engagement lever or from the electro--hydraulic clutch engagement solenoid valve for turning on the related PTO indicator light (with manual transmission only). Side lights indicator light and full beam indicator light.
8. 9. 10. 11. 12. 13.
ISO 11786 socket (only with advanced ADIC). Water contamination in fuel warning light. Theoretical wheel speed sensor (with manual transmissions). Air filter clogged sensor. Engine rpm sensor. Rear PTO speed sensor (with advanced ADIC or Power shuttle transmission).
14. 15. 16. 17. 18. 19. 20.
Diagnostic socket. Ground supplied to ADIC. Ground that ADIC sends to the sensors. CAN BUS line terminator. Engine coolant temperature sensor. Grid heater control module. Grid heater relay.
21. 22. 23. 24. 25. 26. 27.
Grid heater. Grid Heater mega--fuse. Alternator. CAL SEL switch (without keypad). Power supply from the four--wheel drive solenoid valve for turning off the four--wheel drive indicator light. Engine oil pressure switch. Trailer brake 10 bar pressure switch turning off related indicator light.
28. 29. 30. 31. 32. 33. 34.
Transmission/steering oil pressure switch. Differential lock engagement indicator light. Parking Brake Switch. Brake pedals not connected switch. Flasher. Operator present switch (new type with fault diagnosis). Air Brake Pressure Switch.
35. 36. 37. 38.
Keypad connector. Keypad. ADIC connector pins. Positioning of the connectors on the ADIC.
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
253
INPUT/OUTPUT WIRING DIAGRAM FOR THE ELECTRONIC CONTROL UNIT OF THE INSTRUMENT PANEL (ADIC)
MPM1180A
87679925A2 - 02 - 2010
254
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
CONTENTS
1
CONTENTS VOLUME 3 Page
Date
55 -- ELECTRICAL SYSTEM (*) CHAPTER 7 -- Connectors Summary . . . . . . . . . . . . . . . 1
02--10
Electrical circuit components . . . . . . . . . . . . . . . . . . 2÷7
Page
Date
2001--3000 (Transmission) . . . . . . . . . . 235÷248
02--10
5001--6000 (PTO) . . . . . . . 249÷254
02--10
CHAPTER 10 -- HH menu and calibrations Summary . . . . . . . . . . . . . . . 1
02--10
02--10
HH MENU access . . . . . . . 2--3
02--10
Types of versions . . . . . . . . 8
02--10
Harnesses . . . . . . . . . . . . . . 9÷40
02--10
HH MENU of the control panel . . . . . . . . . . . . . . . . . . 4÷12
02--10
List of connectors . . . . . . . . 41÷150
02--10
HH MENU of the transmission . . . . . . . . . . . . . . . . . . . 13÷42
02--10
HH MENU of the advanced keypad . . . . . . . . . . 43--44
02--10
CHAPTER 8 -- Components Summary . . . . . . . . . . . . . . . 1
02--08
Tests on switches, sensors and pressure switches . . . 02÷29
02--08
Removal--Installation windscreen wiper motor . . . . . . 30
02--08
CHAPTER 9 -- Error codes Summary . . . . . . . . . . . . . . . 1
02--08
Introduction . . . . . . . . . . . . . 2
02--08
Special Attachments . . . . . 3
02--08
Repairing the wiring . . . . . . 3÷5
02--08
Digital multimeter . . . . . . . . 6÷8
02--08
Electrical test procedures . 9÷11
02--08
Circuit components . . . . . . 11÷19
02--08
Control unit location . . . . . . 20
02--08
Error code display . . . . . . . 21--22
02--08
CAN system . . . . . . . . . . . . 22
02--08
Error codes lists . . . . . . . . . 24÷29
02--10
Error codes charts Calibration U--Codes . . . . . 29÷32
02--10
1001--2000 Electronic draft control (EDC) . . . . . . . . . . . 33÷86
02--10
2001--3000 (Transmission) . . . . . . . . . . 87÷168
02--10
5001--6000 (PTO) 6001--7000 (4WD) 7001--8000 (DL) . . . . . . . . . 169÷186
02--10
14001--15000 (Analog-Digital Instrument Cluster)
02--10
187÷234
90 -- BODYWORK AND DRIVING POSITION Summary . . . . . . . . . . . . . . . 1
11--07
Removal--Installation -bonnet . . . . . . . . . . . . . . . . . 2--3
11--07
Removal--Installation -platform . . . . . . . . . . . . . . . . 4÷12
11--07
Removal--Installation -driver’s seat . . . . . . . . . . . . 13
11--07
Removal--Installation -14÷25 cab . . . . . . . . . . . . . . . . . . . .
11--07
Removal--Installation -26 door . . . . . . . . . . . . . . . . . . .
11--07
Replacement of glued cab windows . . . . . . . . . . . . . . . 27--28
11--07
Replacement of cab rear window . . . . . . . . . . . . . . . . 29÷31
11--07
Replacement of seal on left--hand upright . . . . . . . . 32
11--07
Replacement of seal on right--hand upright . . . . . . . 33--34
11--07
Replacement of fixed padding on right--hand wall . . . 35÷37
11--07
Replacement of fixed padding on left--hand wall . . . . 38--39
11--07
Replacing hydraulic control lever guard . . . . . . . . . . 40--41
11--07
Replacing cab ceiling fittings . . . . . . . . . . . . . . . . . . . 42--43
11--07
(*)Chapters
prior to section 55 are in volume 2. 87679925A2-- 02 -- 2010
2
87679925A2-- 02 -- 2010
CONTENTS
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
1
SECTION 55 − ELECTRICAL SYSTEM Chapter 7 − WIRING HARNESSES AND CONNECTORS CONTENTS Description
Page
Electrical circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Types of versions for tractors with cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 List of connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
2
ELECTRICAL CIRCUIT COMPONENTS CODE DESCRIPTION
ALTERNATOR ALT−301/314 Alternator AUDIO DEVICES AUD−63 LH speaker AUD−150 RH speaker AUD−169 Audible beep BATTERY BAT−500 Battery CONNECTIONS C−1 Cab/engine main connection C−2 Cab/transmission main connection C−8 Cab/front loader main connection C−11 Cab/trailer brake main connection C−12 Cab/air−conditioning main connection C−21 Transmission/seven−pin socket connection C−23 Connection for switch of indicator light/mechanical power take−off safety device C−33 Engine/front lights connector C−34 ISO rear power socket connector/North America C−37 Extension connector ISO 11786 C−40A Connector for positive cable on motor / alternator side of battery cut−off module C−40B Connector for positive cable on battery side C−46 Cab / battery cut−off cable connector C−50 Front loader prearrangement connector* C−57 Pneumatic seat supply connector C−58 Connector of fitting for ISO 11786 power socket C−60 Implement locking switch arrangement connector* C−60A Antidumping switch arrangement connection* C−69 Grid heater relay connector (coil) C−75 Ignition switch connection C−76 Ignition switch connection C−77 Ignition switch connection C−78 Ignition switch connection C−81 Connector with 3 additional electro−hydraulic functions C−84 Connector with 6 additional electro−hydraulic functions* C−89 Connection of fitting for 80 litre pump variant
87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
3
CODE DESCRIPTION
C−117 Diagnostic socket C−143 Right−hand rotating beacon socket C−144 Left−hand rotating beacon socket C−319 Control unit memory connector C−320 Fuse box protecting memory and safety systems* C−351 Battery cut−off module cable connector* JUMPERS CB−8A Jumper on front loader connection CB−50A Jumper on front loader arrangement connector* DIODE D−47 Starter circuit diode* D−50B Loader arrangement connector jumper diode* D−130 Diode for circuit of main beam headlights on handrail lights* FUSES F−30/31 Mega−fuse box F−160 Grid Heater mega−fuse F−320 Fuse protecting memory and safety systems GROUND GND−92 Cab right upright top ground GND−136 Transmission ground GND−146 Ground on left mudguard GND−151 Ground on right mudguard GND−159 Dashboard ground GND−325 Battery ground LAMPS LMP−17 Front LH light LMP−26 Work light on right handrail LMP−28 Work light on left handrail LMP−49 Front right work light on cab (outside) LMP−66A Rear right direction indicator on cab roof LMP−66B Right rear work light (see page 141) LMP−68 Overhead lighting LMP−72 LH two−faced headlight LMP−74 RH two−faced headlight LMP−95 Front right work light on cab (inside) (see page 141) LMP−96 Front left work light on cab (inside) (see page 141) LMP−98 Right−hand rotating beacon (see page 142)
87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
4
CODE DESCRIPTION
LMP−99 Left−hand rotating beacon (see page 142) LMP−121 RH number plate light LMP−123 RH tail light LMP−124 LH number plate light LMP−126 Front RH light LMP−128 Rear work light LMP−139 Front left work light on cab (outside) LMP−148A Rear left direction indicator on cab roof LMP−148B Rear left work light on cab roof (see page 142) LMP−152 LH tail light LMP−161 Cab upright red light LMP−162 EDC Potentiometer backlighting LMP−170 Left grille work light LMP−171 Right grille work light LMP−172 Left−hand light LMP−173 Right−hand light LMP−180 Left−hand light on handrail LMP−181 Right−hand light on handrail MOTORS M−138 Wiper Motor M−147 Windscreen wiper pump M−149 Rear wiper motor M−163 Rear window wiper pump M−188A Electric fan 1 M−188B Electric fan 2 M−302/308 Starter motor M−304 Air conditioning compressor ELECTRONIC MODULES − CONTROL UNITS MOD−1/3 TCM transmission control unit MOD−27 Instrument MOD−40/41 Electronic battery cut−off relay module* MOD−43 Battery cut−off module* MOD−53 EDC Potentiometers panel MOD−54 EDC Mouse MOD−55 EDC LED panel MOD−56 Radio MOD−61 Grid heater control unit MOD−70 Flasher MOD−100 Fuse box and main relay MOD−166 Key Pad (keypad)
87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
5
CODE DESCRIPTION
MOD−310 Injection pump advance device RESISTORS RES−156 Clutch pedal potentiometer RES−174 Inlet Grid Heater RELAYS RLY−40 Safety relay RLY−41 Timed relay RLY−70A Flasher relay RLY−131 Front loader RL1 relay RLY−132 Front loader RL2 relay RLY−133 Front loader RL3 relay RLY−134 Front loader RL4 relay (high beam headlights) RLY−135 Front loader RL5 relay (high beam headlights) RLY−175 Grid heater relay SENSORS SEN−190 Electronic thermostat SEN−196 Actuated trailer brake warning light pressure switch 10 bar (10.13 kg/cm) SEN−198 Trailer brake circuit safety pressure switch 3.5 bar (3.57 kg/cm) SEN−201 Transmission oil temperature sensor SEN−206 Safety pressure switch clutch A SEN−207 Safety pressure switch clutch B SEN−212 Fuel level sensor SEN−217 Theoretical wheel speed sensor SEN−217B Theoretical wheel speed sensor (PS version with creeper unit 20X20) SEN−218 PTO speed sensor SEN−221 RH draft sensor SEN−224 Arms position sensor SEN−225 LH draft sensor SEN−227 Radar SEN−305 Sediment filter SEN−306 Coolant temperature sensor SEN−309 Thermometric sensor SEN−311 Gearbox oil pressure switch SEN−313 Engine oil pressure switch SEN−315 Engine rpm sensor SEN−317 Air drier filter SEN−340 Air Brake Pressure Switch
87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
6
CODE DESCRIPTION
SOLENOID VALVES SOL−197 Trailer brake solenoid valves SOL−202 Clutch A solenoid valve SOL−203 Clutch B solenoid valve SOL−204 Clutch C solenoid valve (dump solenoid valve Vers. PS 12X12) SOL−205 Clutch D solenoid valve SOL−213 Power take−off solenoid valve SOL−214 Four−wheel drive solenoid valve SOL−215 Differential lock solenoid valve SOL−222 Lifting solenoid valve SOL−223 Lowering solenoid valve SOL−307 Engine shut−down solenoid valve SOL−330 80 litre supplement solenoid valve CONTROL SWITCHES SW−13 Gear lever switch SW−18 Emergency switch SW−23 Safety switch / mechanical power take−off indicator light SW−29 Front Windshield Wiper Switch SW−35 Clutch pedal switch SW−44 Rotating beacon switch SW−45 Rear wiper switch SW−59 Operator present switch SW−64 Lift−O−Matic switch SW−71 Lights switch SW−73 Hand brake switch SW−75/76/77 Key−start ignition switch /78 SW−79 Shuttle lever switch SW−80 Hydraulic power take−off switch SW−82/83 Front lift joystick SW−97 Mechanical battery cut−out switch SW−97A Electronic battery cut−off switch* SW−104 Four−wheel drive switch SW−108 Modulated PTO switch SW−112 Grille work lights switch SW−115 Differential lock switch SW−116 Cab dipped beam headlights switch SW−116A Cab dipped beam headlights switch*
87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
7
CODE DESCRIPTION
SW−122 CAL/SEL Switch SW−125 Power take−off switch on left−hand mudguard SW−127 Power take−off switch on right−hand mudguard SW−145 Door light switch SW−158 Brake pedals not connected switch SW−164 Raise and lower switch on right−hand mudguard EDC SW−165A Electric fan switch SW−165C Air conditioner switch SW−167 Raise and lower switch on left−hand mudguard EDC SW−178 Front work lights switch SW−179 Rear work lights switch SW−209 G gear lever status switch SW−210 R1 range lever status switch SW−211 R2 range lever status switch SW−216 Differential lock warning light switch SW−296 Creeper unit lever status switch* SW−303 Air filter clogged switch SW−312 Brake oil level switch SW−316 Left brake switch SW−318 Right brake switch SW−331 80 litre switch POWER SOCKETS C−21A ISO seven−pin socket C−21B North American seven−pin socket C−81A Extension with 8 Amp socket for additional electro−hydraulic functions* C−84A Extension with 7−pole socket for additional electro−hydraulic functions* C−88 Cigar/Cigarette Lighter C−142 8A auxiliary power socket
(*) The connectors for these elements are shown from page 144 onwards.
87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
8
TYPES OF VERSIONS FOR TRACTORS WITH CAB
VERSION
DESCRIPTION
1
VERSION WITH POWER SHUTTLE AND ELECTRONIC LIFT
2
STANDARD VERSION
TYPES OF VERSIONS FOR TRACTORS WITHOUT CAB
VERSION
DESCRIPTION
3
VERSION WITH POWER SHUTTLE − (ISO)
4
STANDARD VERSION − (ISO)
5
VERSION WITH POWER SHUTTLE − (NORTH AMERICA)
6
STANDARD VERSION − (NORTH AMERICA)
TYPES OF VARIANTS FOR TRACTORS WITH CAB VERSION
DESCRIPTION
A
FRONT LOADER CIRCUIT TL SERIES
B
ELECTRONIC BATTERY CUT−OUT CIRCUIT
87679925A2 − 02 − 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
9
HARNESSES
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
10
VERSION 1 VERSION WITH POWER SHUTTLE AND ELECTRONIC LIFT -- (Cab version)
INDEX TO WIRING HARNESSES DESCRIPTION
PAGE
Wiring diagrams 1, 2, 3
11
Wiring diagrams 4, 5, 6
12
Wiring diagrams 7, 8, 9, 10
13
Wiring diagrams 11, 12, 13
14
Wiring diagrams 14, 15, 16
15
Wiring diagrams 17, 18
16
WIRING DIAGRAM TITLE INDEX Circuit 1
Battery cut--out and handbrake circuit
Circuit 2
Diagnostics connection and CAN line circuit
Circuit 3
Auxiliary functions and radio circuit
Circuit 4
Brakes and differential lock circuit
Circuit 5
Engine, sensors and transmitters circuit
Circuit 6
Front lift and 80 litre combined valve circuit
Circuit 7
Cab ventilation and air--conditioning circuit
Circuit 8
Instrument circuit
Circuit 9
Direction indicator and hazard lights circuit
Circuit 10
External lights circuit
Circuit 11
Power supplies circuit
Circuit 12
Rear power take--off circuit
Circuit 13
Grid heater and engine starter circuit
Circuit 14
Power socket and trailer brake circuit
Circuit 15
Windscreen and rear window washer/wiper circuit
Circuit 16
Work lights circuit
Circuit 17
Power Shuttle circuit
Circuit 18
Electronic lift circuit (EDC)
87679925A - 12 - 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
11
WIRING DIAGRAMS 1−2−3
MPM1219A
1 87679925A2 − 02 − 2010
12
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7 WIRING DIAGRAMS 4 − 5 − 6
MPM1225A
2 87679925A2 − 02 − 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
13
WIRING DIAGRAMS 7 --8 -- 9 -- 10
MPM1216A
3 87679925A1 - 02 - 2008
14
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 WIRING DIAGRAMS 11 -- 12 -- 13
MPM1223A
4 87679925A1 - 02 - 2008
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
15
WIRING DIAGRAMS 14 − 15 − 16
MPM1173A
5 87679925A2 − 02 − 2010
87679925A2 − 02 − 2010
GND−159
C−2
RES−156
MOD−1/3
SW−35
SW−79
MOD−100
SOL−205
SEN−217B
SEN−225
GND−136
SW−167
SEN−224
SOL−222
SEN−217
SOL−204 SOL−203 SOL−202
SEN−207
SW−210
SW−211
SW−296
SEN−221
SW−164 MOD−54 MOD−55
LMP−162
MOD−53
SEN−227
SEN−201
SEN−206
SW−209
C−2
SW−13
GND−151
SOL−223
16 SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7 WIRING DIAGRAMS 17 − 18
MMP0355A
6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
17
VERSION 2 STANDARD VERSION -- (Cab version)
INDEX TO WIRING HARNESSES DESCRIPTION
PAGE
Wiring diagrams 1, 2, 3
18
Wiring diagrams 4, 5, 6
19
Wiring diagrams 7, 8, 9, 10
20
Wiring diagrams 11, 12, 13
21
Wiring diagrams 14, 15, 16
22
WIRING DIAGRAM TITLE INDEX Diagram 1
Battery cut--out and handbrake circuit
Diagram 2
CAN line circuit and fault diagnosis connection
Diagram 3
Radio and auxiliary functions circuit
Diagram 4
Brakes and differential lock circuit
Diagram 5
Engine, sensors and transmitters circuit
Diagram 6
Front lift and 80 litre combined valve circuit
Diagram 7
Cab ventilation and air--conditioning circuit
Diagram 8
Instrument circuit
Diagram 9
Direction indicator and hazard lights circuit
Diagram 10
External lights circuit
Diagram 11
Power supplies circuit
Diagram 12
Rear PTO circuit
Diagram 13
Grid heater and engine starter circuit
Diagram 14
Power sockets and trailer brake circuit
Diagram 15
Windscreen and rear window washer/wiper circuit
Diagram 16
Work lights circuit
87679925A1 - 02 - 2008
18
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 WIRING DIAGRAMS 1 -- 2 -- 3
MPM1218A
7 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
19
WIRING DIAGRAMS 4 -- 5 -- 6
MPM1215A
8 87679925A1 - 02 - 2008
20
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 WIRING DIAGRAMS 7 -- 8 -- 9 -- 10
MPM1222A
9 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
21
WIRING DIAGRAMS 11 -- 12 -- 13
MPM1221A
10 87679925A1 - 02 - 2008
22
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 WIRING DIAGRAMS 14 -- 15 -- 16
MPM1214A
11 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
23
VERSION 3 VERSION WITH POWER SHUTTLE ISO - (Deck version)
INDEX TO WIRING HARNESSES DESCRIPTION
PAGE
Wiring diagrams 1, 2, 3, 4
24
Wiring diagrams 5, 6, 7, 8
25
Wiring diagrams 9, 10, 11
26
Wiring diagram 12
27
WIRING DIAGRAM TITLE INDEX Diagram 1
CAN line circuit and fault diagnosis connection
Diagram 2
Brakes and differential lock circuit
Diagram 3
Engine, sensors and transmitters circuit
Diagram 4
Battery cut--out, handbrake and instrument circuit
Diagram 5
Direction indicator and hazard lights circuit
Diagram 6
External lights circuit
Diagram 7
Power supplies circuit
Diagram 8
Grid heater and engine starter circuit
Diagram 9
Power sockets and trailer brake circuit
Diagram 10
Rear PTO circuit
Diagram 11
Work lights and auxiliary functions circuit
Diagram 12
Power Shuttle circuit
87679925A - 12 - 2007
24
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 WIRING DIAGRAMS 1 -- 2 -- 3 -- 4
MPM1193A
12 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
25
WIRING DIAGRAMS 5 -- 6 -- 7 -- 8
MPM1194A
13 87679925A - 12 - 2007
26
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 WIRING DIAGRAMS 9 -- 10 -- 11
MPM1195A
14 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
27
WIRING DIAGRAM 12
MPM1196A
15 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
28
VERSION 4 STANDARD ISO VERSION - (Deck version)
INDEX TO WIRING HARNESSES DESCRIPTION
PAGE
Wiring diagrams 1, 2, 3, 4
29
Wiring diagrams 5, 6, 7, 8
30
Wiring diagrams 9, 10, 11
31
WIRING DIAGRAM TITLE INDEX Diagram 1
CAN line circuit and fault diagnosis connection
Diagram 2
Brakes and differential lock circuit
Diagram 3
Engine, sensors and transmitters circuit
Diagram 4
Battery cut--out, handbrake and instrument circuit
Diagram 5
Direction indicator and hazard lights circuit
Diagram 6
External lights circuit
Diagram 7
Power supplies circuit
Diagram 8
Grid heater and engine starter circuit
Diagram 9
Power sockets and trailer brake circuit
Diagram 10
Rear PTO circuit
Diagram 11
Work lights and auxiliary functions circuit
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
29
WIRING DIAGRAMS 1 -- 2 -- 3 -- 4
MPM1190A
16 87679925A - 12 - 2007
30
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 WIRING DIAGRAMS 5 -- 6 -- 7 -- 8
MPM1191A
17 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
31
WIRING DIAGRAMS 9 -- 10 -- 11
MPM1192A
18 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
32
VERSION 5 VERSION WITH POWER SHUTTLE NORTH AMERICA - (Deck version)
INDEX TO WIRING HARNESSES DESCRIPTION
PAGE
Wiring diagrams 1, 2, 3, 4
33
Wiring diagrams 5, 6, 7, 8
34
Wiring diagrams 9, 10, 11
35
Wiring diagram 12
36
WIRING DIAGRAM TITLE INDEX Diagram 1
CAN line circuit and fault diagnosis connection
Diagram 2
Brakes and differential lock circuit
Diagram 3
Engine, sensors and transmitters circuit
Diagram 4
Battery cut--out, handbrake and instrument circuit
Diagram 5
Direction indicator and hazard lights circuit
Diagram 6
External lights circuit
Diagram 7
Power supplies circuit
Diagram 8
Grid heater and engine starter circuit
Diagram 9
Power sockets and trailer brake circuit
Diagram 10
Rear PTO circuit
Diagram 11
Work lights and auxiliary functions circuit
Diagram 12
Power Shuttle circuit
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
33
WIRING DIAGRAMS 1 -- 2 -- 3 -- 4
MPM1186A
19 87679925A - 12 - 2007
34
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 WIRING DIAGRAMS 5 -- 6 -- 7 -- 8
MPM1187A
20 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
35
WIRING DIAGRAMS 9 -- 10 -- 11
MPM1188A
21 87679925A - 12 - 2007
36
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 WIRING DIAGRAM 12
MPM1189A
22 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
37
VERSION 6 STANDARD VERSION FOR NORTH AMERICA - (Deck version)
INDEX TO WIRING HARNESSES DESCRIPTION
PAGE
Wiring diagrams 1, 2, 3, 4
38
Wiring diagrams 5, 6, 7, 8
39
Wiring diagrams 9, 10, 11
40
WIRING DIAGRAM TITLE INDEX Diagram 1
CAN line circuit and fault diagnosis connection
Diagram 2
Brakes and differential lock circuit
Diagram 3
Engine, sensors and transmitters circuit
Diagram 4
Battery cut--out, handbrake and instrument circuit
Diagram 5
Direction indicator and hazard lights circuit
Diagram 6
External lights circuit
Diagram 7
Power supplies circuit
Diagram 8
Grid heater and engine starter circuit
Diagram 9
Power sockets and trailer brake circuit
Diagram 10
Rear PTO circuit
Diagram 11
Work lights and auxiliary functions circuit
87679925A - 12 - 2007
38
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 WIRING DIAGRAMS 1 -- 2 -- 3 -- 4
MPM1183A
23 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
39
WIRING DIAGRAMS 5 -- 6 -- 7 -- 8
MPM1184A
24 87679925A - 12 - 2007
40
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 WIRING DIAGRAMS 9 -- 10 -- 11
MPM1185A
25 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
41
LIST OF CONNECTORS
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
42 Pin
Col.
Sect.
Pin
Col.
Sect.
1
V
1.5
26
--
--
2
H
1.5
27
--
--
3
AV
1.5
28
--
--
4
Z
1.0
29
--
--
5
R
1.0
30
LB
1.0
6
B
1.0
31
--
--
7
RV
1.0
32
--
--
8
ZB
1.0
33
--
--
9
MN
0.5
34
--
--
10
NG
1.0
35
--
41
31
21
11
1
42
32
22
12
2
43
33
23
13
3
--
44
34
24
14
4
45
35
25
15
5
46
36
26
16
6
47
37
27
17
7 8
11
BL
1.0
36
--
--
12
RN
1.5
37
--
--
13
RN
1.5
38
--
--
48
38
28
18
49
39
29
19
9
50
40
30
20
10
14
AR
1.0
39
--
--
15
--
--
40
--
--
16
HN
0.5
41
--
--
17
N
0.5
42
--
--
18
VG
1.0
43
--
--
19
CA
1.0
44
--
--
20
M
1.0
45
--
--
21
AB
1.0
46
--
--
22
HR
1.0
47
--
--
23
G
1.0
48
N
1.5
24
BR
1.0
49
N
1.5
25
HV
1.0
50
N
1.5
For model with cab, standard version MAIN CABLE SIDE
87679925A - 12 - 2007
C--1
26
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
1
V
1.5
26
--
--
2
H
1.5
27
--
--
3
AV
1.5
28
--
--
4
Z
1.0
29
--
--
5
R
1.0
30
LB
1.0
6
RG
1.0
31
--
--
7
RV
1.0
32
--
--
8
ZB
1.0
33
--
--
9
MN
0.5
34
--
--
10
NG
1.0
35
--
43
41
31
21
11
1
42
32
22
12
2
43
33
23
13
3
--
44
34
24
14
4
45
35
25
15
5
46
36
26
16
6
47
37
27
17
7 8
11
BL
1.0
36
--
--
12
RN
1.5
37
--
--
13
RN
1.5
38
--
--
48
38
28
18
49
39
29
19
9
50
40
30
20
10
14
AR
1.0
39
--
--
15
--
--
40
--
--
16
HN
0.5
41
--
--
17
N
0.5
42
--
--
18
VG
1.0
43
--
--
19
CA
1.0
44
--
--
20
M
1.0
45
--
--
21
AB
1.0
46
--
--
22
HR
1.0
47
--
--
23
G
1.0
48
N
1.5
24
BR
1.0
49
N
1.5
25
HV
1.0
50
N
1.5
C--1
27
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
44 Pin
Col.
Sect.
Pin
Col.
Sect.
1
V
1.5
26
--
--
2
H
1.5
27
--
--
3
AV
1.5
28
--
--
4
Z
1.0
29
--
--
5
R
1.0
30
--
--
6
B
1.0
31
--
--
7
RV
1.0
32
--
--
8
ZB
1.0
33
--
--
9
MN
0.5
34
--
--
10
NG
1.0
35
--
41
31
21
11
1
42
32
22
12
2
43
33
23
13
3
--
44
34
24
14
4
45
35
25
15
5
46
36
26
16
6
47
37
27
17
7 8
11
BL
1.0
36
--
--
12
RN
1.5
37
--
--
13
RN
1.5
38
--
--
48
38
28
18
49
39
29
19
9
50
40
30
20
10
14
AR
1.0
39
--
--
15
--
--
40
--
--
16
HN
0.5
41
--
--
17
N
0.5
42
--
--
18
VG
1.0
43
--
--
19
CA
1.0
44
--
--
20
M
1.0
45
--
--
21
AB
1.0
46
--
--
22
HR
1.0
47
--
--
23
G
1.0
48
N
1.5
24
BR
1.0
49
N
1.5
25
HV
1.0
50
N
1.5
For model without cab MAIN CABLE SIDE
87679925A - 12 - 2007
C--1
28
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Sect.
--
--
2
H
1.5
27
--
--
3
AV
1.5
28
--
--
4
Z
1.0
29
--
--
5
R
1.0
30
LB
1.0
6
RG
1.0
31
--
--
7
RV
1.0
32
--
--
8
ZB
1.0
33
--
--
9
MN
1.0
34
--
--
10
NG
1.0
35
--
--
11
BL
1.0
36
--
--
12
RN
1.5
37
--
--
13
RN
1.5
38
--
--
14
AR
1.0
39
--
--
15
--
--
40
--
--
16
HN
1.0
41
--
--
17
N
1.0
42
--
--
18
VG
1.0
43
--
--
19
CA
1.0
44
--
--
20
M
1.0
45
--
--
21
AB
1.0
46
--
--
22
HR
1.0
47
--
--
23
G
1.0
48
N
1.5
24
BR
1.0
49
N
1.5
25
HV
1.0
50
N
1.5
41 42 43 44 45 46 47 48 49 50
Col.
26
31 32 33 34 35 36 37 38 39 40
Pin
1.5
21 22 23 24 25 26 27 28 29 30
Sect.
V
11 12 13 14 15 16 17 18 19 20
Col.
1
1 2 3 4 5 6 7 8 9 10
Pin
45
C--1
29
ENGINE CABLE SIDE
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
46 Pin
Col.
Sect.
Pin
Col.
Sect.
1
C
1.0
14
R
1.0
2
C
1.0
15
G
0.75
3
--
--
16
V
0.75
4
AG
1.0
17
--
--
5
SB
1.0
18
--
--
6
LR
1.0
19
N
1.0
7
GR
1.0
20
--
--
8
RN
0.5
21
--
--
9
MN
0.5
22
--
--
10
--
--
23
BR
1.0
11
LG
1.0
24
--
--
12
A
1.0
25
N
1.0
13
--
--
26
N
1.0
7
1
26
20
MOD--1/3 (1A)
For model with cab, version with Power Shuttle MAIN CABLE SIDE
30 Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
18
--
--
2
BL
0.5
19
RN
0.5
3
--
--
20
--
--
4
--
--
21
BV
0.5
5
--
--
22
HN
0.5
1
9
6
--
--
23
N
0.5
10
17
7
--
--
24
B
0.5
18
25
26
34
8
--
--
25
B
1.0
9
HV
1.0
26
--
--
10
GV
1.0
27
--
--
11
--
--
28
NB
0.5
12
H
0.5
29
--
--
13
MB
0.5
30
--
--
14
M
0.5
31
--
--
15
--
--
32
--
--
16
--
--
33
MV
0.5
17
S
0.5
34
HB
0.5
MOD--1/3 (1B)
For model with cab, version with Power Shuttle MAIN CABLE SIDE
31
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
1
ZB
0.5
14
--
--
2
--
--
15
--
--
3
MN
0.5
16
--
--
4
VB
0.5
17
--
--
5
MB
0.5
18
CA
0.5
6
--
--
19
--
--
7
H
0.5
20
--
--
8
SB
0.5
21
--
--
9
--
--
22
--
--
10
LR
0.5
23
--
--
11
CA
0.5
24
CB
0.5
12
H
0.5
25
--
--
13
MZ
0.5
26
MN
0.5
47
7
1
26
20
MOD--1/3 (1A)
For model with cab, version with Power Shuttle MAIN CABLE SIDE
32 Pin
Col.
Sect.
Pin
Col.
Sect.
1
AN
1.0
18
RG
1.0
2
LN
1.0
19
--
--
3
LV
1.0
20
--
--
4
GV
1.0
21
--
--
5
--
--
22
--
--
1
9
6
--
--
23
--
--
10
17
7
--
--
24
--
--
18
25
26
34
8
--
--
25
--
--
9
BG
0.5
26
--
--
10
--
--
27
--
--
11
--
--
28
--
--
12
--
--
29
--
--
13
--
--
30
RV
0.5
14
AV
1.0
31
RG
0.5
15
--
--
32
CL
0.5
16
--
--
33
--
--
17
BN
1.0
34
C
1.0
MOD--1/3 (3B)
For model with cab, version with Power Shuttle MAIN CABLE SIDE
33
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
48 Pin
Col.
Sect.
Pin
Col.
Sect.
1
C
1.0
14
R
1.0
2
C
1.0
15
G
0.75
3
--
--
16
V
0.75
4
AG
1.0
17
--
--
5
SB
1.0
18
--
--
6
LR
1.0
19
N
1.0
7
GR
1.0
20
RV
1.0
8
RN
0.5
21
--
--
9
MN
0.5
22
--
--
10
--
--
23
BR
1.0
11
LG
1.0
24
--
--
12
A
1.0
25
N
1.0
13
--
--
26
N
1.0
7
1
26
20
MOD--1/3 (1A)
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
34 Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
18
VN
0.5
2
BL
0.5
19
RN
0.5
3
LR
0.5
20
MB
0.5
4
GR
0.5
21
BV
0.5
5
SN
0.5
22
HN
0.5
1
9
6
R
0.5
23
N
0.5
10
17
7
LG
0.5
24
B
0.5
18
25
26
34
8
SB
0.5
25
B
1.0
9
HV
1.0
26
--
--
10
GV
1.0
27
--
--
11
--
--
28
NB
0.5
12
H
0.5
29
RL
0.5
13
MB
0.5
30
RB
0.5
14
M
0.5
31
--
--
15
--
--
32
--
--
16
--
--
33
MV
0.5
17
S
0.5
34
HB
0.5
MOD--1/3 (1B)
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
35
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
14
--
--
2
--
--
15
--
--
3
--
--
16
--
--
4
AG
1.0
17
--
--
5
AR
1.0
18
--
--
6
--
--
19
CL
0.5
7
--
--
20
--
--
8
--
--
21
N
0.5
9
--
--
22
--
--
10
--
--
23
--
--
11
S
0.5
24
SN
0.5
12
--
--
25
SB
0.5
13
--
--
26
N
0.5
49
7
1
26
20
MOD--1/3 (2)
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
36 Pin
Col.
Sect.
Pin
Col.
Sect.
1
ZB
0.5
14
--
--
2
--
--
15
--
--
3
MN
0.5
16
--
--
4
VB
0.5
17
--
--
5
MB
0.5
18
C
0.5
6
A
0.5
19
--
--
7
H
0.5
20
--
--
8
SB
0.5
21
--
--
9
--
--
22
--
--
10
L
0.5
23
--
--
11
CA
0.5
24
CB
0.5
12
H
0.5
25
--
--
13
MZ
0.5
26
MN
0.5
7
1
26
20
MOD--1/3 (3A)
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
37
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
50 Pin
Col.
Sect.
Pin
Col.
Sect.
1
AN
1.0
18
RG
1.0
2
LN
1.0
19
--
--
3
LV
1.0
20
--
--
4
GV
1.0
21
--
--
5
--
--
22
--
--
1
9
6
--
--
23
--
--
10
17
7
--
--
24
--
--
18
25
26
34
8
--
--
25
--
--
9
BG
0.5
26
--
--
10
--
--
27
--
--
11
--
--
28
--
--
12
--
--
29
--
--
13
--
--
30
RV
0.5
14
AV
1.0
31
RG
0.5
15
--
--
32
CL
0.5
16
--
--
33
--
--
17
BN
1.0
34
C
1.0
MOD--1/3 (3B)
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
38 Pin
Col.
Sect.
Pin
Col.
Sect.
1
C
1.0
14
R
1.0
2
C
1.0
15
G
0.75
3
--
--
16
V
0.75
4
AG
1.0
17
--
--
5
--
--
18
--
--
6
LR
1.0
19
N
1.0
7
GR
1.0
20
--
--
8
RN
0.5
21
--
--
9
MN
0.5
22
--
--
10
--
--
23
BR
1.0
11
LG
1.0
24
--
--
12
--
--
25
N
1.0
13
--
--
26
N
1.0
For model without Power Shuttle MAIN CABLE SIDE
cab,
version
7
1
26
20
MOD--1/3 (1A)
with
39
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
51
Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
18
--
--
2
--
--
19
--
--
3
--
--
20
--
--
4
--
--
21
BV
0.5
5
--
--
22
HN
0.5
1
9
6
--
--
23
N
0.5
10
17
7
--
--
24
B
0.5
18
25
26
34
8
--
--
25
--
--
9
--
--
26
--
--
10
--
--
27
--
--
11
--
--
28
NB
0.5
12
H
0.5
29
--
--
13
MB
0.5
30
--
--
14
M
0.5
31
--
--
15
--
--
32
--
--
16
--
--
33
--
--
17
S
0.5
34
HB
0.5
For model without Power Shuttle MAIN CABLE SIDE
cab,
version
MOD--1/3 (1B)
with
40 Pin
Col.
Sect.
Pin
Col.
Sect.
1
ZB
0.5
14
--
--
2
--
--
15
--
--
3
--
--
16
--
--
4
VB
0.5
17
--
--
5
MB
0.5
18
--
--
6
--
--
19
--
--
7
H
0.5
20
--
--
8
SB
0.5
21
--
--
9
--
--
22
--
--
10
L
0.5
23
--
--
11
CA
0.5
24
CB
0.5
12
MZ
0.5
25
--
--
13
H
0.5
26
MN
0.5
For model without Power Shuttle MAIN CABLE SIDE
cab,
version
7
1
26
20
MOD--1/3 (3A)
with
41
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
52 Pin
Col.
Sect.
Pin
Col.
Sect.
1
AN
1.0
18
RG
1.0
2
LN
1.0
19
--
--
3
LV
1.0
20
--
--
4
GV
1.0
21
--
--
5
--
--
22
--
--
1
9
6
--
--
23
--
--
10
17
7
--
--
24
--
--
18
25
26
34
8
--
--
25
--
--
9
BG
0.5
26
--
--
10
--
--
27
--
--
11
--
--
28
--
--
12
--
--
29
--
--
13
--
--
30
RV
0.5
14
AV
1.0
31
RG
0.5
15
--
--
32
--
--
16
--
--
33
--
--
17
BN
1.0
34
C
1.0
For model without Power Shuttle MAIN CABLE SIDE
cab,
version
MOD--1/3 (3B)
with
42
87679925A - 12 - 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
Pin
Col.
Sect.
Pin
Col.
Sect.
1
BL
1.0
26
HB
0.5
2
BN
1.0
27
HN
0.5
3
−
−
28
H
1.0
4
−
−
29
−
−
5
−
−
30
−
−
6
−
−
31
−
−
7
−
−
32
NG
1.0
8
−
−
33
−
−
9
−
−
34
−
−
10
−
−
35
ZB
53
41
31
21
11
1
42
32
22
12
2
43
33
23
13
3
1.0
44
34
24
14
4
45
35
25
15
5
46
36
26
16
6
47
37
27
17
7 8
11
AV
1.0
36
−
−
12
−
−
37
−
−
13
−
−
38
−
−
48
38
28
18
14
L
1.0
39
−
−
49
39
29
19
9
15
B
1.0
40
−
−
50
40
30
20
10
16
GN
1.0
41
−
−
17
G
1.5
42
RN
0.5
18
R
1.0
43
B
1.0
19
−
−
44
AG
1.0
20
−
−
45
−
−
21
−
−
46
−
−
22
−
−
47
−
−
23
−
−
48
−
−
24
SN
1.0
49
−
−
25
−
−
50
−
−
C−2
43
For model with cab, standard version MAIN CABLE SIDE
87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
54
Pin
Col.
Sect.
Pin
Col.
Sect.
1
BG
0.5
26
HB
0.5
2
BN
1.0
27
HN
0.5
3
AG
1.0
28
H
1.0
4
AN
1.0
29
MB
0.5
5
LG
1.0
30
MN
0.5
6
LN
1.0
31
VB
0.5
7
LR
1.0
32
NG
1.0
8
LV
1.0
33
BR
1.0
9
GR
1.0
34
ZB
1.0
10
GV
1.0
35
ZB
41
31
21
11
1
42
32
22
12
2
43
33
23
13
3
1.0
44
34
24
14
4
45
35
25
15
5
46
36
26
16
6
47
37
27
17
7 8
11
AV
1.0
36
S
1.0
12
RG
1.0
37
Z
0.5
13
−
−
38
−
−
48
38
28
18
14
L
1.0
39
RN
0.5
49
39
29
19
9
15
B
1.0
40
MV
0.5
50
40
30
20
10
16
GN
1.0
41
−
−
17
G
1.5
42
SB
1.0
18
R
1.0
43
−
−
19
BV
0.5
44
A
1.0
20
NB
0.5
45
−
−
21
BV
1.0
46
S
0.5
22
−
−
47
B
1.0
23
−
−
48
BL
0.5
24
SN
1.0
49
GV
1.0
25
M
0.5
50
HV
1.0
For model with cab, version with Power Shuttle MAIN CABLE SIDE
87679925A2 − 02 − 2010
C−2
44
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
Pin
Col.
Sect.
Pin
Col.
Sect.
1
BG
0.5
26
HB
0.5
2
BN
1.0
27
HN
0.5
3
AG
1.0
28
H
1.0
4
AN
1.0
29
MB
0.5
5
LG
1.0
30
MN
0.5
6
LN
1.0
31
VB
0.5
7
LR
1.0
32
NG
1.0
8
LV
1.0
33
BR
1.0
9
GR
1.0
34
ZB
1.0
10
GV
1.0
35
ZB
55
41
31
21
11
1
42
32
22
12
2
43
33
23
13
3
1.0
44
34
24
14
4
45
35
25
15
5
46
36
26
16
6
47
37
27
17
7 8
11
AV
1.0
36
S
1.0
12
RG
1.0
37
Z
0.5
13
−
−
38
RV
1.0
48
38
28
18
14
L
1.0
39
RN
0.5
49
39
29
19
9
15
B
1.0
40
MV
0.5
50
40
30
20
10
16
GN
1.0
41
−
−
17
G
1.5
42
SB
1.0
18
R
1.0
43
AG
1.0
19
BV
0.5
44
A
1.0
20
NB
0.5
45
AR
1.0
21
BV
1.0
46
S
0.5
22
−
−
47
B
1.0
23
−
−
48
BL
0.5
24
SN
1.0
49
GV
1.0
25
M
0.5
50
HV
1.0
C−2
45
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
56
Pin
Col.
Sect.
Pin
Col.
Sect.
1
BL
1.0
26
HB
0.5
2
BN
1.0
27
HN
0.5
3
−
−
28
H
1.0
4
−
−
29
−
−
5
−
−
30
−
−
6
−
−
31
−
−
7
−
−
32
NG
1.0
8
−
−
33
−
−
9
−
−
34
−
−
10
−
−
35
ZB
41
31
21
11
1
42
32
22
12
2
43
33
23
13
3
1.0
44
34
24
14
4
45
35
25
15
5
46
36
26
16
6
47
37
27
17
7 8
11
RG
1.0
36
−
−
12
−
−
37
−
−
13
−
−
38
−
−
48
38
28
18
14
RG
1.0
39
−
−
49
39
29
19
9
15
RN
1.0
40
−
−
50
40
30
20
10
16
GN
1.0
41
−
−
17
G
1.5
42
RN
0.5
18
R
1.0
43
B
1.0
19
−
−
44
AG
1.0
20
−
−
45
−
−
21
−
−
46
−
−
22
−
−
47
−
−
23
−
−
48
−
−
24
SN
1.0
49
−
−
25
−
−
50
−
−
For model without cab, standard version (ISO) MAIN CABLE SIDE
87679925A2 − 02 − 2010
C−2
46
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
Pin
Col.
Sect.
Pin
Col.
Sect.
1
BG
0.5
26
HB
0.5
2
BN
1.0
27
HN
0.5
3
AG
1.0
28
H
1.0
4
AN
1.0
29
MB
0.5
5
LG
1.0
30
MN
0.5
6
LN
1.0
31
VB
0.5
7
LR
1.0
32
NG
1.0
8
LV
1.0
33
BR
1.0
9
GR
1.0
34
ZB
1.0
10
GV
1.0
35
ZB
57
41
31
21
11
1
42
32
22
12
2
43
33
23
13
3
1.0
44
34
24
14
4
45
35
25
15
5
46
36
26
16
6
47
37
27
17
7 8
11
AV
1.0
36
S
1.0
12
RG
1.0
37
Z
0.5
13
−
−
38
−
−
48
38
28
18
14
RG
1.0
39
−
−
49
39
29
19
9
15
RN
1.0
40
−
−
50
40
30
20
10
16
GN
1.0
41
−
−
17
G
1.5
42
−
−
18
R
1.0
43
−
−
19
BV
0.5
44
−
−
20
NB
0.5
45
−
−
21
BV
1.0
46
−
−
22
−
−
47
−
−
23
−
−
48
−
−
24
SN
1.0
49
−
−
25
M
0.5
50
−
−
C−2
47
For model without cab, version with Power Shuttle (ISO) MAIN CABLE SIDE
87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
58
Pin
Col.
Sect.
Pin
Col.
Sect.
1
BL
1.0
26
HB
0.5
2
BN
1.0
27
HN
0.5
3
−
−
28
H
1.0
4
−
−
29
−
−
5
−
−
30
−
−
6
−
−
31
−
−
7
−
−
32
NG
1.0
8
−
−
33
−
−
9
−
−
34
−
−
10
−
−
35
ZB
41
31
21
11
1
42
32
22
12
2
43
33
23
13
3
1.0
44
34
24
14
4
45
35
25
15
5
46
36
26
16
6
47
37
27
17
7 8
11
RG
1.0
36
−
−
12
−
−
37
−
−
13
−
−
38
−
−
48
38
28
18
14
L
1.0
39
−
−
49
39
29
19
9
15
B
1.0
40
−
−
50
40
30
20
10
16
GN
1.0
41
−
−
17
G
1.5
42
RN
0.5
18
R
1.0
43
B
1.0
19
−
−
44
AG
1.0
20
−
−
45
−
−
21
−
−
46
−
−
22
−
−
47
−
−
23
−
−
48
−
−
24
SN
1.0
49
−
−
25
−
−
50
−
−
For model without cab, standard version (North America) MAIN CABLE SIDE
87679925A2 − 02 − 2010
C−2
48
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
Pin
Col.
Sect.
Pin
Col.
Sect.
1
BG
0.5
26
HB
0.5
2
BN
1.0
27
HN
0.5
3
AG
1.0
28
H
1.0
4
AN
1.0
29
MB
0.5
5
LG
1.0
30
MN
0.5
6
LN
1.0
31
VB
0.5
7
LR
1.0
32
NG
1.0
8
LV
1.0
33
BR
1.0
9
GR
1.0
34
ZB
1.0
10
GV
1.0
35
ZB
59
41
31
21
11
1
42
32
22
12
2
43
33
23
13
3
1.0
44
34
24
14
4
45
35
25
15
5
46
36
26
16
6
47
37
27
17
7 8
11
AV
1.0
36
S
1.0
12
RG
1.0
37
Z
0.5
13
−
−
38
−
−
48
38
28
18
14
L
1.0
39
−
−
49
39
29
19
9
15
B
1.0
40
−
−
50
40
30
20
10
16
GN
1.0
41
−
−
17
G
1.5
42
−
−
18
R
1.0
43
−
−
19
BV
0.5
44
−
−
20
NB
0.5
45
−
−
21
BV
1.0
46
−
−
22
−
−
47
−
−
23
−
−
48
−
−
24
SN
1.0
49
−
−
25
M
0.5
50
−
−
C−2
49
For model without cab, version with Power Shuttle (North America) MAIN CABLE SIDE
87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
60
Sect.
HB
1.0
2
BN
1.0
27
HN
1.0
3
−
−
28
H
1.0
4
−
−
29
−
−
5
−
−
30
−
−
6
−
−
31
−
−
7
−
−
32
NG
1.0
8
−
−
33
−
−
9
−
−
34
−
−
10
−
−
35
ZB
1.0
11
AV
1.0
36
−
−
12
−
−
37
−
−
13
−
−
38
−
−
14
L
1.0
39
−
−
15
B
1.0
40
−
−
16
GN
1.0
41
−
−
17
G
1.5
42
RN
1.0
18
R
1.0
43
B
1.0
19
−
−
44
AG
1.0
20
−
−
45
−
−
21
−
−
46
−
−
22
−
−
47
−
−
23
−
−
48
−
−
24
SN
1.0
49
−
−
25
−
−
50
−
−
For model with manual transmission TRANSMISSION CABLE SIDE
87679925A2 − 02 − 2010
41 42 43 44 45 46 47 48 49 50
Col.
26
31 32 33 34 35 36 37 38 39 40
Pin
1.0
11 12 13 14 15 16 17 18 19 20
Sect.
BG
21 22 23 24 25 26 27 28 29 30
Col.
1
1 2 3 4 5 6 7 8 9 10
Pin
C−2
50
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
Sect.
HB
1.0
2
BN
1.0
27
HN
1.0
3
AG
1.0
28
H
1.0
4
AN
1.0
29
MB
1.0
5
LG
1.0
30
MN
1.0
6
LN
1.0
31
VB
1.0
7
LR
1.0
32
NG
1.0
8
LV
1.0
33
BR
1.0
9
GR
1.0
34
ZB
1.0
10
GV
1.0
35
ZB
1.0
11
AV
1.0
36
S
1.0
12
RG
1.0
37
−
−
13
−
−
38
−
−
14
L
1.0
39
−
−
15
B
1.0
40
−
−
16
GN
1.0
41
−
−
17
G
1.5
42
−
−
18
R
1.0
43
−
−
19
BV
1.0
44
−
−
20
NB
1.0
45
−
−
21
−
−
46
−
−
22
−
−
47
−
−
23
−
−
48
−
−
24
SN
1.0
49
−
−
25
M
1.0
50
−
−
41 42 43 44 45 46 47 48 49 50
Col.
26
31 32 33 34 35 36 37 38 39 40
Pin
1.0
11 12 13 14 15 16 17 18 19 20
Sect.
BG
21 22 23 24 25 26 27 28 29 30
Col.
1
1 2 3 4 5 6 7 8 9 10
Pin
61
C−2
51
For model and version with Power Shuttle. For model with cab and version with Power Shuttle 20X20 see page 143, Fig. 302 TRANSMISSION CABLE SIDE
87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
62
Sect.
HB
1.0
2
BN
1.0
27
HN
1.0
3
AG
1.0
28
H
1.0
4
AN
1.0
29
MB
1.0
5
LG
1.0
30
MN
1.0
6
LN
1.0
31
VB
1.0
7
LR
1.0
32
NG
1.0
8
LV
1.0
33
BR
1.0
9
GR
1.0
34
ZB
1.0
10
GV
1.0
35
ZB
1.0
11
AV
1.0
36
S
1.0
12
RG
1.0
37
−
−
13
−
−
38
RV
1.0
14
L
1.0
39
RN
1.0
15
B
1.0
40
MV
1.0
16
GN
1.0
41
−
−
17
G
1.5
42
SB
1.0
18
R
1.0
43
AG
1.0
19
BV
1.0
44
A
1.0
20
NB
1.0
45
AR
1.0
21
−
−
46
S
1.0
22
−
−
47
B
1.0
23
−
−
48
BL
1.0
24
SN
1.0
49
GV
1.0
25
M
1.0
50
HV
1.0
41 42 43 44 45 46 47 48 49 50
Col.
26
31 32 33 34 35 36 37 38 39 40
Pin
1.0
11 12 13 14 15 16 17 18 19 20
Sect.
BG
21 22 23 24 25 26 27 28 29 30
Col.
1
1 2 3 4 5 6 7 8 9 10
Pin
C−2
52
For model and version with Power Shuttle and Electronic Lift. For model with cab and version with Power Shuttle 20X20 and Electronic Lift see page 144, Fig. 303. TRANSMISSION CABLE SIDE
2
V
1.5
5
H
1.5
3
V
1.5
6
ZB
1.5
C−8
1
1.5
MAIN CABLE SIDE
2
Sect.
HV
3
Col.
4
5 4
Pin
1.5
6
Sect.
N
1
Col.
1
2
Pin
53
87679925A2 − 02 − 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Sect.
Pin
Col.
Sect.
N
1.5
4
HV
1.5
2
VB
1.5
5
H
1.5
3
V
1.5
6
ZB
1.0
C--8
3
1
4 5
FRONT LOADER CABLE SIDE
6
Col.
1
2
Pin
63
54 Pin
Col.
Sect.
1
ZB
1.0
Pin
Col.
Sect.
C--8
For model without cab MAIN CABLE SIDE
55 Sect.
Pin
Col.
Sect.
--
--
4
HV
1.5
2
V
1.5
5
HV
1.5
3
V
1.5
6
--
--
1
Jumper to be made when there is no front loader
CB--8A
3 4 5 6
Col.
1
2
Pin
56 Pin
Col.
Sect.
Pin
Col.
Sect.
1
NG
1.0
5
AR
1.0
2
HL
1.0
6
SB
1.0
3
Z
1.0
7
N
1.0
4
HR
1.0
8
--
--
MAIN CABLE SIDE
C--11
3 8
2 7
6
5
1 4
57 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Col.
Sect.
5
AR
1.0
--
--
6
SB
1.0
3
Z
1.0
7
N
1.0
4
HR
1.0
8
--
--
2
5
2 1
For model with Italian trailer brake TRAILER CABLE SIDE
1
6
2
C--11
3
Pin
--
8
Sect.
--
3
Col.
1
7
Pin
4
64
58 Sect.
--
--
2
HL
1.0
6
--
--
3
--
--
7
--
--
4
--
--
8
--
--
C--11
3
Col.
5
8
Pin
1.0
3
Sect.
NG
7
Col.
1
2
5
2
1
1
For model with pneumatic trailer brake TRAILER CABLE SIDE
4
6
Pin
59 Pin
Col.
Sect.
Pin
Col.
Sect.
1
L
2.5
3
N
2.5
2
L
0.5
--
--
--
C--12
1
MAIN CABLE SIDE
3 2
60 Pin
Col.
Sect.
Pin
Col.
Sect.
1
G
4.0
3
N
1.5
2
--
--
3
N
1.5
For model without air--conditioner CAB CABLE SIDE
C--12
1 3 2
61 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
1
G
4.0
3
N
4.0
2
L
1.0
--
--
--
65
C--12
For model with air--conditioner CAB CABLE SIDE
1 3 2
62
2
L
0.5
4
SB
0.5
SW--13
1
0.5
2
For model with cab, version with Power Shuttle and Electronic Lift For model without cab, version with Power Shuttle
2
Sect.
MN
3
Col.
3
4
Pin
0.5
1
Sect.
CA
3
Col.
1
4
Pin
63 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
3
AN
1.0
2
--
--
4
GN
1.0
LMP--17
For model with cab
1
4
2
3
64 Pin
Col.
Sect.
A
RN
1.0
B
GN
1.0
C
N
1.0
Pin
For model without cab (ISO)
Col.
Sect.
LMP--17 A B C
65 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
66
Pin
Col.
Sect.
Pin
Col.
Sect.
1
BR
0.5
3
--
--
2
C
0.5
4
--
--
3
1
4
2
A
SW--18
Pin
Col.
Sect.
9
BN
0.5
10
N
0.5
Pin
Col.
Sect. 9
10
B
For model with cab For model without cab (North America)
66
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
D
BR
1.0
T
LR
1.0
H
--
--
U
BN
0.5
I
HL
1.0
V
C
2.5
L
--
--
--
--
-V
67
D
T
A U
H
L
I
SW--18
Pin
Col.
Sect.
9
BN
0.5
10
N
0.5
Pin
Col.
Sect. 9
B
10
For model without cab, standard version, ISO version
67 Pin
Col.
Sect.
D
BR
1.0
H
--
--
I
HL
1.0
L
--
--
Pin
Col.
Sect.
T
HL
1.0
U
BN
0.5
V
C
2.5
--
--
-V
D
T
A U
H
L
I
SW--18
Pin
Col.
Sect.
9
BN
0.5
10
N
1.0
Pin
For model without cab, Power Shuttle, ISO version
Col.
Sect. 9
version
10
B
with
68 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Col.
Sect.
Pin
Col.
Sect.
1
B
1.0
4
L
1.0
2
G
1.5
5
GN
1.0
3
--
--
6
R
1.0
C--21
2
Pin
3
1
4 5
TRANSMISSION CABLE SIDE
6
68
69 Sect.
M
1.5
--
--
6
R
1.5
3
B
1.5
7
N
1.5
4
V
1.0
--
--
--
For ISO model SOCKET CABLE SIDE
2
5 4
2
C--21
1
Col.
5
3
Pin
1.5
6
Sect.
G
1
Col.
1
2
Pin
70 1.0
2
N
1.5
6
M
1.5
3
G
1.5
7
N
1.5
4
R
1.5
--
--
--
C--21
1
Sect.
VB
3
Col.
5
For North American model SOCKET CABLE SIDE
2
5 4
Pin
1.5
6
Sect.
B
1
Col.
1
2
Pin
71 1.0
3
B
1.0
2
AG
1.0
4
RN
1.0
For standard version models TRANSMISSION CABLE SIDE
C--23
4
ZB
3
1
2
Sect.
1
Col.
4
Pin
3
Sect.
2
Col.
1
Pin
72 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Sect.
Pin
Col.
Sect.
HL
1.0
3
M
1.0
2
HG
1.0
4
M
1.0
C--23
1
Col.
1
1
Pin
69
3
3
4
4
2
2
For standard version models SWITCH CABLE SIDE
73
--
--
4
M
1.0
For Dual Command (2 Speed Power Shift) 30--40 kmh models SWITCH CABLE SIDE
1
2
C--23
2
1.0
3
Sect.
M
4
Col.
3
1
Pin
--
2
Sect.
--
3
Col.
1
4
Pin
74 Pin
Col.
Sect.
Pin
Col.
Sect.
1
HL
1.0
3
M
1.0
2
HG
1.0
4
M
1.0
SW--23
For models fitted with Power Shuttle
75 Pin
Col.
Sect.
1
N
1.0
2
AG
--
Pin
Col.
Sect.
LMP--26
2
1
For model with cab
76 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
70 Pin
Col.
Sect.
Pin
Col.
Sect.
1
HB
0.5
14
--
--
2
HN
0.5
15
GN
1.0
3
HV
1.0
16
RN
0.5
4
BR
1.0
17
--
--
5
RN
0.5
18
--
--
6
RG
0.5
19
--
--
7
BN
1.0
20
--
--
8
--
--
21
--
--
9
--
--
22
NG
1.0
10
V
0.5
23
N
1.0
11
M
1.0
24
LR
1.0
12
--
--
25
RV
1.0
13
G
1.0
26
R
1.0
Sect.
Pin
Col.
Sect.
MOD--27--1
For standard version
77 Pin
Col.
1
--
--
14
--
--
2
HN
0.5
15
GN
1.0
3
HV
1.0
16
RN
0.5
4
BR
1.0
17
--
--
5
RN
0.5
18
--
--
6
RG
0.5
19
--
--
7
BN
1.0
20
--
--
8
--
--
21
--
--
9
V
0.5
22
NG
1.0
10
--
--
23
N
1.0
11
M
1.0
24
LR
1.0
12
--
--
25
RV
1.0
13
G
1.0
26
R
1.0
MOD--27--1
For model with cab, version with Power Shuttle and Electronic Lift
78
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
14
--
--
2
HN
0.5
15
--
--
3
HV
1.0
16
RN
0.5
4
BR
1.0
17
--
--
5
RN
0.5
18
--
--
6
RG
0.5
19
--
--
7
BN
1.0
20
--
--
8
--
--
21
--
--
9
V
0.5
22
NG
1.0
10
--
--
23
N
1.0
11
M
1.0
24
LR
1.0
12
--
--
25
RV
1.0
13
G
1.0
26
R
1.0
For model without Power Shuttle
cab,
version
71
MOD--27--1
with
79 Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
14
MB
0.5
2
--
--
15
--
--
3
--
--
16
--
--
4
--
--
17
--
--
5
--
--
18
--
--
6
--
--
19
MN
0.5
7
--
--
20
MV
0.5
8
--
--
21
GV
0.5
9
--
--
22
--
--
10
--
--
23
--
--
11
--
--
24
--
--
12
--
--
25
--
--
13
--
--
26
--
--
MOD--27--2
For model with cab, standard version
80
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
72 Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
14
MB
0.5
2
--
--
15
MN
0.5
3
--
--
16
MV
0.5
4
--
--
17
GV
0.5
5
--
--
18
--
--
6
--
--
19
--
--
7
--
--
20
--
--
8
--
--
21
--
--
9
--
--
22
--
--
10
--
--
23
--
--
11
--
--
24
--
--
12
--
--
25
--
--
13
--
--
26
--
--
MOD--27--2
For model with cab, version with Power Shuttle and Electronic Lift
81 Pin
Col.
Sect.
Pin
Col.
Sect.
1
Z
0.5
14
SN
1.0
2
--
--
15
HL
1.0
3
BN
0.5
16
CN
0.5
4
H
1.0
17
AV
1.0
5
CA
1.0
18
V
0.5
6
SB
1.0
19
BL
1.0
7
RB
1.0
20
AB
1.0
8
--
--
21
VN
1.0
9
BG
0.5
22
--
--
10
--
--
23
--
--
11
BV
0.5
24
AG
1.0
12
VG
1.0
25
V
0.75
13
CB
0.5
26
G
0.75
MOD--27--3
For standard version
82
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
14
SN
1.0
2
--
--
15
HL
1.0
3
BN
0.5
16
CN
0.5
4
H
1.0
17
AV
1.0
5
CO
1.0
18
V
0.5
6
SB
1.0
19
BL
1.0
7
RB
1.0
20
AB
1.0
8
--
--
21
VN
1.0
9
BG
0.5
22
--
--
10
--
--
23
--
--
11
BV
0.5
24
--
--
12
VG
1.0
25
V
0.75
13
CB
0.5
26
G
0.75
73
MOD--27--3
For model with cab, version with Power Shuttle and Electronic Lift
83 Pin
Col.
Sect.
Pin
Col.
Sect.
1
Z
0.5
14
SN
1.0
2
--
--
15
HL
1.0
3
BN
0.5
16
CN
0.5
4
H
1.0
17
AV
1.0
5
CO
1.0
18
V
0.5
6
SB
1.0
19
BL
1.0
7
RB
1.0
20
AB
1.0
8
--
--
21
VN
1.0
9
BG
0.5
22
--
--
10
--
--
23
--
--
11
BV
0.5
24
--
--
12
VG
1.0
25
V
0.75
13
CB
0.5
26
G
0.75
MOD--27--3
For model without cab, version with Power Shuttle
84
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
74 Col.
Sect.
1
N
1.0
2
AG
1.0
Pin
Col.
Sect.
LMP--28
2
1
Pin
85 1.0
2
L
1.0
5
AB
1.0
3
--
--
6
CN
1.0
SW--29
1
Sect.
V
1
Col.
4
3
Pin
1.0
2
5 4
Sect.
R
6
Col.
1
2
Pin
86 Pin
Col.
Sect.
A
R
6.0
B
M
6.0
Pin
Col.
Sect.
F--30
For model with cab, standard version
B
A
87 Pin
Col.
Sect.
A
R
10.0
B
M
6.0
Pin
Col.
Sect.
F--30
For model with cab, version with Power Shuttle
B
A
88 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
A
B
1.0
B
--
--
Pin
Col.
Sect.
75
F--30
For model without cab, standard version
B
A
89 Pin
Col.
Sect.
A
B
10.0
B
--
--
Pin
For model without cab, Power Shuttle (North America)
Col.
version
Sect.
F--30
with
B
A
90 Pin
Col.
Sect.
A
R
6.0
B
R
6.0
Pin
Col.
Sect.
F--31
B
A
91 1
N
1.5
4
H
1.5
2
N
1.5
5
AV
1.0
3
V
1.5
6
--
--
C--33
5 4
ENGINE CABLE SIDE
1
Sect.
2
Col.
1
Pin
3
Sect.
6
Col.
2
Pin
92 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Sect.
Pin
Col.
Sect.
N
1.5
4
H
1.5
2
N
1.5
5
B
1.5
3
V
1,5
6
Z
1.0
C--33
1
4 5
HEADLIGHT CABLE SIDE
6
Col.
1
2
Pin
3
76
93 Pin
Col.
Sect.
1
R
6.0
Pin
Col.
Sect.
C--34
94 Sect.
Pin
Col.
Sect.
B
1.0
3
--
--
2
--
--
4
R
0.5
SW--35
1
Col.
1
1
Pin
3
3
4
4
2
2
For standard version
95 Pin
Col.
Sect.
1
B
0.5
3
RN
0.5
2
B
0.5
4
R
0.5
3
3
4
4
2
For Power--Shuttle version
SW--35
1
Sect.
2
Col.
1
Pin
96 87679925A - 12 - 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
Pin
Col.
Sect.
Pin
Col.
Sect.
1
MB
0.5
5
B
0.5
2
MN
0.5
6
N
0.5
3
MV
0.4
7
−
−
4
GV
0.5
−
−
−
77
C−37 1
2
5
3 6 4
7
97 Pin
Col.
Sect.
Pin
Col.
Sect.
1
CB
0.5
3
−
−
2
ZN
1.0
4
−
−
3
1
4
2
A
SW−44
Pin
Col.
Sect.
9
CB
0.5
10
N
0.5
Pin
Col.
Sect. 9
10
B
For model with cab
98
87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
78
Pin
Col.
Sect.
Pin
Col.
Sect.
1
−
−
5
−
−
2
−
−
6
VN
1.0
3
CL
1.0
7
CN
1.0
4
CN
1.0
8
VN
1.0 1
2
3
4
A 5
6
7
8
SW−45
Pin
Col.
Sect.
Pin
Col.
Sect.
9
GN
0.5
10
N
0.5
Pin
Col.
Sect.
Pin
Col.
Sect.
1
RN
1.0
3
R
1.0
2
LR
1.0
4
N
1.0
9
10
B
99
1 2 3 4
For model with cab, standard version Main cable side, for the battery cut−off side see page 145 Fig. 306.
C−46
100 Col.
Sect.
3
R
1.0
2
HL
1.0
4
N
1.0
For model with cab, version with Power Shuttle and Electronic Lift Main cable side, for the battery cut−off side see page 145 Fig. 306.
C−46
1
Pin
1.0
2
Sect.
RN
3
Col.
1
4
Pin
101 87679925A2 − 02 − 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Col.
Sect.
1
N
1.0
2
AN
1.0
Pin
Col.
Sect.
LMP--49
2
1
Pin
79
102 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GR
0.5
5
R
0.5
2
SN
0.5
6
LG
0.5
3
--
--
7
BR
0.5
4
--
--
8
S
0.5
MOD--53
5
8
1
4
For model with cab, version with Power Shuttle and Electronic Lift
103 Pin
Col.
Sect.
Pin
Col.
Sect.
A
LR
0.5
E
MB
0.5
B
SB
0.5
F
RV
0.5
C
S
0.5
G
VN
0.5
D
BR
0.5
H
A
0.5
MOD--54
For model with cab, version with Power Shuttle and Electronic Lift
E
F
G
H
D
C
B
A
104 Pin
Col.
Sect.
Pin
Col.
Sect.
1
S
0.5
5
RV
0.5
2
SB
0.5
6
RV
0.5
3
SN
0.5
7
--
--
4
CL
0.5
8
--
--
MOD--55
5
8
1
4
For model with cab, version with Power Shuttle and Electronic Lift
105 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
80 Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
5
--
--
2
--
--
6
--
--
3
--
--
7
V
1.0
4
R
1.0
8
N
1.0
Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
5
GN
1.0
2
--
--
6
GN
1.0
3
AN
1.0
7
--
--
4
AN
1.0
8
--
--
1
3
5
7
2
4
6
8
1
3
5
7
2
4
6
8
A
MOD--56
B
106 Pin
Col.
Sect.
1
N
1.0
2
Z
1.0
Pin
Col.
Sect.
C--57
1
2
107 --
2
MN
0.5
6
B
1.0
3
MV
0.5
7
N
1.0
4
GV
0.5
8
--
--
For model with cab MAIN CABLE SIDE
C--58
3
--
2
5
1
0.5
8
MB
3
1
7
Sect.
6
Col.
2
Pin
5
Sect.
1
Col.
4
Pin
108 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
2
MN
0.5
6
B
0.5
3
MV
0.4
7
N
0.5
4
GV
0.5
8
--
--
C--58 1
--
2
Sect.
--
4
Col.
5
5
Pin
0.5
6
Sect.
MB
1
Col.
1
2
Pin
81
3
8
3
7
For model with cab EXTENSION CABLE SIDE
109 1.0
2
NG
1.0
Pin
Col.
Sect.
C--58
2
5
2
1
4
1
6
7
3
Sect.
VN
8
Col.
1
3
Pin
110 Operator present jumper
2
2
1
1
SW--59
111 Col.
Sect.
1
V
0.5
6
AR
1.0
2
--
--
7
LR
1.0
3
AR
1.0
8
N
1.0
4
RV
1.0
9
--
--
5
RN
0.5
10
HR
1.0
MOD--61
6
Pin
10
Sect.
1
Col.
5
Pin
112 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
82 Pin
Col.
Sect.
A
GN
1.0
B
GN
1.0
Pin
Col.
Sect.
AUD--63 A
B
113 Pin
Col.
Sect.
1
ZN
0.5
2
LR
0.5
Pin
Col.
Sect.
SW--64
For model with cab, standard version 1
2
114 Pin
Col.
Sect.
1
Z
0.5
2
LR
0.5
Pin
Col.
Sect.
SW--64
For model without cab 1
2
115 Pin
Col.
Sect.
1
N
1.0
2
RG
1.0
Pin
Col.
Sect.
LMP--66A
2
1
For model with cab
116 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
A
N
0.5
B
G
0.5
C
ZN
0.5
Pin
Col.
Sect.
83
LMP--68 A B C
117 Col.
Sect.
1
N
1.0
2
AR
1.0
Pin
Col.
Sect.
C--69
2
1
Pin
118 Pin
Col.
Sect.
Pin
Col.
Sect.
A1
C
2.5
B5
CN
0.5
A2
RG
1.0
B6
AN
1.0
A3
L
1.0
B7
A
1.0
A4
RN
1.0
B8
N
1.0
A5
B
1.0
C1
--
--
A6
BN
0.5
C2
--
--
A7
CB
0.5
C3
--
--
A8
LR
1.0
C4
--
--
B1
C
2.5
C5
--
--
B2
V
1.0
C6
--
--
B3
VB
1.0
C7
--
--
B4
BR
0.5
C8
--
--
8 7 6 5 4 3 2 1 A
A
B
B
C
C
8 7 6 5 4 3 2 1
MOD--70
For model with cab For model without cab (North America)
119 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Sect.
Pin
Col.
Sect.
BR
1.0
87
CB
0.5
85
N
1.0
87A
HL
1.0
86
CN
0.5
--
--
--
85
30
For model without cab (ISO)
RLY--70--A
86
Col.
30
87a
Pin
87
84
120 Pin
Col.
Sect.
Pin
Col.
Sect.
1
Z
1.0
5
HN
0.5
2
ZN
1.0
6
LR
1.0
3
BN
0.5
7
VB
1.0
4
VN
0.5
8
V
1.0
For model with cab, standard version For model without cab, standard version (North America)
SW--71
3 8
2 7
6
1 4
5
121 Pin
Col.
Sect.
Pin
Col.
Sect.
1
Z
1.0
5
HN
0.5
2
ZN
1.0
6
HL
1.0
3
BN
0.5
7
VB
1.0
4
VN
0.5
8
V
1.0
For model with cab, version with Power Shuttle and Electronic Lift For model without cab, version with Power Shuttle (North America)
SW--71
3 8
2 7
6
1 4
5
122 Pin
Col.
Sect.
Pin
Col.
Sect.
1
Z
1.0
5
HN
0.5
2
ZN
1.0
6
HL
1.0
3
BN
0.5
7
RN
1.0
4
VN
0.5
8
RG
1.0
For model without cab (ISO)
SW--71
3 8
2 7
6
5
1 4
123 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 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
--
--
--
85
LMP--72
1
For model without cab (North America)
3
2
5
4
124
2
RB
1.0
Pin
Col.
Sect.
SW--73
1
1.0
2
Sect.
R
1
Col.
1
2
Pin
125 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
--
--
--
For model without cab (North America)
LMP--74
1 3
2
5
4
126
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
86 Pin
Col.
Sect.
15/54
C
4.0
30
R
4.0
30
R
4.0
50a
R
0.5
58
M
1.5
Pin
Col.
Sect.
SW--75/76/77/78
15/54
C--75
58
C--76
50a
C--77
30
C--78--A
30
C--78--B
127 N
0.5
2
H
0.5
9
--
--
3
MB
0.5
10
--
--
SW--79
9
8
8
0.5
--
--
11
--
--
5
R
0.5
12
--
--
6
RN
0.5
13
--
--
7
B
0.5
--
--
--
3
4
12 13
S
7
1
6
Sect.
10 11
Col.
5
Pin
4
Sect.
2
Col.
1
Pin
For model with cab, version with Power Shuttle and Electronic Lift For model without cab, version with Power Shuttle Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
1.0
3
H
1.0
2
AG
0.5
--
--
--
128 SW--80
For model with cab, standard version 3
2
1
129 87679925A - 12 - 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
Pin
Col.
Sect.
Pin
Col.
Sect.
1
HL
0.5
3
MZ
0.5
2
H
0.5
−
−
−
87
SW−80
For model with cab, version with Power Shuttle and Electronic Lift 3
2
1
130 Sect.
Pin
Col.
Sect.
1
GV
1.0
3
AG
1.0
2
H
1.0
4
−
−
SW−80
1
Col.
1
Pin
3
3
4
4
2
2
For model without cab, standard version
131 Sect.
Pin
Col.
Sect.
1
HL
0.5
3
MZ
0.5
2
H
0.5
4
−
−
SW−80
1
Col.
3 4
2
3 4
For model without cab, version with Power Shuttle
2
1
Pin
132 1
V
1.0
3
L
1.0
2
H
1.0
−
−
−
Front loader side, for the 8 Amp power socket side see page 147 Fig. 313.
C−81
1
Sect.
2
Col.
3
Pin
1
Sect.
2
Col.
3
Pin
133 87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
88
Col.
Sect.
Pin
Col.
Sect.
1
ZN
0.5
3
ZB
0.5
2
Z
0.5
−
−
−
SW−82
2
2
3
3
1
1
Pin
134 Col.
Sect.
1
ZB
0.5
2
BN
0.5
Pin
Col.
Sect.
SW−83
2
1
Pin
135 Pin
Col.
Sect.
1
G
0.5
Pin
Col.
Sect.
C−88 A
Pin
Col.
Sect.
1
N
1.0
2
ZN
1.5
Pin
Col.
Sect.
1
ZB
1.0
2
N
1.0
Pin
Col.
Sect.
B
1
2
136 Pin
Col.
Sect.
C−89
1
1
2
2
MAIN CABLE SIDE
137 87679925A2 − 02 − 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
1
ZB
1.0
2
N
1.0
Pin
Col.
Sect.
89
C--89
1
2
80 LITRE CABLE SIDE
138 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
2.5
6
N
1.0
2
N
1.0
7
N
1.0
3
N
1.0
8
N
1.0
4
N
1.0
9
N
1.0
5
N
0.5
10
N
1.0
GND--92
139 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
50.0
2
N
50.0
1
R
1.5
--
--
--
SW--97 1
1
2
140
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
90 Pin
Col.
Sect.
Pin
Col.
Sect.
33A
B
1.5
R4--30
HN
1.5
33B
VN
1.5
R4--85
N
0.5
34A
B
1.5
R4--86
HN
0.5
34B
HN
1.5
R4--87
HV
1.5
35A
M
1.5
R5--30
Z
1.0
35B
Z
1.5
R5--85
N
0.5
36A
M
1.5
R5--86
HN
0.5
36B
V
1.5
R5--87
R
1.0
R1--30
RB
1.0
R6--30
V
1.5
R1--85
N
0.5
R6--85
B
0.5
R1--86
Z
0.5
R6--86
BG
0.5
R1--87
BN
0.5
R6--87
AV
1.5
R2--30
B
2.5
R7--30
--
--
R2--85
N
0.5
R7--85
--
--
R2--86
BN
0.5
R7--86
--
--
R2--87
GR
2.5
R7--87
--
--
R3--30
VN
1.5
R8--30
--
--
R3--85
N
0.5
R8--85
--
--
R3--86
VN
0.5
R8--86
--
--
R3--87
V
1.5
R8--87
--
--
85
R8
R7
30
30
87
87 86
87a
85
86
87a
F35
F36 R6
R5
30
30
87
87
85
87a
86
85
87a
86
86
87a
85
86
87a
85
MOD--100A 87
87
30
30
R4
R3 F33
F34 86
85
87a
86
87
For model with cab, standard version
85
87a
87
30
30
R2
R1
141 Pin
Col.
Sect.
Pin
Col.
Sect.
33A
B
1.5
R4--30
HN
1.5
33B
VN
1.5
R4--85
N
0.5
34A
B
1.5
R4--87
HV
1.5
34B
HN
1.5
R4--86
HN
0.5
35A
M
1.5
R5--30
Z
1.0
35B
Z
1.5
R5--85
N
0.5
36A
M
1.5
R5--86
HN
0.5
36B
V
1.5
R5--87A
R
1.0
R1--30
RB
1.0
R6--30
V
1.5
R1--85
N
0.5
R6--85
B
0.5
R1--86
Z
0.5
R6--86
BG
0.5
R1--87
BN
0.5
R6--87
AV
1.5
R2--30
B
2.5
R7--30
--
--
R2--85
N
0.5
R7--85
--
--
R2--86
BN
0.5
R7--86
--
--
R2--87
GR
2.5
R7--87
--
--
R3--30
VN
1.5
R8--30
--
--
R3--85
N
0.5
R8--85
--
--
R3--86
VN
0.5
R8--86
--
--
R3--87
V
1.5
R8--87
--
--
For model with cab, version with Power Shuttle and Electronic Lift
85
R8
R7
30
30
87
87
87a
86
85
87a
86
F35
F36 R6
R5
30
30
87
87
85
87a
86
85
87a
86
86
87a
85
86
87a
85
MOD--100A 87
87
30
30
R4
R3 F33
F34 86
87a
85
86
87a
87
87
30
30
R2
R1
85
142
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
37A
M
1.5
R11--30
BL
1.5
37B
BL
1.5
R11--85
N
0.5
38A
M
1.5
R11--86
BL
0.5
38B
BN
1.5
R11--87
AN
1.5
39A
--
--
R12--85
N
0.5
39B
--
--
R12--30
BN
1.5
40A
M
0.5
R12--86
BG
0.5
40B
BL
1.5
R12--87
AG
1.5
R9--30
G
1.0
R13--30
--
--
R9--85
N
0.5
R13--85
--
--
R9--86
L
0.5
R13--86
--
--
R9--87
LB
1.0
R13--87
--
--
R10--30
G
2.5
R14--30
BL
1.5
R10--85
N
0.5
R14--85
N
0.5
R10--86
V
0.5
R14--86
BV
0.5
R10--87
L
2.5
R14--87
AB
1.5
R15--30
L
1.5
R15--85
N
0.5
R15--86
BL
0.5
R15--87
AR
1.5
For model with cab
85
91
R16
R15
30
30
87
87 86
87a
85
87a
86
F39
F40 R14
R13
30
30
87
87
85
87a
86
85
87a
86
86
87a
85
86
87a
85
MOD--100B 87
87
30
30
R12
R11 F37
F38 86
87a
87
85
86
87a
85
87
30
30
R10
R9
143
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
92 Pin
Col.
Sect.
Pin
Col.
Sect.
1A
CB
1.5
17A
M
1.0
1B
LR
1.0
17B
B
1.0
2A
--
--
18A
CB
1.0
2B
--
--
18B
ZB
1.0
3A
CB
1.0
19A
CB
1.0
3B
MN
0.5
19B
CN
1.0
4A
--
--
20A
CB
1.0
4B
--
--
20B
MN
1.0
5A
CB
1.0
21A
CB
1.0
5B
BL
1.0
21B
CN
1.0
30B
27B
F30 30A
27A
29B
26B
F29
26A
28B
25B
F28
25A
22A
M
1.0
4.0
22B
V
1.0
7A
B
2.5
23A
--
--
7B
C
2.5
23B
--
--
8A
B
2.5
24A
--
--
8B
ZN
1.0
24B
--
--
15A
12A
9A
B
1.5
25A
M
1.5
14B
11B
1.5
10A
--
--
26A
CB
1.0
10B
--
--
26B
GN
1.0
11A
--
--
27A
CB
1.0
11B
--
--
27B
Z
1.0
12A
R
1.0
28A
R
0.5
12B
R
1.0
28B
R
0.5
13A
--
--
29A
GR
1.0
13B
--
--
29B
GN
1.0
14A
--
--
30A
GR
1.5
14B
--
--
30B
GN
1.5
15A
CB
1.0
31A
--
--
15B
ZB
1.5
31B
--
--
16A
GR
1.5
32A
--
--
16B
G
2.5
32B
--
--
For model with cab, standard version
87679925A1 - 02 - 2008
16B
F19
F16 16A
32A
4.0
L
19B
F17 17A
MF32
B
25B
17B
F20
F22 19A
32B
G
1.5
23A
F18 18A
22A
6B
ZN
20B
F23 20A
F25 22B
6A
9B
24A
18B
F21
F24 21A
F26 23B
29A
28A
21B
F27 24B
MOD--100C
MF31 31B
31A 9B
15B F15
F14
12B
11A
13B
10B
13A
8B F8
F11 8A
14A
F13
F9
F12 9A
7B F7
F10 7A
10A
6B F6
3B F3
6A
3A
5B
2B
F5
F2
5A
2A
4B
1B
F4 4A
F1 1A
144
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
1A
CB
1.5
17A
M
1.0
1B
LR
1.0
17B
B
1.0
2A
CB
1.5
18A
CB
1.0
2B
HL
1.0
18B
ZB
1.0
3A
CB
1.0
19A
CB
1.0
3B
MN
0.5
19B
CN
1.0
4A
CB
1.5
20A
--
--
4B
--
--
20B
--
--
5A
CB
1.0
21A
CB
1.0
5B
BL
1.0
21B
CN
1.0
30B
27B
F30
27A
29B
26B
F29
26A
28B
25B
F28 28A
4.0
22A
M
1.0
4.0
22B
V
1.0
7A
B
2.5
23A
CB
1.5
7B
C
2.5
23B
C
1.5
8A
B
2.5
24A
CB
0.5
8B
ZN
1.0
24B
R
0.5
15A
12A
9A
B
1.5
25A
M
1.5
14B
11B
L
1.5
10A
--
--
26A
--
--
10B
--
--
26B
--
--
11A
--
--
27A
CB
1.0
11B
--
--
27B
Z
1.0
12A
R
1.0
28A
R
0.5
12B
R
1.0
28B
R
0.5
13A
--
--
29A
GR
1.0
13B
--
--
29B
GN
1.0
14A
--
--
30A
GR
1.5
14B
--
--
30B
GN
1.5
15A
CB
1.0
31A
R
4.0
15B
ZB
1.5
31B
RG
4.0
16A
GR
1.5
32A
R
6.0
16B
G
2.5
32B
B
6.0
19B
16B
F19
F16 16A
32A
G
25B
F17 17A
MF32
RG
1.5
F20
F22 19A
32B
6B
ZN
17B
20B
F23 20A 23A
F18 18A
22A
6A
9B
24A
F25 22B 25A
F21
F24 21A
F26 23B
29A
18B
21B
F27 24B
30A
93
MOD--100C
MF31 31B
31A 9B
15B F15
F14
12B
11A
13B
10B
13A
8B F8
F11 8A
14A
F13
F9
F12 9A
7B F7
F10 7A
10A
6B
3B
F6
F3
6A
3A
5B
2B
F5
F2
5A
2A
4B
1B
F4 4A
F1 1A
145
For model with cab, version with Power Shuttle
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
94 Pin
Col.
Sect.
Pin
Col.
Sect.
1A
CB
1.5
17A
M
1.0
1B
LR
1.0
17B
B
1.0
2A
CB
1.5
18A
CB
1.0
2B
HL
1.0
18B
ZB
1.0
3A
CB
1.0
19A
CB
1.0
3B
MN
0.5
19B
CN
1.0
4A
CB
1.5
20A
--
--
4B
RV
1.5
20B
--
--
5A
CB
1.0
21A
CB
1.0
5B
BL
1.0
21B
CN
1.0
30B
27B
F30 30A
27A
29B
26B
F29
26A
28B
25B
F28
25A
22A
M
1.0
4.0
22B
V
1.0
7A
B
2.5
23A
CB
1.5
7B
C
2.5
23B
C
1.5
8A
B
2.5
24A
CB
0.5
8B
ZN
1.0
24B
R
0.5
15A
12A
9A
B
1.5
25A
M
1.5
14B
11B
1.5
10A
--
--
26A
--
--
10B
--
--
26B
--
--
11A
--
--
27A
CB
1.0
11B
--
--
27B
Z
1.0
12A
R
1.0
28A
R
0.5
12B
R
1.0
28B
R
0.5
13A
--
--
29A
GR
1.0
13B
--
--
29B
GN
1.0
14A
--
--
30A
GR
1.5
14B
--
--
30B
GN
1.5
15A
CB
1.0
31A
R
4.0
15B
ZB
1.5
31B
RG
4.0
16A
GR
1.5
32A
R
6.0
16B
G
2.5
32B
B
6.0
For model with cab, version with Power Shuttle and Electronic Lift
87679925A1 - 02 - 2008
16B
F19
F16 16A
32A
4.0
L
19B
F17 17A
MF32
G
25B
17B
F20
F22 19A
32B
RG
1.5
23A
F18 18A
22A
6B
ZN
20B
F23 20A
F25 22B
6A
9B
24A
18B
F21
F24 21A
F26 23B
29A
28A
21B
F27 24B
MOD--100C
MF31 31B
31A 9B
15B F15
F14
12B
11A
13B
10B
13A
8B F8
F11 8A
14A
F13
F9
F12 9A
7B F7
F10 7A
10A
6B F6
3B F3
6A
3A
5B
2B
F5
F2
5A
2A
4B
1B
F4 4A
F1 1A
146
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
R17--30
N
0.5
R20--30
MN
1.0
R17--85
N
0.5
R20--85
C
0.5
R17--86
HN
0.5
R20--86
CL
0.5
R17--87
HN
0.5
R20--87
HN
0.5
R17--87A
C
0.5
R20--87A
CN
1.s0
R18--30
RV
1.0
R23--30
H
1.0
R18--85
HN
0.5
R23--85
N
0.5
R18--86
Z
0.5
R23--86
AG
0.5
R18--87
Z
1.0
R23--87
AV
1.0
R19--30
MN
1.0
R24--30
GN
1.0
R19--85
N
0.5
R24--85
N
0.5
R19--86
N
0.5
R24--86
H
0.5
R19--87
RV
1.0
R24--87
H
1.0
R19--87A
CL
0.5
~
--
--
85
95
R24
R23
30
30
87
87 86
87a
85
86
87a
F43
F44 R22
R21
30
30
87
87
85
87a
86
85
87a
86
86
87a
85
86
87a
85
MOD--100D
For model with cab, standard version
87
87
30
30
R20
R19 F41
F42 86
87a
85
86
87
85
87a
87
30
30
R18
R17
147 Pin
Col.
Sect.
Pin
Col.
Sect.
33A
B
1.5
R4--30
HN
1.5
33B
VN
1.5
R4--85
N
0.5
34A
B
1.5
R4--86
HN
0.5
34B
HN
1.5
R4--87
H
1.5
35A
M
1.5
R5--30
Z
1.0
35B
Z
1.5
R5--85
N
0.5
36A
B
1.5
R5--86
HN
1.0
36B
V
1.5
R5--87
R
1.0
R1--30
RB
1.0
R6--30
V
1.5
R1--85
N
0.5
R6--85
N
0.5
R1--86
Z
0.5
R6--86
BG
0.5
R1--87
BN
0.5
R6--87
AV
1.5
R2--30
B
2.5
R7--30
--
--
R2--85
N
0.5
R7--85
--
--
R2--86
BN
0.5
R7--86
--
--
R2--87
GR
2.5
R7--87
--
--
R3--30
VN
1.5
R8--30
--
--
R3--85
N
0.5
R8--85
--
--
R3--86
VN
0.5
R8--86
--
--
R3--87
V
1.5
R8--87
--
--
For model without cab, standard version
85
R8
R7
30
30
87
87
87a
86
85
86
87a
F35
F36 R6
R5
30
30
87
87
85
87a
86
85
87a
86
86
87a
85
86
87a
85
MOD--100A 87
87
30
30
R4
R3 F33
F34 86
87a
85
86
85
87a
87
87
30
30
R2
R1
148
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
96 Pin
Col.
Sect.
Pin
Col.
Sect.
33A
B
1.5
R4--30
HN
1.5
33B
VN
1.5
R4--85
N
0.5
34A
B
1.5
R4--86
HN
0.5
34B
HN
1.5
R4--87
H
1.5
35A
M
1.5
R5--30
Z
1.0
35B
Z
1.5
R5--85
N
0.5
36A
B
1.5
R5--86
HN
1.0
36B
V
1.5
R5--87A
R
1.0
R1--30
RB
1.0
R6--30
V
1.5
R1--85
N
0.5
R6--85
B
0.5
R1--86
Z
0.5
R6--86
BG
0.5
R1--87
BN
0.5
R6--87
AV
1.5
R2--30
B
2.5
R7--30
--
--
R2--85
N
0.5
R7--85
--
--
R2--86
BN
0.5
R7--86
--
--
R2--87
GR
2.5
R7--87
--
--
R3--30
VN
1.5
R8--30
--
--
R3--85
N
0.5
R8--85
--
--
R3--86
VN
0.5
R8--86
--
--
R3--87
V
1.5
R8--87
--
--
For model without Power Shuttle
cab,
version
with
85
R8
R7
30
30
87
87
87a
86
85
87a
86
F35
F36 R6
R5
30
30
87
87
85
87a
86
85
87a
86
86
87a
85
86
87a
85
MOD--100A 87
87
30
30
R4
R3 F33
F34 86
87a
87
85
86
87a
85
87
30
30
R2
R1
149
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
1A
CB
1.5
17A
--
--
1B
LR
1.0
17B
--
--
2A
--
--
18A
CB
1.0
2B
--
--
18B
ZB
1.0
3A
CB
1.0
19A
--
--
3B
MN
0.5
19B
--
--
4A
--
--
20A
CB
1.0
4B
--
--
20B
MN
1.0
5A
CB
1.0
21A
--
--
5B
BL
1.0
21B
--
--
30B
27B
F30
27A
29B
26B
F29
26A
28B
25B
F28 28A
--
22A
--
--
--
22B
--
--
7A
B
2.5
23A
--
--
7B
C
2.5
23B
--
--
8A
--
--
24A
--
--
8B
--
--
24B
--
--
15A
12A
9A
B
1.5
25A
--
--
14B
11B
--
--
10A
--
--
26A
CB
1.0
10B
--
--
26B
GV
1.0
11A
--
--
27A
CB
1.0
11B
--
--
27B
Z
1.0
12A
R
1.0
28A
R
0.5
12B
R
1.0
28B
R
0.5
13A
--
--
29A
GR
1.0
13B
--
--
29B
GN
1.0
14A
CB
1.5
30A
GR
1.5
14B
BL
1.0
30B
GN
1.5
15A
CB
1.0
31A
--
--
15B
ZB
1.5
31B
--
--
16A
GR
1.5
32A
--
--
16B
G
2.5
32B
--
--
19B
16B
F19
F16 16A
32A
--
25B
F17 17A
MF32
--
1.5
F20
F22 19A
32B
6B
ZN
17B
20B
F23 20A 23A
F18 18A
22A
6A
9B
24A
F25 22B 25A
F21
F24 21A
F26 23B
29A
18B
21B
F27 24B
30A
97
MOD--100C
MF31 31B
31A 9B
15B F15
F14
12B
11A
13B
10B
13A
8B F8
F11 8A
14A
F13
F9
F12 9A
7B F7
F10 7A
10A
6B
3B
F6
F3
6A
3A
5B
2B
F5
F2
5A
2A
4B
1B
F4 4A
F1 1A
150
For model without cab, standard version (ISO)
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
98 Pin
Col.
Sect.
Pin
Col.
Sect.
1A
CB
1.5
17A
--
--
1B
LR
1.0
17B
--
--
2A
CB
1.5
18A
CB
1.0
2B
HL
1.0
18B
ZB
1.0
3A
CB
1.0
19A
--
--
3B
MN
0.5
19B
--
--
4A
--
--
20A
--
--
4B
--
--
20B
--
--
5A
CB
1.0
21A
--
--
5B
BL
1.0
21B
--
--
30B
27B
F30 30A
27A
29B
26B
F29
26A
28B
25B
F28
25A
22A
--
--
--
22B
--
--
7A
B
2.5
23A
CB
1.5
7B
C
2.5
23B
C
1.5
8A
--
--
24A
CB
0.5
8B
--
--
24B
R
0.5
15A
12A
9A
B
1.5
25A
--
--
14B
11B
--
10A
--
--
26A
--
--
10B
--
--
26B
--
--
11A
--
--
27A
CB
1.0
11B
--
--
27B
Z
1.0
12A
R
1.0
28A
R
0.5
12B
R
1.0
28B
R
0.5
13A
--
--
29A
GR
1.0
13B
--
--
29B
GN
1.0
14A
CB
1.5
30A
GR
1.5
14B
BL
1.0
30B
GN
1.5
15A
CB
1.0
31A
--
--
15B
ZB
1.5
31B
--
--
16A
GR
1.5
32A
--
--
16B
G
2.5
32B
--
--
For model without Power Shuttle (ISO)
87679925A - 12 - 2007
cab,
version
with
16B
F19
F16 16A
32A
--
--
19B
F17 17A
MF32
--
25B
17B
F20
F22 19A
32B
--
1.5
23A
F18 18A
22A
6B
ZN
20B
F23 20A
F25 22B
6A
9B
24A
18B
F21
F24 21A
F26 23B
29A
28A
21B
F27 24B
MOD--100C
MF31 31B
31A 9B
15B F15
F14
12B
11A
13B
10B
13A
8B F8
F11 8A
14A
F13
F9
F12 9A
7B F7
F10 7A
10A
6B F6
3B F3
6A
3A
5B
2B
F5
F2
5A
2A
4B
1B
F4 4A
F1 1A
151
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
1A
CB
1.5
17A
--
--
1B
LR
1.0
17B
--
--
2A
--
--
18A
CB
1.0
2B
--
--
18B
ZB
1.0
3A
CB
1.0
19A
--
--
3B
MN
0.5
19B
--
--
4A
--
--
20A
CB
1.0
4B
--
--
20B
MN
1.0
5A
CB
1.0
21A
--
--
5B
BL
1.0
21B
--
--
30B
27B
F30
27A
29B
26B
F29
26A
28B
25B
F28 28A
--
22A
--
--
--
22B
--
--
7A
B
2.5
23A
--
--
7B
C
2.5
23B
--
--
8A
--
--
24A
--
--
8B
--
--
24B
--
--
15A
12A
9A
B
1.5
25A
--
--
14B
11B
--
--
10A
--
--
26A
CB
1.0
10B
--
--
26B
GV
1.0
11A
--
--
27A
CB
1.0
11B
--
--
27B
Z
1.0
12A
R
1.0
28A
R
0.5
12B
R
1.0
28B
R
0.5
13A
--
--
29A
GR
1.0
13B
--
--
29B
GN
1.0
14A
CB
1.5
30A
GR
1.5
14B
BL
1.0
30B
GN
1.0
15A
CB
1.0
31A
--
--
15B
ZB
1.5
31B
--
--
16A
GR
1.5
32A
--
--
16B
G
2.5
32B
--
--
19B
16B
F19
F16 16A
32A
--
25B
F17 17A
MF32
--
1.5
F20
F22 19A
32B
6B
ZN
17B
20B
F23 20A 23A
F18 18A
22A
6A
9B
24A
F25 22B 25A
F21
F24 21A
F26 23B
29A
18B
21B
F27 24B
30A
99
MOD--100C
MF31 31B
31A 9B
15B F15
F14
12B
11A
13B
10B
13A
8B F8
F11 8A
14A
F13
F9
F12 9A
7B F7
F10 7A
10A
6B
3B
F6
F3
6A
3A
5B
2B
F5
F2
5A
2A
4B
1B
F4 4A
F1 1A
152
For model without cab, standard version (North America)
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
100 Pin
Col.
Sect.
Pin
Col.
Sect.
1A
CB
1.5
17A
--
--
1B
LR
1.0
17B
--
--
2A
CB
1.5
18A
CB
1.0
2B
HL
1.0
18B
ZB
1.0
3A
CB
1.0
19A
--
--
3B
MN
0.5
19B
--
--
4A
--
--
20A
--
--
4B
--
--
20B
--
--
5A
CB
1.0
21A
--
--
5B
BL
1.0
21B
--
--
30B
27B
F30 30A
27A
29B
26B
F29
26A
28B
25B
F28
25A
22A
--
--
--
22B
--
--
7A
B
2.5
23A
CB
1.5
7B
C
2.5
23B
C
1.5
8A
--
--
24A
CB
0.5
8B
--
--
24B
R
0.5
15A
12A
9A
B
1.5
25A
--
--
14B
11B
--
10A
--
--
26A
--
--
10B
--
--
26B
--
--
11A
--
--
27A
CB
1.0
11B
--
--
27B
Z
1.0
12A
R
1.0
28A
R
0.5
12B
R
1.0
28B
R
0.5
13A
--
--
29A
GR
1.0
13B
--
--
29B
GN
1.0
14A
CB
1.5
30A
GR
1.5
14B
BL
1.0
30B
GN
1.0
15A
CB
1.0
31A
--
--
15B
ZB
1.5
31B
--
--
16A
GR
1.5
32A
--
--
16B
G
2.5
32B
--
--
For model without cab, Power Shuttle (North America)
87679925A - 12 - 2007
version
with
16B
F19
F16 16A
32A
--
--
19B
F17 17A
MF32
--
25B
17B
F20
F22 19A
32B
--
1.5
23A
F18 18A
22A
6B
ZN
20B
F23 20A
F25 22B
6A
9B
24A
18B
F21
F24 21A
F26 23B
29A
28A
21B
F27 24B
MOD--100C
MF31 31B
31A 9B
15B F15
F14
12B
11A
13B
10B
13A
8B F8
F11 8A
14A
F13
F9
F12 9A
7B F7
F10 7A
10A
6B F6
3B F3
6A
3A
5B
2B
F5
F2
5A
2A
4B
1B
F4 4A
F1 1A
153
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
R17--30
N
0.5
R20--30
MN
1.0
R17--85
N
0.5
R20--85
C
0.5
R17--86
HN
0.5
R20--86
CL
0.5
R17--87
HN
0.5
R20--87
HN
0.5
R17--87A
C
0.5
R20--87A
CN
1.0
R18--30
RV
1.0
R23--30
H
1.0
R18--85
HN
0.5
R23--85
N
0.5
R18--86
Z
0.5
R23--86
AG
0.5
R18--87
Z
1.0
R23--87
RG
1.0
R19--30
MN
1.0
R24--30
GV
1.0
R19--85
N
0.5
R24--85
N
0.5
R19--86
N
0.5
R24--86
H
0.5
R19--87
RV
1.0
R24--87
H
1.0
R19--87A
CL
0.5
~
--
--
85
101
R24
R23
30
30
87
87 86
87a
85
86
87a
F43
F44 R22
R21
30
30
87
87
85
87a
86
85
87a
86
86
87a
85
86
87a
85
MOD--100D
For model without cab, standard version (ISO)
87
87
30
30
R20
R19 F41
F42 86
87a
85
86
87
85
87a
87
30
30
R18
R17
154 Pin
Col.
Sect.
Pin
Col.
Sect.
R17--30
N
0.5
R20--30
MN
1.0
R17--85
N
0.5
R20--85
C
0.5
R17--86
HN
0.5
R20--86
CL
0.5
R17--87
HN
0.5
R20--87
HN
1.0
R17--87A
C
0.5
R20--87A
CN
1.0
R18--30
RV
0.5
R23--30
H
1.0
R18--85
HN
0.5
R23--85
N
0.5
R18--86
Z
0.5
R23--86
AG
0.5
R18--87
Z
1.0
R23--87
RG
1.0
R19--30
MN
1.0
R24--30
GV
1.0
R19--85
N
0.5
R24--85
N
0.5
R19--86
N
0.5
R24--86
H
0.5
R19--87
RV
1.0
R24--87
H
1.0
R19--87A
CL
0.5
~
--
--
For model without cab, standard version (North America)
85
R24
R23
30
30
87
87 86
87a
85
86
87a
F43
F44 R22
R21
30
30
87
87
85
87a
86
85
87a
86
86
87a
85
86
87a
85
MOD--100D 87
87
30
30
R20
R19 F41
F42 86
87a
85
86
87a
85
87
87
30
30
R18
R17
155
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
102 Pin
Col.
Sect.
Pin
Col.
Sect.
MR1--30
R
4.0
R27--86
BN
0.5
MR1--85
N
0.5
R27--87
AR
1.0
MR1--86
RN
0.5
R28--30
Z
1.0
MR1--87
RN
4.0
R28--85
N
0.5
R27--30
Z
1.0
R28--86
HR
1.0
R27--85
N
0.5
R28--87
AR
1.0
R28
R27
30
30
87
87
85
87a
86
85 87a
86
85
87
30
87a
R26
86
MOD--100E
85
87
30
87a
R25
86
MR1 86
30
87
85
156 Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
3
BN
1.0
2
CN
1.0
4
--
--
3
1
4
2
A
SW--104
Pin
Col.
Sect.
9
GN
0.5
10
N
0.5
Pin
Col.
Sect. 9
10
B
For standard version
157
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
1
CB
0.5
3
--
--
2
HL
0.5
4
--
--
103
3
1
4
2
A
SW--104
Pin
Col.
Sect.
9
GN
0.5
10
N
0.5
Pin
Col.
Sect. 9
B
10
For model with cab, version with Power Shuttle and Electronic Lift For model without cab, version with Power Shuttle
158 Pin
Col.
Sect.
Pin
Col.
Sect.
1
CL
0.5
3
--
--
2
HL
0.5
4
--
--
3
1
4
2
A
SW--108
Pin
Col.
Sect.
9
GN
0.5
10
N
0.5
Pin
Col.
Sect. 9
10
B
For model with cab, version with Power Shuttle and Electronic Lift
159
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
104 Pin
Col.
Sect.
Pin
Col.
Sect.
1
GN
0.5
3
--
--
2
BG
0.5
4
--
--
3
1
4
2
A
SW--112
Pin
Col.
Sect.
9
GN
0.5
10
N
0.5
Pin
Col.
Sect. 9
B
10
For model without cab
160 Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
5
--
--
2
BL
1.0
6
--
--
3
Z
1.0
7
BL
1.0
4
RV
1.0
8
Z
1.0 1
2
3
4
A 5
6
7
8
SW--115
Pin
Col.
Sect.
9
GN
0.5
10
N
0.5
Pin
Col.
Sect. 9
10
B
For standard version
161
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
1
RG
0.5
5
RV
0.5
2
HL
0.5
6
HL
0.5
3
HL
0.5
7
RV
0.5
4
RG
0.5
8
--
-1
2
105
3
4
A 5
6
7
8
SW--115
Pin
Col.
Sect.
9
GN
0.5
10
N
0.5
Pin
Col.
Sect. 9
10
B
For model with cab, version with Power Shuttle and Electronic Lift For model without cab, version with Power Shuttle
162 Col.
Sect.
1
BR
0.5
2
ZB
0.5
Pin
Col.
Sect.
Pin
Col.
Sect.
A
N
1.0
F
--
--
SW--116
2
Pin
4
Sect.
1
Col.
3
Pin
163
0.75
J
--
--
--
--
--
--
--
F
V
E
G
D
H
--
A
1.0
--
J
BL
H
C
G
0.75
B
1.0
G
E
R
C
D
B
C--117
164 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
106 Pin
Col.
Sect.
A
GN
0.5
B
N
0.5
Pin
Col.
Sect.
LMP--121
A
For model with cab
B
165 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
3
--
--
2
--
--
4
GN
1.0
LMP--121
For model without cab (ISO)
1
4
2
3
166 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
0.5
3
--
--
2
BN
1.0
4
--
--
3
1
4
2
A
SW--122
Pin
Col.
Sect.
9
GN
1.0
10
N
0.5
Pin
Col.
Sect. 9
10
B
For model with cab For model without cab (ISO)
167 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
0.5
3
--
--
2
BN
1.0
4
--
--
107
3
1
4
2
A
SW--122
Pin
Col.
Sect.
9
GN
0.5
10
N
0.5
Pin
Col.
Sect. 9
10
B
For model without cab (North America)
168 Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
4
R
1.0
2
N
1.0
5
GN
1.0
3
A
1.0
--
--
--
LMP--123
1
For model with cab
3
2
5
4
169 Pin
Col.
Sect.
A
RG
1.0
B
GN
1.0
C
N
1.0
D
R
1.0
Pin
Col.
For model without cab, standard version
Sect.
LMP--123 A B C D
170 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
108 Pin
Col.
Sect.
A
G
0.5
B
N
0.5
Pin
Col.
Sect.
LMP--124 A
For model with cab
B
171 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
3
--
--
2
--
--
4
G
1.0
LMP--124
For model without cab (ISO)
1
4
2
3
172 Pin
Col.
Sect.
Pin
Col.
Sect.
1
HL
0.5
3
C
0.5
2
RV
0.5
--
--
--
SW--125
For model with cab, version with Power Shuttle and Electronic Lift 3
2
1
173 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
3
A
1.0
2
--
--
4
G
1.0
For model with cab
LMP--126
1
4
2
3
174 87679925A - 12 - 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
Pin
Col.
Sect.
A
RG
1.0
B
G
1.0
C
N
1.0
Pin
Col.
109
Sect.
LMP−126 A
For model without cab (ISO) B C
175 Pin
Col.
Sect.
Pin
Col.
Sect.
1
RV
0.5
3
C
0.5
2
MN
0.5
−
−
−
SW−127
For model with cab, version with Power Shuttle and Electronic Lift 3
2
1
176 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
3
BV
1.0
2
BL
1.0
4
−
−
For model without cab (ISO) For model without cab, standard version (North America)
LMP−128
1
4
2
3
177 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
3
BV
0.5
2
BL
1.0
4
−
−
For model without cab, version with Power Shuttle (North America)
LMP−128
1
4
2
3
178 87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
110
Pin
Col.
Sect.
Pin
Col.
Sect.
30
ZB
1.0
86
ZN
0.5
85
N
0.5
87
V
1.0
RLY−131
87
30
86
I
85
179 Pin
Col.
Sect.
Pin
Col.
Sect.
30
ZB
1.0
86
Z
0.5
85
N
0.5
87
H
1.0
RLY−132
87
30
86
II
85
180 Pin
Col.
Sect.
Pin
Col.
Sect.
30
ZB
1.0
86
BN
0.5
85
N
0.5
87
L
1.0
RLY−133
87
30
86
III
85
181 Pin
Col.
Sect.
Pin
Col.
Sect.
30
HV
1.5
87
RN
1.5
85
N
0.5
87a
H
1.5
86
BR
0.5
−
−
−
RLY−134
30
Pin
Col.
Sect.
Pin
Col.
Sect.
30
HV
1.5
87
R
1.5
85
BR
0.5
87a
H
1.5
86
HV
0.5
−
−
−
87
86
With FL series loader
87a
IV
85
With TL series loader 182 87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
Pin
Col.
Sect.
Pin
Col.
Sect.
30
GN
1.5
87
RN
1.5
85
N
0.5
87a
V
1.5
86
BN
0.5
−
−
−
RLY−135
30
Pin
Col.
Sect.
Pin
Col.
Sect.
30
GN
1.5
87
RN
1.5
85
N
0.5
87a
V
1.5
86
GN
0.5
−
−
−
87
86
With FL series loader
111
87a
V
85
With TL series loader 183 Pin
Col.
Sect.
Pin
Col.
Sect.
−
N
1.5
−
N
1.0
−
N
1.0
−
−
−
GND−136
For models fitted with Power Shuttle
184 Pin
Col.
Sect.
Pin
Col.
Sect.
−
N
1.5
−
N
1.0
−
N
1.0
−
N
1.0
GND−136
For model with manual transmission For models with Power Shuttle and Electronic Lift
185 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
4
−
−
2
V
1.0
5
R
1.0
3
CN
1.0
6
L
1.0
M−138
186 87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
112
Col.
Sect.
1
N
1.0
2
AN
1.0
Pin
Col.
Sect.
LMP−139
2
1
Pin
187 Pin
Col.
Sect.
1
N
1.0
2
ZN
1.0
Pin
Col.
Sect.
C−142
1
2
188 Pin
Col.
Sect.
1
N
1.0
2
CB
1.0
Pin
Col.
Sect.
C−143
1
2
189 Pin
Col.
Sect.
1
N
1.0
2
CB
1.0
Pin
Col.
Sect.
C−144
1
2
190 87679925A2 − 02 − 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
1
G
0.5
Pin
Col.
Sect.
113
SW--145
191 Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
10
N
1.0
2
--
--
11
N
0.5
3
N
1.0
12
N
1.0
4
N
0.5
13
N
1.05
5
N
1.0
14
N
1.0
6
N
1.0
15
N
1.0
7
N
1.0
16
N
1.0
8
--
--
17
N
1.0
9
--
--
GND--146
192 Pin
Col.
Sect.
1
N
1.0
2
AB
1.0
Pin
Col.
Sect.
M--147
1
2
193 Sect.
1
N
1.0
2
RN
1.0
Pin
Col.
Sect.
LMP--148A
1
Col.
2
Pin
194 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
114 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
3
CN
1.0
2
--
--
4
VN
1.0
M--149
1
4
2
3
195 Pin
Col.
Sect.
A
AN
1.0
B
AN
1.0
Pin
Col.
Sect.
AUD--150 A
B
196 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
8
--
--
2
N
0.5
9
N
1.0
3
--
--
10
N
0.5
4
--
--
11
N
1.0
5
--
--
12
N
0.5
6
N
0.5
13
N
0.5
7
N
0.5
--
--
--
GND--151
For model with cab, standard version
197 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
9
N
1.0
2
N
0.5
10
N
0.5
3
--
--
11
N
1.0
4
--
--
12
N
0.5
5
N
0.5
13
N
0.5
6
N
0.5
14
--
--
7
N
0.5
15
--
--
8
--
--
16
--
--
GND--151
For model with cab, version with Power Shuttle 198 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
9
N
1.0
2
N
0.5
10
N
0.5
3
--
--
11
N
1.0
4
--
--
12
N
0.5
5
N
0.5
13
N
0.5
6
N
0.5
14
N
0.5
7
N
0.5
15
--
--
8
--
--
16
--
--
3
--
--
--
--
--
115
GND--151
For model with cab, version with Power Shuttle and Electronic Lift Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
4
R
1.0
2
N
1.0
5
G
1.0
3
AN
1.0
--
--
--
199 LMP--152
1
For model with cab
3
2
5
4
200 Pin
Col.
Sect.
A
R
1.0
B
G
1.0
C
N
1.0
D
RN
1.0
Pin
Col.
Sect.
LMP--152 A B
For model without cab (ISO)
C D
201 Pin
Col.
Sect.
Pin
Col.
Sect.
1
BR
0.5
3
S
0.5
2
H
0.5
--
--
--
For model with cab, version with Power Shuttle and Electronic Lift For model without cab, standard version
RES--156
3
2
1
202 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
116 Pin
Col.
Sect.
1
AV
1.0
2
LR
1.0
Pin
Col.
Sect.
SW--158
2
1
203 Pin 1 2 3 4 5 6 8 11 12 13 14
Col. N N N N N N N N N N N
Sect. 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Pin 15 16 17 18 19 20 22 23 24 25 26
Col. B N N N N N N N N N N
Sect. 0.5 0.5 0.5 0.5 0.5 0.5 1.5 1.5 1.5 1.5 1.5
Pin 1
Col. N
Sect. 1.0
Pin 13
Col. N
Sect. 1.0
2 3 4 5 9 10 11 12
N N N N N N N N
1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
14 15 16 17 18 19 20 21 22
N N N N N N N N N
1.0 1.0 1.0 0.5 0.5 0.5 0.5 0.5 0.5
For model with cab, standard version
87679925A1 - 02 - 2008
GND--159 A
B
204
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin 1 2 3 4 5 6 7 8 11 12 13 14
Col. N N N N N N N N N N N N
Sect. 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Pin 15 16 17 18 19 20 22 23 24 25 26 --
Col. B N N N N N N N N N N --
Sect. 0.5 0.5 0.5 0.5 0.5 0.5 1.5 1.5 1.5 1.5 1.5 --
Pin 1 2 3 4 5 6 7 8
Col. N N N N N N N N
Sect. 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Pin 9 10 11 12 13 14 15 16
Col. N N N N N N N N
Sect. 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
117
GND--159 A
B
For model with cab, version with Power Shuttle 205 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13
Col. N N N N N N N N N N N N N
Sect. 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Pin 14 15 16 17 18 19 20 22 23 24 25 26 --
Col. N B N N N N N N N N N N --
Sect. 0.5 0.5 0.5 0.5 0.5 0.5 0.5 1.5 1.5 1.5 1.5 1,5 --
Pin 1 2 3 4 5 6 7 8
Col. N N N N N N N N
Sect. 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Pin 9 10 11 12 13 14 15 16 17
Col. N N N N N N N N N
Sect. 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 0.5
For model with cab, version with Power Shuttle and Electronic Lift
GND--159 A
B
206 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
118
Pin 4 5 11 12 13 14 15 16 17 18 19
Col. N N N N N N N N N N N
Sect. 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Pin 20 21 22 23 24 25 26 27 28 29 30
Col. B N N N N N N N N N N
Sect. 0.5 0.5 0.5 0.5 1.5 1.5 1.5 1--0 1.0 1.0 1.0
Pin 1 2 5 9 10 11 12 13 14
Col. N N N N N N N N N
Sect. 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Pin 15 16 17 18 19 20 21 22 --
Col. N N N N N N N N --
Sect. 1.0 1.0 0.5 0.5 0.5 0.5 0.5 1.0 --
GND--159 A
B
For model without cab, standard version (ISO) 207 Pin 4 5 7 11 12 13 14 15 16 17 18 19
Col. N N N N N N N N N N N N
Sect. 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Pin 20 21 22 23 24 25 26 27 28 29 30 --
Col. B N N N N N N N N N N --
Sect. 1.0 0.5 0.5 0.5 1.5 1.5 1.5 1.0 1.0 1.0 1.0 --
Pin 1 2 5 6 7 8 9 10
Col. N N N N N N N N
Sect. 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Pin 11 12 13 14 15 16 22 --
Col. N N N N N N N --
Sect. 1.0 1.0 1.0 1.0 1.0 1.0 1.0 --
For model without cab, version with Power Shuttle (ISO)
87679925A1 - 02 - 2008
GND--159 A
B
208
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
4
N
0.5
18
N
0.5
5
N
0.5
19
N
0.5
11
N
0.5
20
N
0.5
12
N
0.5
21
N
0.5
13
N
0.5
22
N
0.5
14
N
0.5
23
N
0.5
15
N
0.5
24
N
1.5
16
N
0.5
25
N
1.5
17
N
0.5
26
N
1.5
Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
15
N
1.0
2
N
1.0
16
N
1.0
3
N
1.0
17
N
0.5
4
N
1.0
18
N
0.5
5
N
1.0
19
N
0.5
9
N
1.0
20
N
0.5
10
N
1.0
21
N
0.5
11
N
1.0
22
N
1.0
12
N
1.0
--
--
--
119
GND--159 A
B
For model without cab, standard version (North America) 209 Pin
Col.
Sect.
Pin
Col.
Sect.
4
N
0.5
18
N
0.5
5
N
0.5
19
N
0.5
7
N
0.5
20
N
0.5
11
N
0.5
21
N
0.5
12
N
0.5
22
N
0.5
13
N
0.5
23
N
0.5
14
N
0.5
24
N
1.5
15
B
0.5
25
N
1.5
16
N
0.5
26
N
1.5
17
N
0.5
--
--
--
Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
10
N
1.0
2
N
1.0
11
N
1.0
3
N
1.0
12
N
1.0
4
N
1.0
13
N
1.0
5
N
1.0
14
N
1.0
6
N
1.0
15
N
1.0
7
N
1.0
16
N
1.0
8
N
1.0
22
N
1.0
9
N
1.0
--
--
--
For model without cab, Power Shuttle (North America)
version
GND--159 A
B
with 210
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
120 Pin
Col.
Sect.
1
R
16.0
2
R
16.0
Pin
Col.
Sect.
F--160
211 Pin
Col.
Sect.
A
N
0.5
B
GN
0.5
Pin
Col.
Sect.
LMP--161 A
For model with cab
B
212 Pin
Col.
Sect.
1
N
0.5
2
GN
0.5
Pin
Col.
Sect.
LMP--162
For model with cab, version with Power Shuttle and Electronic Lift 1
2
213 Pin
Col.
Sect.
1
N
1.0
2
CL
1.0
Pin
Col.
Sect.
M--163
1
2
214 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
1
RV
0.5
4
RB
0.5
2
--
--
5
RL
0.5
121
SW--164
For model with cab, version with Power Shuttle and Electronic Lift
1
4
5
215 Pin
Col.
Sect.
Pin
Col.
Sect.
C
G
4.0
L
G
1.5
H
C
1.5
M
R
1.5
H
C
1.5
M
R
1.5
L
G
1.5
--
--
--
For model with cab without air--conditioner
SW--165A
C
H
L
M
216
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
122 Pin
Col.
Sect.
Pin
Col.
Sect.
B
V
1.0
L
G
1.5
C
G
4.0
L
G
1.5
H
C
1.5
M
R
1.5
H
C
1.5
M
R
1.5
SW--165A B
For model with cab with air--conditioner C
H
L
M
217 Col.
Sect.
Pin
Col.
Sect.
1
V
1.0
2
V
1.0
Pin
Col.
Sect.
Pin
Col.
Sect.
1
LR
1.0
3
G
0.75
2
V
0.75
4
N
1.0
SW--165C
1
2
Pin
218
1 3 4
2
3 4
2
1
MOD--166
219 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
Pin
Col.
Sect.
1
RV
0.5
4
RB
0.5
2
--
--
5
RL
0.5
3
--
--
--
--
--
123
SW--167
1
For model with cab, version with Power Shuttle and Electronic Lift 4
5
220 Pin
Col.
Sect.
--
N
1.0
--
Z
1.0
Pin
Col.
Sect.
AUD--169
221
B
N
1.0
Pin
Col.
Sect.
LMP--170
B
1.0
A
Sect.
B
B
Col.
A
A
Pin
222 B
1.0
B
N
1.0
Col.
Sect.
LMP--171
B
A
Pin
A
Sect.
B
Col.
A
Pin
223 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
1.0
3
V
1.0
2
--
--
4
H
1.0
LMP--172
2
Sect.
N
1
Col.
1
4
Pin
3
124
224 Col.
Sect.
3
V
1.0
2
--
--
4
H
1.0
LMP--173
2
Pin
1.0
1
Sect.
N
4
Col.
1
3
Pin
225 Pin
Col.
Sect.
1
R
16.0
Pin
Col.
Sect.
RES--174
226 Col.
Sect.
30
R
16.0
86
AR
1.0
85
N
1.0
87
R
16.0
RLY--175
1
Pin
2
Sect.
1
Col.
2
Pin
227 87679925A - 12 - 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
Pin
Col.
Sect.
Pin
Col.
1
−
−
5
−
−
2
−
−
6
GN
0.5
3
BL
0.5
7
BG
0.5
4
GN
0.5
8
GN
0.5
125
Sect.
1
2
3
4
A 5
6
7
8
SW−178
Pin
Col.
Sect.
9
GN
0.5
10
N
0.5
Pin
Col.
Sect. 9
B
10
For model with cab
228 Pin
Col.
Sect.
Pin
Col.
Sect.
1
−
−
5
−
−
2
−
−
6
−
−
3
−
−
7
BV
0.5
4
−
−
8
GN
0.5 1
2
3
4
A 5
6
7
8
SW−179
Pin
Col.
Sect.
9
GN
0.5
10
N
1.0
Pin
Col.
Sect. 9
10
B
For model with cab
229
87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
126
Pin
Col.
Sect.
Pin
Col.
Sect.
1
RN
1.0
2
N
1.0
LMP−180
Col.
Sect.
Pin
Col.
Sect.
1
R
1.0
2
N
1.0
2
Pin
1
With FL series loader
With TL series loader
230 Pin
Col.
Sect.
Pin
Col.
Sect.
1
RN
1.0
2
N
1.0
LMP−181
Col.
Sect.
Pin
Col.
Sect.
1
R
1.0
2
N
1.0
2
Pin
1
With FL series loader
With TL series loader
231 Col.
Sect.
1
N
1.5
3
R
1.5
2
C
1.5
4
G
1.5
Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.5
3
R
1.5
2
C
1.5
4
G
1.5
M−188A
1
Pin
2
Sect.
3
Col.
4
Pin
232
3
1
4
2
M−188B
233 87679925A2 − 02 − 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Col.
Sect.
Pin
Col.
Sect.
1
V
1.0
3
N
1.0
2
L
1.0
--
--
--
SEN--190
1
2
3
Pin
127
234 Pin
Col.
Sect.
1
SB
1.0
2
N
1.0
Pin
Col.
Sect.
SEN--196
For model with Italian trailer brake
235 Pin
Col.
Sect.
1
AR
1.0
2
AR
1.0
Pin
Col.
Sect.
SOL--197
For model with Italian trailer brake
236 Pin
Col.
Sect.
1
Z
1.0
2
HR
1.0
Pin
Col.
Sect.
SEN--198
For model with Italian trailer brake
237 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
128 Pin
Col.
Sect.
A
BR
1.0
B
M
1.0
Pin
Col.
Sect.
SEN--201
For model fitted with Power Shuttle and Electronic Lift
238 Col.
Sect.
A
AN
1.0
B
AG
1.0
Pin
Col.
Sect.
2
For model fitted with Power Shuttle and Electronic Lift
SOL--202
1
Pin
239 Col.
Sect.
A
LN
1.0
B
LG
1.0
Pin
Col.
Sect.
2
For model fitted with Power Shuttle and Electronic Lift
SOL--203
1
Pin
240 Col.
Sect.
A
LV
1.0
B
LR
1.0
Pin
Col.
Sect.
2
For model fitted with Power Shuttle and Electronic Lift
SOL--204
1
Pin
241 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Col.
Sect.
A
GV
1.0
B
GR
1.0
Pin
Col.
Sect.
2
For model fitted with Power Shuttle and Electronic Lift
SOL--205
1
Pin
129
242 Pin
Col.
Sect.
1
BV
1.0
2
ZB
1.0
Pin
Col.
Sect.
For model fitted with Power Shuttle and Electronic Lift
SEN--206
1
2
243 Pin
Col.
Sect.
1
NB
1.0
2
ZB
1.0
Pin
Col.
Sect.
For model fitted with Power Shuttle and Electronic Lift
SEN--207
1
2
244 Sect.
1
S
1.0
2
VB
1.0
Pin
Col.
Sect.
For model fitted with Power Shuttle and Electronic Lift
SW--209
1
Col.
2
Pin
245 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
Pin
Col.
Sect.
1
S
1.0
2
MB
1.0
Pin
Col.
Sect.
2
For model fitted with Power Shuttle and Electronic Lift
SW--210
1
130
246 Col.
Sect.
1
S
1.0
2
MN
1.0
Pin
Col.
Sect.
2
For model fitted with Power Shuttle and Electronic Lift
SW--211
1
Pin
247
2
SN
1.0
Pin
Col.
Sect.
SEN--212
1
1.0
2
Sect.
NG
1
Col.
1
2
Pin
248 Pin
Col.
Sect.
1
AV
1.0
2
N
1.0
Pin
Col.
Sect.
SOL--213
2
1
For model with manual transmission
249 87679925A - 12 - 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
Col.
Sect.
1
AV
1.0
2
RG
1.0
Pin
Col.
Sect.
2
For models with Power Shuttle and Electronic Lift
SOL−213
1
Pin
131
250 Col.
Sect.
1
BN
1.0
2
N
1.0
Pin
Col.
Sect.
SOL−214
2
1
Pin
251 Col.
Sect.
Pin
Col.
Sect.
1
BG
1.0
2
N
1.0
Pin
Col.
Sect.
Pin
Col.
Sect.
1
ZB
1.0
3
−
−
2
−
−
4
H
1.0
SOL−215
2
1
Pin
252
1
1
SW−216
Col.
Sect.
Pin
Col.
Sect.
1.0
3
−
−
3
1
HL
3
2
−
−
4
H
1.0
4
2
Pin
4
2
For model with manual transmission
For model with Power Shuttle transmission 253 87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
132
Pin
Col.
Sect.
1
HB
1.0
2
NG
1.0
Pin
Col.
Sect.
SEN−217
1
HB
1.0
2
BR
1.0
Pin
Col.
Sect.
1
Sect.
2
Col.
1
Pin
2
For model with manual transmission
For models fitted with Power Shuttle 254 Pin
Col.
Sect.
Pin
Col.
Sect.
1
ZB
1.0
3
BR
1.0
2
BV
1.0
SEN−217B
2
2
3
3
1
1
For models fitted with Power Shuttle with creeper unit 20X20
255 Col.
Sect.
1
HN
1.0
2
NG
1.0
Pin
Col.
Sect.
Pin
Col.
Sect.
1
BR
1.0
3
LB
1.0
2
HV
1.0
−
−
−
SEN−218
1
Pin
2
Sect.
1
Col.
2
Pin
256 SEN−221
2 3
1
2 3
1
For models with Power Shuttle and Electronic Lift
257 87679925A2 − 02 − 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
1
SB
1.0
2
AG
1.0
Pin
Col.
Sect.
133
SOL--222
For model fitted with Power Shuttle and Electronic Lift
258 Pin
Col.
Sect.
1
A
1.0
2
AR
1.0
Pin
Col.
Sect.
SOL--223
For model fitted with Power Shuttle and Electronic Lift
259 1.0
2
BL
1.0
--
--
--
For model fitted with Power Shuttle and Electronic Lift
SEN--224
1
Sect.
S
2
Col.
3
3
Pin
1.0
1
Sect.
BR
2
Col.
1
3
Pin
260 1
BR
1.0
3
B
1.0
2
GV
1.0
--
--
--
For model fitted with Power Shuttle and Electronic Lift
SEN--225
1
Sect.
2
Col.
3
Pin
1
Sect.
2
Col.
3
Pin
261 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
134 Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
3
RN
1.0
2
MV
1.0
4
RV
1.0
4
3
2
1
For model fitted with Power Shuttle and Electronic Lift
SEN--227
262 Pin
Col.
Sect.
D+
RV
1.0
Pin
Col.
Sect.
ALT--301/314
263 Pin
Col.
Sect.
50
RN
2.5
Pin
Col.
Sect.
M--302/308
50
Pin
Col.
Sect.
30
N
25.0
30
R
16.0
30
N
50.0
Pin
Col.
Sect.
30
264 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
1
N
1.0
1
M
1.0
Pin
Col.
Sect.
135
SW--303
A
B
265 Col.
Sect.
Pin
Col.
Sect.
1
L
1.0
2
--
--
M--304
2
1
Pin
266 Sect.
Pin
Col.
Sect.
G
1.0
3
ZB
1.0
2
N
1.0
--
--
--
SEN--305
1
Col.
1
2
2
3
3
1
Pin
267 Pin
Col.
Sect.
Pin
Col.
Sect.
A
AB
1.0
C
NG
1.0
B
HR
1.0
--
--
--
SEN--306
C B
A
268 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
136 Pin
Col.
Sect.
1
BL
1.0
Pin
Col.
Sect.
SOL--307
269 Col.
Sect.
1
ZB
1.0
2
ZB
1.0
Pin
Col.
Sect.
SEN--309
2
1
Pin
270 Pin
Col.
Sect.
1
ZB
1.0
Pin
Col.
Sect.
MOD--310
271 Pin
Col.
Sect.
A
N
1.0
B
VG
1.0
Pin
Col.
Sect.
SEN--311
A
B
272 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Pin
Col.
Sect.
A
BR
1.0
B
ZB
1.0
Pin
Col.
Sect.
137
SW--312
A
B
273 Pin
Col.
Sect.
1
CA
1.0
Pin
Col.
Sect.
SEN--313
274 Pin
Col.
Sect.
Pin
Col.
Sect.
1
NG
1.0
3
--
--
2
HV
1.0
--
--
--
SEN--315
275 Sect.
1
MN
1.0
2
HN
1.0
Pin
Col.
Sect.
SW--316
1
Col.
2
Pin
276 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
138 Pin
Col.
Sect.
1
L
1.0
2
LB
1.0
Pin
Col.
Sect.
SEN--317
1
2
277 Col.
Sect.
1
MN
1.0
2
N
1.0
Pin
Col.
Sect.
SW--318
2
1
Pin
278 Col.
Sect.
1
R
1.0
2
RG
1.0
Pin
Col.
Sect.
C--319
2
1
Pin
279 R
1.5
2
--
--
Col.
Sect.
C--319
2
1
Pin
1
Sect.
2
Col.
1
Pin
280 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
2
VN
1.0
Pin
Col.
Sect.
Jumper valid on model without mechanical battery cut--out
C--319
2
1.0
1
Sect.
VN
2
Col.
1
1
Pin
139
281 Pin
Col.
Sect.
1
Z
1.0
2
N
1.0
Pin
Col.
Sect.
SOL--330
282 Pin
Col.
Sect.
1
ZB
1.0
2
Z
1.0
Pin
Col.
Sect.
SW--331
283 Pin
Col.
Sect.
1
NG
1.0
2
HL
1.0
Pin
Col.
Sect.
SEN--340
For model with pneumatic trailer brake
284 87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
140 Pin
Col.
Sect.
1
N
50.0
2
N
50.0
Pin
Col.
Sect.
BAT--500
285
87679925A - 12 - 2007
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
141
NOTE: for the connector LMP--66A see page 82
Pin
Col.
Sect.
1
N
1.0
2
AB
1.0
Pin
Col.
Sect.
LMP--66B
2
1
For model with cab
296 Col.
Sect.
1
N
1.0
2
AR
1.0
Pin
Col.
Sect.
1
N
1.0
2
AR
1.0
Pin
Col.
Sect.
Pin
Col.
Sect.
LMP--95
2
1
Pin
297
2
1
LMP--96
298
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
142
Col.
Sect.
1
N
1.0
2
CB
1.0
Pin
Col.
Sect.
1
N
1.0
2
CB
1.0
Pin
Col.
Sect.
Pin
Col.
Sect.
LMP--98
2
1
Pin
299
2
1
LMP--99
300
NOTE: for the connector LMP--148A see page 113
Col.
Sect.
1
N
1.0
2
AB
1.0
Pin
Col.
Sect.
LMP--148B
2
1
Pin
301
87679925A1 - 02 - 2008
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
Sect.
HB
1.0
2
BN
1.0
27
HN
1.0
3
AG
1.0
28
H
1.0
4
AN
1.0
29
MB
1.0
5
LG
1.0
30
MN
1.0
6
LN
1.0
31
VB
1.0
7
LR
1.0
32
NG
1.0
8
LV
1.0
33
BR
1.0
9
−
−
34
ZB
1.0
10
−
−
35
ZB
1.0
11
AV
1.0
36
S
1.0
12
RG
1.0
37
Z
1.0
13
−
−
38
−
−
14
L
1.0
39
−
−
15
B
1.0
40
−
−
16
GN
1.0
41
−
−
17
G
1.5
42
−
−
18
R
1.0
43
−
−
19
−
−
44
−
−
20
−
−
45
−
−
21
BV
1.0
46
−
−
22
−
−
47
−
−
23
−
−
48
−
−
24
SN
1.0
49
−
−
25
M
1.0
50
−
−
41 42 43 44 45 46 47 48 49 50
Col.
26
31 32 33 34 35 36 37 38 39 40
Pin
1.0
11 12 13 14 15 16 17 18 19 20
Sect.
BG
21 22 23 24 25 26 27 28 29 30
Col.
1
1 2 3 4 5 6 7 8 9 10
Pin
143
C−2
302
For model with cab, version with Power Shuttle 20X20. For models fitted with Power Shuttle see page 61, Fig. 51. TRANSMISSION CABLE SIDE
87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
144
Sect.
−
−
2
BN
1.0
27
HN
1.0
3
AG
1.0
28
H
1.0
4
AN
1.0
29
MB
1.0
5
LG
1.0
30
MN
1.0
6
LN
1.0
31
VB
1.0
7
LR
1.0
32
NG
1.0
8
LV
1.0
33
BR
1.0
9
GR
1.0
34
ZB
1.0
10
GV
1.0
35
ZB
1.0
11
AV
1.0
36
S
1.0
12
RG
1.0
37
Z
1.0
13
−
−
38
RV
1.0
14
L
1.0
39
RN
1.0
15
B
1.0
40
MV
1.0
16
GN
1.0
41
−
−
17
G
1.5
42
SB
1.0
18
R
1.0
43
AG
1.0
19
−
−
44
A
1.0
20
−
−
45
AR
1.0
21
BV
1.0
46
S
1.0
22
−
−
47
B
1.0
23
−
−
48
BL
1.0
24
SN
1.0
49
GV
1.0
25
M
1.0
50
HV
1.0
41 42 43 44 45 46 47 48 49 50
Col.
26
31 32 33 34 35 36 37 38 39 40
Pin
1.0
11 12 13 14 15 16 17 18 19 20
Sect.
BG
21 22 23 24 25 26 27 28 29 30
Col.
1
1 2 3 4 5 6 7 8 9 10
Pin
C−2
303
For model with cab and version with Power Shuttle 20X20 and Electronic Lift. For model and version with Power Shuttle and Electronic Lift see page 62, Fig. 52. TRANSMISSION CABLE SIDE Pin
Col.
Sect.
Pin
Col.
Sect.
15
RV
1.0
87
VB
1.0
30
R
1.0
87A
−
−
31
N
1.0
−
−
−
1
HL
1.0
4
RV
1.0
2
N
1.0
5
−
−
3
V
1.0
−
−
−
RLY−40
MOD−40/41 RLY−40 RLY−41
RLY−41
304
87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
Pin
Col.
Sect.
Pin
Col.
Sect.
1
VB
1.0
3
N
1.0
2
N
1.0
4
RG
1.0
145
MOD−43
4
3
2
1
305 Pin
Col.
Sect.
Pin
Col.
Sect.
1
RN
1.0
3
R
1.0
2
HL
1.0
4
N
1.0
C−46
3
3 1 2
1
2
4
4
Battery cut−off side, for the main cable side see page 78, Fig. 100 and 101.
306 Pin
Col.
Sect.
Pin
Col.
Sect.
1
RN
1.0
−
−
−
2
RG
1.0
−
−
−
D−47
1
2
307 1.0
3
R
1.0
2
V
1.0
4
V
1.0
C−50
1
L
2
1
3
Sect.
4
Col.
1
Pin
2
Sect.
3
Col.
4
Pin
308 87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
Pin
Col.
Sect.
1.0
3
−
−
2
V
1.0
4
V
1.0
CB−50A
34
Sect.
RV
12
Col.
1
34
Pin
12
146
309 Pin
Col.
Sect.
1
RV
1.0
2
V
1.0
Pin
Col.
Sect.
D−50B
1
2
310 Col.
Sect.
Pin
Col.
Sect.
1
ZB
1.0
3
N
1.0
2
M
1.0
−
−
−
Pin
Col.
Sect.
Pin
Col.
Sect.
1
ZB
1.0
3
N
1.0
2
A
1.0
−
−
−
C−60
2
2
3
3
1
1
Pin
311
2 1
3
2 1
3
C−60A
312 87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
Pin
Col.
Sect.
Pin
Col.
Sect.
1
V
1.0
3
L
1.0
2
H
1.0
−
−
−
147
C−81
2
2
1
1
3
3
8−Amp power socket side, for the front loader side see page 87 fig. 133.
313 Pin
Col.
Sect.
Pin
Col.
Sect.
1
V
1.0
3
L
1.0
2
H
1.0
−
−
−
C−81A
1
2
3 314
Sect.
Pin
Col.
Sect.
L
1.0
4
H
1.0
2
V
1.0
5
G
1.0
3
R
1.0
6
M
1.0
C−84
1
Col.
1
1
Pin
5
5
6
6
4
4
3
3
2
2
Front loader side.
315
1.0
M
1.0
7−pole socket side.
6
G
6
5
5
1.0
4
1.0
R
3
V
3
2
2
C−84
1
1.0
6
Sect.
H
5
Col.
4
4
Pin
1.0
3
Sect.
L
2
Col.
1
1
Pin
316 87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
148
Pin
Col.
Sect.
Pin
Col.
Sect.
1
L
1.0
5
G
1.0
2
V
1.0
6
M
1.0
3
R
1.0
7
−
−
4
H
1.0
−
−
−
C−84A
3
4
2
7
5 6
1
317 Col.
Sect.
1
−
−
5
N
1.0
2
−
−
6
BR
1.0
3
V
1.0
7
−
−
4
BR
1.0
8
−
−
SW−97A
8
Pin
2
6
1
5
7
Sect.
4
Col.
3
Pin
318 Col.
Sect.
1
−
−
5
N
1.0
2
−
−
6
BR
1.0
3
N
1.0
7
−
−
4
BR
1.0
8
−
−
Pin
Col.
Sect.
Pin
Col.
Sect.
A
GN
1.5
N
UR
1.5
SW−116A
8
Pin
2
6
1
5
7
Sect.
4
Col.
3
Pin
319 D−130
A
B 320 87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
Col.
Sect.
1
S
1.0
2
Z
1.0
Pin
Col.
Sect.
SW−296
2
1
Pin
149
321 Pin
Col.
Sect.
Pin
Col.
Sect.
1
R
1.5
2
R
1.5
C−320
322 Sect.
Pin
Col.
Sect.
1
VB
1.0
3
N
1.0
2
N
1.0
4
RG
1.0
Pin
Col.
Sect.
Pin
Col.
Sect.
1
VB
1.0
3
N
1.0
2
N
1.0
4
RG
1.0
C−351
1
Col.
3
3
4
4
2
2
1
Pin
323
34
34
12
12
C−351
324 87679925A2 − 02 − 2010
150
87679925A2 − 02 − 2010
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
1
SECTION 55 -- ELECTRICAL SYSTEM Chapter 8 -- COMPONENTS CONTENTS Description Page 1 -- 4WD gearbox oil pressure switch (Sen--311) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 -- Coolant temperature sensor (Sen--306) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 -- Sediment filter (Sen--305) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4 -- Engine rpm sensor (Sen--315) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5 -- Brake pump switches (SW--316 and SW--318) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 6 -- Air filter clogged switch (SW--303) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 7 -- Brake fluid level switch (SW--312) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 8 -- Mechanical battery cut--out switch (SW--97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 9 -- Thermometric sensor (SEN--309) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 10 -- Engine oil pressure switch (SEN--313) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1a -- 2WD gearbox oil pressure switch (Sen--311) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 11 -- 80 litre pump supplement solenoid valve (SOL--330) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 12 -- Handbrake switch (SW--73) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 13 -- CAN Terminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 14 -- Clutch pedal potentiometer (RES--156) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 15 -- Clutch pedal switch (SW--35) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 16 -- Trailer brake circuit pressure switch 3 ± 0.5 bar (3.06 ± 0.51 kg/cm2) (SEN--198) . . . . . . . . . . . . . . . 13 17 -- Trailer brake warning light pressure switch 10 ± 0.5 bar (10.19 -- 0.51 kg/cm2) (SEN--196) . . . . . . . . . 14 18 -- Air brake pressure switch (SEN--340) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 19 -- Lift--O--Matic switch (SW--64) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 20 -- Gear lever (SW--13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 21 -- Gear lever status switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 22 -- 80 litre switch (SW--331) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 23 -- Shuttle lever switch (SW--79) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 24 -- 4WD disengagement solenoid valve (SOL--214) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 25 -- Fuel level sensor (SEN--212) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 26 -- Theoretical wheel speed sensor (SEN--217) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 27 -- Operator present switch (SW--59) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 28 -- Mechanical power take--off safety/warning light switch (SW--23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 29 -- Radar (SEN--227) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 30 -- Gearbox control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 31 -- Arms position sensor (SEN--224) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 32 -- Differential lock warning light switch (SW--216) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 33 -- PTO speed sensor (SEN--218) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 34 -- Draft sensing pins (SEN--221 and SEN--225) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Removal--Installation windscreen wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
2 COMPONENTS
1 2
4
3
1. 2.
Gearbox oil pressure switch Coolant temperature sensor
1
Gearbox oil pressure switch (Sen--311) Pin
Col.
Sect.
A
N
1.0
B
VG
1.0
Pin
3. 4.
Col.
Sect.
Pressure switch normally on, turns off with a pressure greater than 0.8 รท 1.2 bar (0.81 รท 1.01 kg/cm@), mounted on 4WD and 2WD machines with hydraulic devices. It receives a ground signal on pin A wire 1 (N), via the main engine -- driving module connector C1 pin 48, with pressures lower than the setting pressure from pin B sends it to pin 12 wire 1 (VG) of the ADIC connector MOD--27 (3) via the main engine -- driving module connector C1 pin 18. The ADIC makes the related red alarm warning light blink the icon appears on the performance monitor and the buzzer sounds a critical alarm (see chapter 1 in this section).
87679925A1 - 02 - 2008
Sediment filter Engine rpm sensor
1
SEN--311
A
B
2
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 Coolant temperature sensor (Sen--306). Pin
Col.
Sect.
Pin
Col.
Sect.
A
AB
1.0
C
NG
1.0
B
HR
1.0
--
--
--
Temperature sensor containing two resistors with the value in Ohms that decreases as the resistance increases (NTC). Pin C receives a ground signal straight from the ADIC MOD--27 (1) pin 22 wire 1 (NG). Pin A (at the output of the first resistor) sends a signal via the main engine -- driving module connector C1 pin 21 to the ADIC MOD--27 (3) pin 20 wire 1 (AB), according to the temperature the ADIC governs the indicator. With temperatures that are too high (approximately 109)C) the ADIC makes the related red alarm warning light blink the icon appears on the performance monitor and the buzzer sounds a critical alarm (see chapter 1 in this section). Pin B (at the output of the second resistor) sends a signal via the main engine -- driving module connector C1 pin 22 to pin 10 wire 1 (HR) of the grid heater control module MOD--61. Functional test HH menu ADIC, menu H9 ch 23.
C B
A
3
Sensor setting --10 °C kΩ
8.244÷10.661
20 °C
80 °C
2.262÷2.760 0.304÷0.342
Sediment filter (Sen--305). Col.
Sect.
1
G
1.0
3
ZB
1.0
2
N
1.0
--
--
--
It is supplied from fuse F18 (5A) via the main engine -- driving module connection C1 pin 8 to pin 3 wire 1 (ZB), it receives a ground signal at pin 2 wire 1 (N) and when the coolant reaches a certain level it sends a signal via the main engine -- driving module connection C1 pin 23 to pin 13 wire 1 (G) of the ADIC module MOD--27 (1). This makes the amber warning light blink for 5 seconds and then stay on, the performance module shows the icon and the buzzer emits a non--critical sound (see chapter 1 in this section).
SEN--305
1
Pin
2
Sect.
3
Col.
1
Pin
2
3
SEN--306
3
2
3
4
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
4 4
Engine rpm sensor (Sen--315). Pin
Col.
Sect.
Pin
Col.
Sect.
1
NG
1.0
3
--
--
2
HV
1.0
--
--
--
Variable reluctance sensor associated with the phonic wheel mounted on the front of the crankshaft. It receives a ground signal via the main engine -driving module connector C1 pin 10 directly from the ADIC pin 22 wire 1 (NG) MOD--27 (1) at pin 1 of SEN--315. The signal leaves pin 2 wire 1 (HV) and via the main engine -- driving module cable C1 pin 25 to pin 3 of MOD--27 (1) ADIC. Functional test HH menu ADIC, menu HE ch 18 Functional test HH menu TCM, menu HE ch 3.
87679925A1 - 02 - 2008
SEN--315
5
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
5
6
5a
8
7
5. 6.
5
Brake switches Air filter clogged switch
7. 8.
Brake fluid level switch. Mechanical battery cut--out switch
6
5a Left brake switch (SW--316) 5 Right brake switch (SW--318) Sect.
Pin
Col.
Sect.
1
MN
1.0
1
L
1,0
2
HN
1.0
2
LB
1,0
SW--316
SW--318
Pressure switches normally on, they turn off when braking. Supplied from fuse F 3 (5A) via the main engine -driving module connector C1 pin 9 to pin 1 wire 1 (MN). Standard version On the left SW--316 the pin 2 is connected to pin 86 of the differential lock/four--wheel drive relay RLY--17 wire 0.5 (Z) via the main engine -- driving module connector C1 pin16. On the right SW--318 the pin 2 is connected to pin 86 of the differential lock relay RLY--19 wire 0.5 (N) via the main engine -- driving module connector C1 pin 17.
SW--316 SW--318
1
Col.
2
Pin
7
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
6
Power Shuttle version. On the left SW--316 the pin 2 is connected to the pin 22 of the transmission control module (TCM) MOD--1/3 (1B) wire 0.5 (HN) via the main engine -driving module connector C1 pin16, inside the driving module it is also connected to pin 86 of the stop lights relay RLY--5 wire 0.5 (HN). On the right SW--318 the pin 2 is connected pin 23 of the transmission control module (TCM) MOD--1/3 (1B) wire 0.5 (N) via the main engine -- driving module connector C1 pin17. Functional test HH menu TCM, menu H5 on pressing the pedals the display shows ch 73 left switch and ch 74 right switch. Using both pedals engages four--wheel drive and the brake lights come on (standard version, on the power shuttle it suffices to use the left one); using a single pedal does not engage four--wheel drive, but disengages the differential lock. 6
Air filter clogged switch (SW--303) Pin
Col.
Sect.
1
N
1.0
1
M
1.0
Pin
Col.
Sect.
SW--303
A
This switch, normally off, is turned on with a pressure of 62 mbar. At pin A wire 1 (N) receives a ground signal via the main engine -- driving module connector C1 pin 48. When the switch turns on it sends a signal, via the main engine -- driving module connector C1 pin 20, from pin B to the ADIC control module pin 11 MOD--27 (1) wire 1 (M). The ADIC makes the amber warning light blink for 5 seconds and then stay on, the performance monitor shows the relevant icon (see chapter 1 in this section). 7
B
8
Brake fluid level switch (SW--312) Pin
Col.
Sect.
A
BR
1.0
B
ZB
1.0
Pin
Col.
Sect.
Switch normally on, with the reservoir full the contact is opened. It is supplied from fuse F18 (5A) via the main engine -- driving module connector C1 pin 8 on pin B of SW--312 wire 1 (ZB), with a low oil level the contacts close and it sends a signal via the main engine -driving module connector C1 pin 24 to the ADIC control module pin 4 of MOD--27 (1) wire 1 (BR).
SW--312
A
B
9
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
7
The ADIC makes the amber warning light blink for 5 seconds and then stay on, the performance monitor shows the relevant icon (see chapter 1 in this section). 8
Mechanical battery cut--out switch (SW--97) Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
50.0
2
N
50.0
1
R
1.5
--
--
--
Switch that cuts off the tractorâ&#x20AC;&#x2122;s electric supply cable. Pin 1 is connected to cable 50 (N) from the positive pin of the battery BAT--500, and the wire 1.5 (R) that, bypassing the switch, takes the supply to the fuse F12 (5A) that supplies the machineâ&#x20AC;&#x2122;s vital services (control unit memories,....). Pin 2 is connected to cable 50 (N) that carries the supply to pin 30 of the starter motor M--302/308 and via pin 30 to all the machine.
SW--97 1
1
2
10
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
8
9
10
1a
11 11
9. Thermometric sensor 10. Engine oil pressure switch
Temperature gauge sensor (SEN--309) Col.
Sect.
1
ZB
1.0
2
ZB
1.0
Pin
Col.
Sect.
Switch normally on, the contacts open with temperature increasing to 63 ± 3_C, with temperature decreasing to 53 ± 3_C; working range from --30_C to 130_C. Pin 1 is connected to wire 1 (ZB) from fuse F18 (5A) via the main engine -- driving module connector C1 pin 8. At pin 2 cable 1 (ZB) that, with contacts closed, sends 12 volts to the advance cut--out module MOD--310 that with temperatures greater than 63 ± 3_C eliminates the starting advance.
87679925A1 - 02 - 2008
SEN--309
1
Pin
2
9
1a Gearbox oil pressure switch 11. 80 litre supplement solenoid valve
12
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
9
10 Engine oil pressure switch (SEN--313) Pin
Col.
Sect.
1
CA
1.0
Pin
Col.
Sect.
SEN--313
Switch normally on, it turns off with pressures 0.6 รท 0.9 bar. The only pin is connected to wire 1 (CA) that carries a ground signal (the switch takes it from the engine ground) to the ADIC control module MOD--27 (3) pin 5 via the main engine -- driving module connector C1 pin 19. With the engine running and low pressure, the ADIC makes the red warning light blink, emits a critical beep and the relevant icon is displayed on the performance monitor (see chapter 1 in this section).
13
1a Gearbox oil pressure switch (Sen--311). Pin
Col.
Sect.
A
N
1.0
B
VG
1.0
Pin
Col.
Sect.
Pressure switch normally on, turns off with a pressure greater than 10 รท 12 bar (10.2 รท 12.2 kg/cm@), mounted on fully mechanical two--wheel drives. It receives a ground signal on pin A wire 1 (N), with pressures lower than the setting pressure from pin B sends it to pin 12 wire 1 (VG) of the ADIC connector MOD--27 (3) via the main engine -- cab connector C1 pin 18. The ADIC makes the related red alarm warning light blink the icon appears on the performance monitor and the buzzer sounds a critical alarm (see chapter 1 in this section).
SEN--311
A
B
14
11 80 litre supplement solenoid valve (SOL--330). Pin
Col.
Sect.
1
Z
1.0
2
N
1.0
Pin
Col.
Sect.
SOL--330
Solenoid valve, mounted on the power steering pump that normally closed sends 18 litres to lubrication, when energized sends it to the ventral control valves (see section 35 chapter 7). The supply to pin 1 comes from the switch on the ventral control valves SW--331 (22, page18) wire 1 (Z), to pin 2 ground signal wire 1 (N), via the 80l connector C89 pin 1. 15
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
10
13
14
12
15
18
16
17
12. 13. 14. 15.
16
Hand brake switch CAN Terminator Clutch pedal potentiometer Clutch pedal switch
16. Trailer brake circuit pressure switch 3 Âą 0.5 bar (3.06 -- 0.51 kg/cm2) 17. Trailer brake warning light pressure switch 10 Âą 0.5 bar (10.19 -- 0.51 kg/cm2) 18. Air brake pressure switch
12 Handbrake switch (SW--73)
R
1.0
2
RB
1.0
Col.
Sect.
Magnetic switch normally on, when the magnet, fixed to the handbrake lever, moves near to the switch, secured to the base of the lever, the contact opens. Pin 1 receives 12 volts from the fuse F12 (5A) wire 1 (R); from pin 2 a signal originates, with the brake operated, and goes: A. To the ADIC control unit MOD--27 (3) pin 7 wire 1 (RB), for turning on the handbrake warning light and for the handbrake logic element. -- Starting with brake engaged, warning light (P) blinks, the buzzer emits a critical alarm and the performance monitor shows the icon (P), all this as long as the condition is present. _ Key OFF, handbrake disengaged, warning light (P) blinks, the buzzer emits a continuous sound for 10 seconds. 87679925A1 - 02 - 2008
SW--73
1
1
Pin
2
Sect.
1
Col.
2
Pin
17
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
11
--
Key ON, engine running, the operator leaves the driving seat, the warning light (P) blinks, the buzzer emits a continuous sound for 10 seconds, it stops if the operator operates the parking brake or returns to the driving seat. B. At pin 30 parking brake relay RLY--1 wire 1 (RB).35. With key ON pin 86 of the relay RLY--1 receives 12 volts from the fuse F27 (5A) wire 0.5 (Z), pin 85 grounded wire 0.5 (N), thereby closing the contacts. Pin 87 provides the supply from the handbrake that goes to pin 86 of the coil of the trailer brake circuit relay RLY--27 that, closing the contacts, has the job of reversing the solenoid valves of the hydraulic trailer brake Italian version, so the oil at 10 bars (10.19 kg/cm@) is discharged and the trailer is braked by the mechanical emergency brake. Functional test HH menu ADIC, menu H5, on operating the parking brake the display will show d65.
2
V
0.75
4
N
1.0
The terminator is basically a 120 â&#x201E;Ś resistor mounted between the two wires of the CAN line. It is used to balance the line voltage, without which there can be errors in interpreting the signals among the various control units. The terminator can be inside or outside the control unit. -- Transmission with power shuttle Two internal terminators, one on the ADIC instrument panel control unit and the other on the TCM power shuttle control unit. -- Mechanical transmission with standard ADIC An internal terminator on the standard ADIC instrument panel control unit and one in place of the keypad with the connector (similar to 2 with connector with 4 pins). -- Mechanical transmission with advanced ADIC and keypad An internal terminator on the advanced ADIC instrument panel control unit and before connecting the keypad a jumper (1) must be inserted with the terminator (2) inside, this jumper should then have inserted the terminator.
1
0.75
2
Sect.
G
3
Col.
3
4
Pin
1.0
2
Sect.
LR
3
Col.
1
4
Pin
1
13 CAN Terminator
2
1
18
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
12
14 Clutch pedal potentiometer (RES--156) Pin
Col.
Sect.
Pin
Col.
Sect.
1
BR
0.5
3
S
0.5
2
H
0.5
--
--
--
RES--156
A potentiometer used to make starting with power shuttle transmissions gradual. Pin 1 receives ground directly from the TCM control unit MOD--1/3 (1A) pin 23, wire 0.5 (BR). Pin 2 sends a signal to pin 7 from the TCM control unit MOD--1/3 (3A) wire 0.5 (H). Pin 3 receives the reference 5V directly from the TCM control unit MOD--1/3 (1B) pin 17 wire 0.5 (S). Functional test HH menu TCM, menu H5, on operating the potentiometer the display will show d20, menu H9 ch 1.
3
2
1
19
15 Clutch pedal switch (SW--35) Mechanical transmission version 3
--
--
--
4
R
0.5
Switch normally off, mounted in series with the PTO warning light/safety switch (transport safety with mechanical power take--off. Pin 4 receives 12 volts from the starting fuse F28 (5A) wire 0.5 (R), from pin 1 with pedal pressed the signal is sent: -- to pin 3 of the mechanical PTO warning light/safety switch SW--23 wire 1 (B) via the transmission -- driving module connector C2 pin 43. -- when there is the electrohydraulic PTO the warning light/safety switch is replaced by a jumper than the 12 volts will be sent to pin 86 of the starting relay MOD--100 wire 0.5 (RN), pin 5 of the grid heater control module MOD--61 wire 0.5 (RN) and pin 16 of the ADIC module MOD 27 (1) wire 0.5 (RN), via the transmission -- driving module connector C2 first on pin 43 then on pin 42 Power shuttle transmission version Pin
Col.
Sect.
Pin
Col.
Sect.
1
B
0.5
3
RN
0.5
2
B
0.5
4
R
0.5
Pin 4 receives 12 volts from the starting fuse F28 (5A) wire 0.5 (R), from pin 1 with pedal pressed the signal is sent:
87679925A1 - 02 - 2008
1
1.0
--
2
B
2
3
1
SW--35
Sect.
4
Col.
1
Pin
2
Sect.
3
Col.
4
Pin
20
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
13
--
to pin 24 of the transmission control module MOD--1/3 (1B) wire 0.5 (B). -- to pin 7 of the shuttle lever SW--79 wire 0.5 (B), then with the lever in neutral it will reach the starting relay MOD--100. -- to pin 2 of the same switch SW--35 wire 0.5 (B). With the shuttle lever engaged, pin 5 receives from the same SW--79, 12 volts from the starting fuse F24 (5A) wire 0.5 (R), thus leaving pin 7 thereby reaching pin 2 of switch SW--35 wire 0.5 (B), with the pedal released the signal leaves pin 3 of the switch and is sent to pin 8 of the transmission control module TCM MOD--1/3 (1A) wire 0.5 (RN), the control unit uses this voltage (12 VD) to supply the clutches A and B. Functional test HH menu TCM, menu H5, operating the clutch pedal with the shuttle lever engaged the display will show d21, with the same conditions menu H9 ch 20. 16 Trailer brake circuit pressure switch 3 ± 0.5 bar (3.06 ± 0.51 kg/cm2) (SEN--198)
Pin
Col.
Sect.
1
Z
1.0
2
HR
1.0
Pin
Col.
Sect.
Switch normally on, it turns off with pressures of 3 ± 0.5 bar (3.06 ± 0.51 kg/cm2). Pin 1 receives 12 volts from fuse F27 (5A) wire 1 (Z) via the trailer brake connector C11 pin 3, with pressures lower than the setting (due to low pressure in the trailer brake circuit for example because of pump failure) the contacts close and the voltage crosses the pressure switch and reaches pin 86 of the trailer brake relay RLY--28 via the trailer brake connector C11 pin 4, that, since the coil is already grounded, trips and reverses the solenoid valves discharging the braking line that goes to the trailer, preventing the unbraking pressure of the trailer safety brake from being reached.
SEN--198
21
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
14
17 Trailer brake warning light pressure switch 10 ± 0.5 bar (10.19 -- 0.51 kg/cm2) (SEN--196)
Pin
Col.
Sect.
1
SB
1.0
2
N
1.0
Pin
Col.
Sect.
SEN--196
Switch normally on, it turns off with pressures of 10 ± 0.5 bar (10.19 -- 0.51 kg/cm2). Pin 2 receives a ground signal wire 1 (N) via the trailer brake connector C11 pin 7, as the trailer brake line discharges the oil pressure goes to 0 bar (see point B, page11) so the switch turns on and ground reaches the ADIC instrument panel control module MOD--27 (3) pin 6 wire 1 (SB) the trailer brake warning light comes on. 22 18 Air brake pressure switch (SEN--340) Pin
Col.
Sect.
1
NG
1.0
2
HL
1.0
Pin
Col.
Sect.
SEN--340
Pressure sensor, with pressures below 4.5 bar (4.59 kg/cm2) the amber warning light blink for 5 seconds and then stay on, the performance monitor shows the icon with the bar code of low trailer brake pressure. The following table shows the pressure in relation to resistance. Bar
0
1
2
3
4
kg/cm2
0
0,98
2,04
3,06
4,08
Ω
10
31
52
71
88
Bar
5
6
7
8
9
kg/cm2
5,10
6,12
7,14
8,16
9,18
Ω
106
124
140
155
170
Pin 1 (washer fixed to base) receives a ground signal via pin 7 of the hydraulic brake connector C11, wire 1 (N) directly from the ADIC module MOD--27 (1) pin 22. From pin 2 (G) the signal goes to pin 15 of the ADIC instrument panel module MOD--27 (3) wire 1 (HL), via pin 2 of the hydraulic brake connector C11. Functional test HH menu ADIC, menu H9 ch 24.
87679925A1 - 02 - 2008
23
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
19
15
20
21 22
19. Lift--O--Matic switch 20. Gear lever
21. Gear lever status switches 22. 80 litre switch
24
19 Lift--O--Matic switch (SW--64) Pin
Col.
Sect.
1
Z
0.5
2
LR
0.5
Pin
Col.
Sect.
Switch normally off, mounted on the Lift--O--Matic. Mounted on versions without the electronic lift, with the lift on switch off, pressing the lowering lever closes the contacts of the switch, sends the data to the ADIC instrument panel module for the period in which the lift works to calculate the worked surface area. Pin 2 receives 12 volts from the fuse F1 (5A) wire 0.5 (LR). From pin 1, with the lift working, the 12 volts reach the ADIC MOD--27 (3) pin 1. Functional test HH menu ADIC, menu H5 on operating the LIFT--O_Matic the display will show d72.
SW--64
1
2
25
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
16
20 Gear lever (SW--13)
0.5
3
MN
0.5
2
L
0.5
4
SB
0.5
Three push--buttons (HI, LO and clutch cut--out) normally open, pressing a button sends a signal to the control unit that packs or frees the relevant clutches. Pin 3 receives a signal from the transmission control unit MOD--1/3 (1A) pin 9 wire 0.5 (MN). HI button From pin 2 a signal goes to the transmission control unit MOD--1/3 (3A) pin 10 wire 0.5 (L), the control unit packs the HI clutch. LO button From pin 1 a signal goes to the transmission control unit MOD--1/3 (3A) pin 11 wire 0.5 (CA), the control unit packs the LO clutch. Clutch cut--out From pin 4 a signal goes to the transmission control unit MOD--1/3 (3A) pin 8 wire 0.5 (SB), the control unit, freeing the clutches makes it possible to shift gear (for a total of 4) within the same range. Functional test HH menu ADIC, menu H5 on operating the buttons the display will show d24 for LO, d25 for HI and d55 for the clutch cut--out button.
SW--13
1
CA
2
1
3
Sect.
4
Col.
1
Pin
2
Sect.
3
Col.
4
Pin
26
21 Gear lever status switches R2
Pin
Col.
Sect
Col
Sect
Col
Sect.
1
S
1.0
S
1.0
S
1.0
2
VB
0,5
MB
0,5
MN
0,5
SW-- 209
SW-- 210
SW-- 211
Power supply At pin 1 wire 1 (S) 5 volts directly from the transmission control unit MOD--1/3 (1B) pin 17 wire via the driving module transmission main connector C2 pin 36. G (SW--209) From pin 2 it sends a signal to pin 4 of MOD3/1 (3A) wire 0.5 (VB) via the driving module transmission main connector C2 pin 31. R1 (SW--210) From pin 2 it sends a signal to pin 5 of MOD3/1 (3A) wire 0.5 (MB) via the driving module transmission main connector C2 pin 29.
87679925A1 - 02 - 2008
1
R1
2
G
27
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
17
R2 (SW--211) From pin 2 it sends a signal to pin 26 of MOD3/1 (3A) wire 0.5 (MN) via the driving module transmission main connector C2 pin 30.
Functional test With a tester switched onto ohmmeter putting the rods at the ends of the various switches we will have the values in the tables under the column of Ω, with the various gears engaged. In the TCM module program H9 of the diagnostics HH MENU of the control unit of the gearbox (TCM) the values in the table are the values that will be read on the display as the engaged gear varies. In the TCM module program H7 channel Ch 2 move the gear lever if the gearbox lever status switches have no trouble, the display will show the selected gear. In the TCM module program H5 on operating the gear and range levers the display will show d33 (G), d34 (R1) and d50 (R2).
28 Gearbox sensor G
With lever in.........
Switch status
Ω
Analog--digital conversion H9 (Channel 16)
Neutral
Closed
560
67
1st
Open
2760
30
2nd
Open
2760
30
3rd
Open
2760
30
4th
Open
2760
30
MDG0165A
29 Range sensor R1
Range sensor R2
With lever in.........
Switch status
Ω
Analog--digital conversion H9 (Channel 17)
Switch status
Ω
Analog--digital conversion H9 (Channel 18)
Neutral
Open
2760
30
Open
2760
30
Medium
Closed
2760
67
Open
560
30
Fast
Closed
560
67
Closed
560
67
Low
Open
560
30
Closed
2760
67
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
18
22 80 litre switch (SW--331) Pin
Col.
Sect.
A
ZB
1.0
B
Z
1.0
Pin
Col.
Sect.
Switch normally off, operating 1st ventral control valve pin (double acting + floating -- with mechanical coupling in float), supplies the solenoid valve (11, page 9) if it is necessary to raise the arm of the front loader the extra flow of oil increases the lifting speed. Pin A receives 12 volts from fuse F15 (7.5 A) wire 1 (ZB), via the 80 litre connector C89 pin 1. With the joystick pulled fully back, the switch turns on and from pin B wire 1 (Z), the supply reaches the 80 litre supplement solenoid valve SOL--330.
87679925A1 - 02 - 2008
SW--331
30
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
19
24
23
26
25
23. Shuttle lever switch 24. 4WD disengagement solenoid valve
25. Fuel level sensor 26. Theoretical wheel speed sensor
31
23 Shuttle lever switch (SW--79)
9
--
--
0.5
10
--
--
9
0.5
MB
8
H
3
--
--
11
--
--
5
R
0.5
12
--
--
6
RN
0.5
13
--
--
7
B
0.5
--
--
--
3
4
12 13
2
SW--79
7
0.5
6
Sect.
N
10 11
Col.
8
5
Pin
0.5
4
Sect.
S
2
Col.
1
1
Pin
32
87679925A1 - 02 - 2008
20
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
Shuttle lever on neutral: Mounted in series with the clutch pedal switch SW--35 (15, Page12): with the starting safety pedal pressed, with the pedal released supply to the control unit 12VD for clutches A and B. At pin 7 wire 0.5 (B) connection with: -- pin 1 wire 0.5 (B) and 2 wire 0,5 (B) clutch pedal switch SW--35, -- pin 24 wire 0.5 (B) transmission control module MOD--1/3 (1B), gives the control unit the data on starting. At pin 6 connection with: -- pin 86 starting relay MOD--100 wire 0.5 (RN), -- pin 5 grid heater control module MOD--61 wire 0.5 (RN), -- pin 16 ADIC panel control module MOD--27 (1) wire 0.5 (RN).
33
Shuttle lever in forward gear. At pin 1 5 volts supply directly from the transmission control module TCM MOD1/3 (1B) pin 17 wire 0.5 (S). From pin 2 the signal to the TCM module MOD1/3 (1B) pin 12 wire 0.5 (H). Shuttle lever in reverse gear. At pin 1 as above. From pin 3 the signal to the TCM module MOD1/3 (1B) pin 13 wire 0.5 (S). Pin 8 must be connected to ground wire 0.5 (N), in actual fact the diagram is not exactly that of fig. 33, inside, especially for the selection of neutral and forward/reverse gear there are simply no switches but there are electronic switches, for this reason they must be powered and a ground signal is needed. Functional test With a tester switched onto ohmmeter putting the rods at the ends of the connector (3 -- 1 for reverse gear switch, 2 -- 1 forward gear switch) we will have the values in the tables under the column of Ω, as the lever position changes. In program H9 of the diagnostics HH MENU of the control unit of the gearbox TCM the values in the table are the values that will be read on the display at channel Ch9 (forward gear) and Ch10 (reverse gear) as the lever position varies. In program H5 of the diagnostics HH MENU of the control unit of the gearbox TCM Moving the lever, if this presents no trouble, the display will show the codes d22 and d23 for the forward and reverse gears respectively.
87679925A1 - 02 - 2008
Switch forward
Switch reverse
Lever position
Switch status
Ω pin 6--5
H9 (Ch 9)
Forward
Closed
560
60
Backward
Open
2760
30
Forward
Open
2760
30
Backward
Closed
560
60
Lever position
Switch status
Ω pin 6--4
H9 (Ch 10)
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
21
24 4WD disengagement solenoid valve (SOL--214) Sect.
1
BN
1.0
2
N
1.0
Pin
Col.
Sect.
At pin 2 a ground signal wire 1 (N). Standard version at pin 1 12 volts from the 4WD switch pin 3 SW--104 wire 0.5 (BN) via pin 2 of the main transmission -driving module connector C2, to energize the solenoid valve and cut off the four--wheel drive, plus connection to pin 3 wire 0.5 (BN) of the ADIC module MOD--27 (3) to turn off the 4WD warning light. Power shuttle version at pin 1 12 volts from the transmission control module TCM MOD--1/3 (3B) pin 17 wire 0.5 (BN) via pin 2 of the main transmission -- driving module connector C2, to energize the solenoid valve and cut off the four--wheel drive, plus connection to pin 3 wire 0.5 (BN) of the ADIC module MOD--27 (3) to turn off the 4WD warning light.
SOL--214
1
Col.
2
Pin
34
25 Fuel level sensor (SEN--212)
NG
1.0
2
SN
1.0
Col.
Sect.
Al pin 1 receives a ground signal directly from the ADIC module pin 22 MOD--27 (1) wire 1 (NG). From pin 2 the signal goes to the ADIC module pin 14 MOD--27 (3) wire 1 (SN). The table gives the resistances as the fuel level changes. Level
1/5
2/5
3/5
Ω
50,75 ± 3,25
106,00 ± 6,00
160,75 ± 8,75
4/5
SEN--212
1
1
Pin
2
Sect.
1
Col.
2
Pin
5/5
220,75 276,00 ± 11,75 ± 14,50
35
Functional test HH module TCM menu H9 Ch 25.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
22
26 Theoretical wheel speed sensor (SEN--217) Pin
Col.
Sect.
Pin
Col.
Sect.
1
HB
1.0
1
HB
1.0
2
NG
1.0
2
BR
1.0
Standard
Power shuttle + EDC
Standard version At pin 2 it receives a ground signal directly from the ADIC module MOD--27 (1) pin 22 wire 1 (NG) via the main transmission -- driving module connector C2 pin 32. From pin 1 the signal returns directly to the ADIC module MOD--27 (1) pin 1 wire 0.5 (HB) via the main transmission -- driving module connector C2 pin 26. Power shuttle version At pin 2 it receives a ground signal directly from the TCM module MOD--1/3 (1A) pin 23 wire 1 (BR) via the main transmission -- driving module connector C2 pin 33. From pin 1 the signal returns directly to the TCM module MOD--1/3 (1B) pin 34 wire 0.5 (HB) via the main transmission -- driving module connector C2 pin 26. Functional test HH module ADIC menu HE Ch 19. Functional test HH module TCM menu HE Ch 1.
87679925A1 - 02 - 2008
SEN--217
36
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
23
27
28
29
30
27. Operator present switch 28. Safety switch / mechanical power take--off indicator light
29. Radar 30. Gearbox control valve
37
27 Operator present switch (SW--59) Sect.
VN
1.0
2
NG
1.0
Pin
Col.
Sect.
Standard At pin 2 it receives a signal directly from the ADIC instrument panel module MOD--27 (1) pin 22 wire 1 (NG). From pin 1 the signal goes to the ADIC module MOD--27 (3) pin 21 wire 1 (VN). Functional test HH module ADIC, menu H5 d10.
SW--59
1
Col.
1
2
Pin
38
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
24
Version with diagnostics At pin 2 it receives a signal directly from the ADIC instrument panel module MOD--27 (1) pin 22 wire 1 (NG), From pin 1 the signal goes to the ADIC module MOD--27 (1) pin 3 wire 1 (VN). In the diagnostics program HH menu of the ADIC module the type of operator present switch must be set in H3 (see chapter 10 in this section). Functional test HH module ADIC, menu H9 ch26.
1K5 500
39 28 Mechanical power take--off safety/warning light switch (SW--23) Pin
Col.
Sect.
Pin
Col.
Sect.
1
HL
1.0
3
M
1.0
2
HG
1.0
4
M
1.0
Switch normally off (pin 4 and pin 3) mounted on machines with mechanical transmission and mechanical power take--off in series with the clutch pedal switch as starting safety. On versions with an electro--hydraulic power take--off in place of the switch a U--bolt joining the two pins is fitted. At pin 3 wire 1 (B) 12 volts from the clutch pedal switch SW--35 pin 1 (with pedal pressed) via the main transmission -- driving module connector C2 pin 43. From pin 4, with the clutch disengaged the contacts close and the voltage reaches: -- The pin 86 of the starting relay MOD--100 wire 0.5 (RN), -- the pin 5 of the grid heater control module MOD--61 wire 0.5 (RN), -- the pin 16 of the ADIC control module MOD--27 (1) wire 0.5 (RN), via the driving module transmission main connector C2 pin 42. Switch normally off (pin 1 and pin 2) mounted on machines with mechanical transmission and mechanical power take--off for switching on the warning light. At pin 1 12 volts from fuse F18 (5A) wire 1 (ZB), via the main transmission -- driving module connector C2 pin 35. With the PTO clutch engaged the voltage reaches the ADIC module MOD--27 (3) pin 24 wire 1 (AG) via the main transmission -- driving module connector C2 pin 44.
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SW--23
40
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
25
29 Radar (SEN--227) Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
3
RN
1.0
2
MV
1.0
4
RV
1.0
SEN--227
3
2
1
30 Gearbox control valve Power Shuttle version 24X24 -- A + B + C Power Shuttle version 12X12 -- C
4
At pin 1 ground signal wire 1 (N). At pin 4 supply from fuse F4 (5A) wire 1 (LB), via the main transmission -- driving module connector C2 pin 38. From pin 3 present signal to the transmission module MOD--1/3 (1B) pin 19 wire 0.5 (RN) via the main transmission -- driving module connector C2 pin 39. From pin 2 signal in frequency to the transmission module MOD--1/3 (1B) pin 33 wire 0.5 (MV) via the main transmission -- driving module connector C2 pin 40. Functional test HH module TCM, menu HE ch4.
41
A
B
C 42
A) Clutch A safety pressure switch (SEN--206) B) Clutch B safety pressure switch (SEN--207). Pin
Col.
Sect.
Pin
Col.
Sect.
1
BV
1.0
1
NB
1.0
2
ZB
1.0
2
ZB
1.0
A SEN--206
B SEN--207
Switches normally on, they turn off with pressures greater than 3 Âą 0.5 bar (3.06 Âą 0.55 kg/cm2). At pin 2 of both supply from fuse F18 (5A) wire 1 (ZB), via the main transmission -- driving module connector C2 pin 34.
SEN--206 SEN--207 1
2
43
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
26
From pin 1 of the pressure switch A SEN--206 with normal pressures the voltage reaches the TCM module MOD--1/3 (1B) pin 21 wire 0.5 (BV), via the main transmission -- driving module connector C2 pin 19. From pin 1 of the pressure switch B SEN--207 with normal pressures the voltage reaches the TCM module MOD--1/3 (1B) pin 28 wire 0.5 (NB), via the main transmission -- driving module connector C2 pin 20. Functional test HH module TCM, menu H5, create a transition on the buttons the display will show codes d42 for that of clutch A and d43 for that of clutch B. C) Gearbox oil temperature sensor (SEN--201) Pin
Col.
Sect.
A
BR
1.0
B
M
1.0
Pin
Col.
Sect.
Temperature sensor containing a resistor and as the temperature increases the resistance decreases (NTC). At pin A it receives a ground signal directly from the TCM module MOD--1/3 (1A) pin 23 wire 1 (BR), via the main transmission -- driving module connector C2 pin 33. From pin B the signal reaches the TCM module MOD--1/3 (1B) pin 14 wire 0.5 (M), via the main transmission -- driving module connector C2 pin 25. The table alongside gives the resistance as the temperature changes. Functional test HH module TCM, menu H9 ch2.
87679925A1 - 02 - 2008
SEN--201
44 Nom. temp._ te p _C
Resistance â&#x201E;Ś MIN
MAX
--30_C
4432
5203
0_C
1140
1339
25_C
460
540
40_C
285
335
130_C
34
40
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
27
31
32
33 34
31. Arms position sensor 32. Differential lock warning light switch
45
33. PTO speed sensor 34. Draft sensing pins
31 Arms position sensor (SEN--224)
1
BR
1.0
3
S
1.0
2
BL
1.0
--
--
--
At pin 3 supply, 5 volts directly from the transmission control module TCM MOD--1/3 (1B) pin 17 wire 0.5 (S), via the driving module transmission main connector C2 pin 46. At pin 1 ground directly from the TCM module MOD--1/3 (1A) pin 23 wire 1 (BR), via the driving module transmission main connector C2 pin 33. From pin 2 the signal reaches the TCM module MOD--1/3 (1B) pin 2 wire 0.5 (BL), via the main transmission -- driving module connector C2 pin 48. Functional test HH module TCM, menu H5 operating the clutch pedal the display will show the code d20. Functional test HH module TCM, menu H9 ch1.
SEN--224
1
Sect.
2
Col.
3
Pin
1
Sect.
2
Col.
3
Pin
46
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
28
32 Differential lock warning light switch (SW--216)
1.0
3
GN
1.0
2
G
1.0
4
H
1.0
Switch normally off, the rod for engaging the differential lock closes the contacts of the switch. At pin 1 supply from fuse F18 (5A) wire 1 (ZB), via the main transmission -- driving module connector C2 pin 35. With the lock engaged from pin 4 the 12 volts reach the ADIC module MOD--27 (3) pin 4 wire 1 (H), via the main transmission -- driving module connector C2 pin 28.
SW--216
1
ZB
2
1
3
Sect.
4
Col.
1
Pin
2
Sect.
3
Col.
4
Pin
47
33 PTO speed sensor (SEN--218) Pin
Col.
Sect.
1
HN
1.0
2
NG
1.0
Pin
Col.
Sect.
SEN--218
At pin 2 the ground directly from the ADIC module MOD--27 (1) pin 22 wire 1 (NG), via the main transmission -- driving module connector C2 pin 32. From pin 1 the signal returns to the ADIC module MOD--27 (1) pin 2 wire 1 (HN), via the main transmission -- driving module connector C2 pin 27. Functional test HH module ADIC, menu HE ch96. 48 34 Draft sensing pins Right sensor (SEN--221) Left sensor (SEN--225) Pin
Col.
Sect.
Pin
Col.
Sect.
SEN--221 SEN--225
BR
1.0
3
B
1.0
2
HV
1.0
--
--
--
1 2
2 3
SEN--225 1
BR
1.0
3
B
1.0
2
GV
1.0
--
--
--
At pin 3 of both 8 volts directly from the TCM module MOD--1/3 (1B) pin 25 wire 1 (B), via the main transmission -- driving module connector C2 pin 47.
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1
1
3
SEN--221
49
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
29
At pin 1 a ground signal directly from the TCM module MOD--1/3 (1A) pin 23 wire 1 (BR), via the main transmission -- driving module connector C2 pin 33. From pin 2 of the right sensor SEN--221 the signal to the TCM module MOD--1/3 (1B) pin 9 wire 1 (HV), via the main transmission -- driving module connector C2 pin 50. From pin 2 of the left sensor SEN--225 the signal to the TCM module MOD--1/3 (1B) pin 10 wire 1 (GV), via the main transmission -- driving module connector C2 pin 49. -- Component test procedure -- With the pin connected, turn the key ON. -- Using a voltmeter, check the supply of the pin between pin 1 and pin 3, it must be 8 Volts (supply of the control unit to the pin. -- Now, again with the voltmeter, test between pin 2 and pin 1 and the signal of the pin to the control unit must be 50 Âą 2.5 % of the supply Functional test HH module TCM, menu H9 ch13 right pin, d14 left pin.
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
30 FRONT WIPER MOTOR R.I.
ATTENTION
Handle all parts with great caution. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 1. Detach THE CAB CEILING TRIM from the framework, carrying out the sequences stated in operation as described in section 90 of this manual.
1
24797
50 2. Working from the outside of the cab, unhook the hood, unscrew the retaining screws and the windscreen wiper blade. 3. Unscrew the two retaining nuts and the windscreen wiper motor. 4. Refit the wiper motor as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
Refit the motor unit and secure it with the two nuts.
--
Fit the wiper blade back on.
--
Fit the CAB CEILING TRIM back onto the framework, carrying out the sequences described in the operation in section 90 of this manual.
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
1
SECTION 55 -- ELECTRICAL SYSTEMS Chapter 9 -- FAULT CODES CONTENTS Description
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Wiring Harness Repairs
..................................................................... 3
Digital Multi--Meter -- Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Electrical Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Circuit Components -- Basic Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Controller Area Network (CAN) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Locations of the control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Fault Code Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Fault Code Charts Calibration U--Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 1001--2000 (EDC) Electronic draft control (EDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 2001--3000 (Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 5001--6000 (Rear Power Take--Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 6001--7000 (Four Wheel Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 7001--8000 (Differential Lock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 14001--15000 (Analog--Digital Instrument Cluster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
INTRODUCTION
Fault Codes and Fault Finding The tractors have an inbuilt self diagnostic facility. This facility utilises the digital display of the Analog-Digital Instrument Cluster (ADIC) and the electronic draft control panel to indicate, in coded format, malfunctions in the electrical and electronic circuitry and in the micro--processor. It should be noted that the self diagnostic capability is generally limited to diagnosis of the electrical and electronic circuitry and related components, however, there are some codes, which can be generated if pressure switch circuits are not closed because of an actual lack of hydraulic pressure. Any malfunction of the mechanical and hydraulic components must be diagnosed using conventional techniques, performance characteristics and tooling, such as pressure testing equipment. Troubleshooting and fault finding should always be carried out in a logical and planned sequence, many apparent faults associated with electronic components are often hastily diagnosed and result in the replacement of expensive components. An extra few minutes confirming the apparent fault will result in a more positive and cost effective repair. With the use of micro--processors it is often that this item is blamed for any malfunction but the real truth is that this item is usually sound and that the fault is due to poor contacts in the associated connectors. The connection references indicate: connector number, pin number, wire dimension and wire colour. Example: C124 pin 10, wire 0.5 (MV) MOD--1/3 (1A) pin 10, wire 0.5 (MV) C124 Connector number MOD--1/3Component number (1A) MOD--1/3 component connector pin 10 Connector pin wire 0.5 Wire cross--section (MV) Wire colour
87679925A1 - 02 - 2008
Where two colours are specified, the first letter indicates the base colour and the second letter indicates a straight stripe. All tests are carried out on the harness side of the connector, unless otherwise stated. Refer to the relevant chapter for complete wiring diagrams and how to use them. Where the fault finding procedure requires checks for continuity a visual inspection of the wiring should be made prior to conducting tests to ensure that obvious ‘mechanical’ damage has not occurred to the harness or the connectors. A good quality multi--meter is an essential item to perform fault finding. It should be capable of measuring resistance of at least 20,000 ohms and measuring voltage and current. When using the multi--meter it is good practice to select a high range and work downwards to avoid damaging the instrument. Refer to the ’Basic Multi--Meter use’ section of this chapter for further details. IMPORTANT: Care should be used when using the multi--meter, only use the instrument as instructed to avoid damage to the internal elements of the micro-processor. When checking the continuity of wiring, sensors or switches it is necessary to isolate the electronic micro--processor and ensure the keystart is turned off to prevent possible further damage. The keystart should only be switched on and the processor connected where specifically instructed in the fault finding procedure. If it is found necessary to clean the connectors a contact spray should be used. DO NOT USE ANY OTHER METHOD FOR CLEANING TERMINALS. Do not use a cleaner that contains Trichloro--ethylene, this solvent will damage the plastic body of the connector. It is preferable to use a cleaner with a Freon T.F. base.
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
3
SPECIAL TOOLS Description
No. tool.
Harness Repair Kit (Except North America)
380030042
Test Probe Kit (Except North America)
380050010
WIRING HARNESS REPAIRS Temporary Wiring Harness Repair
ATTENTION It is acceptable to use the following repair procedure on the CAN BUS wiring. It is important though to ensure that the wire lengths are not altered from the original as this will affect the performance of the CAN BUS system. The following method to repair wiring is a temporary expedient only. Wiring should be replaced as soon as possible. Do not attempt to repair the wire on any system sensors as these are sealed and should only be replaced with a new component. NOTE: When conducting a cable repair it is important that only RESIN CORED SOLDER is used. Use of other types of solder may result in further cable damage. To carry out a temporary repair, proceed as follows:-1. Locate damaged portion of cable then cut away outer protective cover on both sides of the damaged area, Figure 1.
2. Using a suitable solvent, clean about 50 mm from each cover end. Clean the grey cable cover and the individual leads.
1
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4
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
3. Twist two bare leads together for each damaged lead, being careful to match wire colours, then solder the leads using resin cored solder. Tape each repaired lead with vinyl insulation tape, Figure 2.
4. Wind a layer of vinyl insulation tape up to the grey cable cover at each end of the repair section. Make a paper trough, Figure 3, then apply silicone rubber compound (non hardening sealant) over the repaired section up to the cover ends. Sufficient sealant must be used to fill the ends of the cut away area.
2
3 5. Allow the compound to set then cover the area with insulating tape taking the tape well over each end of the repair. An overlap of at least 50 mm of tape at each end is necessary, Figure 4. 6. Check to ensure the repair is satisfactory and secure the repaired cable so that repeat damage is avoided. NOTE: This is a temporary repair only. Ensure the damaged cable is replaced as soon as possible to prevent ingress of water or chemicals.
4
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
5
Harness Wire Replacement If a wire within the harness is found to be beyond repair or is open circuit, a jumper wire may be installed as a temporary repair until such time when a new harness assembly can be installed. Use the following procedure to install an additional wire: 1. Locate the faulty wire using the procedures described in the fault code charts. 2. Disconnect the affected connectors. 3. If fitted carefully roll back the seal between the connector and harness outer covering. 4. Remove the pins from the connector blocks of the affected wire using the appropriate removal tool found in the harness repair kit. NOTE: Use the instructions supplied with the kit to ensure correct pin removal.
5. From the harness repair kit select the correct pin for the connectors. Obtain locally the correct cross--sectional size wire and measure out the length required by following the harness routing. 6. Join the new wire to the new pins as described in the harness repair kit and install one of the pins into its connector. 7. If possible attempt to run the new wire within the existing harness outer covering; if this is not possible, run the wire along the harness, securing regularly with suitable ties. With the wire correctly routed install the second terminal into its connector block. Replace the connector seal if removed. 8. To ensure that the repair has been effective check for continuity of the new wire using a suitable multi--meter.
5
NOTE: This is a temporary repair only. Ensure the damaged cable is replaced as soon as possible to prevent ingress of water or chemicals.
6
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
6
DIGITAL MULTIMETER NOTE: This section is only intended as a general guide to using a digital multimeter. Always refer to the manufactures operators manual for correct operation.
A multimeter is an electronic measuring device. The different types of measurement that can be made depend upon the make and model of the multi--meter. Most types of multimeter have the capacity to measure: •
Current (A) ac or dc
•
Resistance (Ω)
•
Voltage (V) ac or dc
•
Continuity (Buzz test)
More expensive multimeters have other functions, such as the capacity to measure frequency (Hz) and test diodes.
7
General Operation: Before proceeding with a test, decide on what is going to be measured (Voltage, Current etc.). Rotate the dial until the pointer is within the relevant zone. Within each zone there are different scales. The scale that is selected will represent the maximum value that the multimeter will read. Always select a scale which is greater than the value that you intend to measure. If you are unsure of the value to be measured, always select the highest scale and then reduce the scale once you have an idea of the measured value.
Why are there different scales ?
8
The closer that the scale is to the measured value, the more accurate the reading will be e.g. If measuring the voltage of a battery with the scale set at 200V, the display may read 12V. However, if the scale was set to 20V the display may read a more accurate reading of 12.27V.
9
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
7
Measuring Voltage (Volts): Set the range dial to either ac or dc volts. Connect the Black test probe to the ”COM” terminal and the Red test probe to the ”V/Ω” terminal. Place the test probes across the component to be measured with the circuit complete (closed). Read off the display value.
Measuring Current (Amps):
10
Set the range dial to either ac or dc current. When measuring current up to 2 amps, connect the Red test probe to the ”A” terminal. When measuring current up to 10 amps, connect the Red test probe to the 10 ”A” terminal. Always connect the Black test probe to the ”COM” terminal. When taking measurement of current, always break the circuit and connect the multi meter in series with the circuit. Read off the display value. NOTE: For protection, multimeters are usually fused at 10 A.
11 Measuring Resistance (Ohms): Set the range dial to the desired Q position. Connect the Red test probe to the ”V/Ω” terminal. Connect the Black test probe to the ”COM” terminal. If the resistance being measured is connected in a circuit, then turn off the power to the circuit. Connect the test probes to the measuring point and read off the display value.
12
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8
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Continuity (Buzzer) test: Set the range dial to the ”Buzz” position. Connect the Red test probe to the ”V/Ω” terminal. Connect the Black test probe to the ”COM” terminal. Connect the test probes to the measuring point. In general, if the resistance is less than 50Ω then the buzzer will sound, indicating continuity.
NOTE: Buzzers on different multimeters will sound at different ohmic values, depending on the quality of the meter. This can often be misleading, for example when checking a corroded earth point. A poor quality multimeter may buzz at 150Ω, indicating continuity and no problem. When using a higher quality multimeter for the same test, it would not buzz due to the high resistance. When carrying out such tests, we should always check the value of resistance as well as listening out for the buzz.
13
A good connection gives low resistance. A bad connection gives high resistance. SUMMARY: Types of measurement -Voltage (V): Connection to the component with the circuit closed. Current (A): Connection in series with the circuit. Circuit closed. Resistance (Ω Ω): Connection to the component with the circuit open. Continuity (buzzer): Connect the meter to the component with the circuit open. Always check the value of resistance as well!!)
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14
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
9
ELECTRICAL TEST PROCEDURES Four electrical tests will be required to properly troubleshoot electrical concerns on the vehicle. Each test is described in detail. Ensure that all steps are reviewed and followed when testing. 1. Continuity Test, Short to ground 2. Measuring voltage, shorted to 12 Volts 3. Resistance test for components 4. Continuity test, Open circuits ELECTRICAL TEST PROCEDURE 1: CONTINUITY TEST -- SHORT TO GROUND CONDITIONS FOR PERFORMING TESTS: 1. Power supply OFF, key switch OFF (sometimes battery disconnected or fuse removed, if specified in the procedure). 2. Connectors at each end or ends of circuit disconnected to prevent false readings. 3. Set the meter to measure resistance (Ohms) and measure the resistance in the circuit. Use black lead to make contact with a plated metal part on the chassis such as a jump start post if fitted. Make sure the surface of the part is not corroded. Use the red meter lead to touch the connector pins, one pin at a time, and avoid contact with the case of metal connectors. 4. Determine if measured resistance falls within guidelines specified in the procedure. 3 to 4 ohms indicates a direct short to chassis ground and must be located and repaired. Higher resistances usually indicate circuit paths through modules, and that an additional connector needs to be disconnected to perform the test. More than 100 kOhms indicates that the circuit is free of shorts to ground.
15
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ELECTRICAL TEST PROCEDURE 2: VOLTAGE MEASUREMENT OR SHORT TO POSITIVE SUPPLY VOLTS CONDITIONS FOR PERFORMING SHORT TO POSITIVE SUPPLY TESTS: 1. Key switch ON (sometimes OFF, if specified in procedure). 2. Connectors at sensor, switch or potentiometer end disconnected. All other connectors must be reconnected to perform test. 3. Set the meter to measure dc voltage (DC VOLTS) and measure the circuit voltage as illustrated. Use the red meter lead to touch the connector pins, one pin at a time, and avoid contact with the case of metal connectors. Use black lead to make contact with a plated metal part on the chassis such as a jump start post if fitted. Make sure the surface of the part is not corroded. 4. Determine if measured voltage falls within guidelines specified in the procedure.
ELECTRICAL TEST PROCEDURE 3: RESISTANCE TEST FOR ELECTRICAL PARTS
16
CONDITIONS FOR PERFORMING RESISTANCE TEST NOTE: The resistance values shown are valid for a temperature of 20 °C. With higher or lower tractor temperatures, the relative resistance values shown in the manual should vary accordingly. 1. Disconnect tractor part by unplugging electrical connectors to expose the part assembly connector for testing. 2. Set electrical meter to measure resistance or Ohms and insert test probes into connector terminals specified in procedure. When checking potentiometers, measure from wiper terminal to each of the other terminals while TURNING THE POT SHAFT. This will ensure no open spots escape detection. When checking rocker or rotary switches, actuate the switch while measuring for opens and shorts. 3. Compare measured values to values specified in the fault code procedures. Allow plus or minus 5% of range tolerance for all measurements.
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ELECTRICAL TEST PROCEDURE 4: CONTINUITY TEST -- CHECK FOR OPEN CIRCUITS
CONDITIONS FOR PERFORMING CONTINUITY TESTS: 1. Key switch OFF (sometimes disconnect battery or remove fuses). 2. Connectors at both ends of the circuit disconnected. All other connectors must be reconnected to perform test. 3. Set the meter to measure resistance (Ohms) and measure the resistance in the circuit as illustrated. Use the red meter lead to touch the connector pins, one pin at a time, and avoid contact with the case of metal connectors. Use black lead to make contact with the connector pin at the other end of the circuit. Avoid contact with other pins in the connector and the connector case, if it is metal. 4. Determine if measured resistance falls within guidelines specified in the procedure. If the resistance is no more than 3 to 4 ohms, the circuit is continuous. More resistance usually indicates dirty or corroded terminals in connectors, and 100 kOhms indicates an open circuit.
18
CIRCUIT COMPONENTS -BASIC DESCRIPTION CIRCUIT PROTECTION DEVICES Circuit protection devices are used to protect wiring and components from excessive current. Three different types of protection are fitted in tractors. Two of them (fuses and fusible links) are currently used, while circuit breakers are no longer used.
FUSES, FUSIBLE LINKS Fuses and fusible links protect circuits with thin pieces of metal and wire which heat up and melt to open up the circuit when too much current flows through them. Fuses are used to protect the circuit from overload. This can occur in the event of a short circuit or by connecting equipment which demands a current greater than the circuit is designed to carry.
19
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
There are several types of fuses, but they all consist of a metal conductor which is capable of carrying a limited current. If the specified current is exceeded then the metal conductor will overheat, causing it to melt and break. This will in turn cause an open circuit. The rating of the fuse relates to the current that the fuse can carry continuously. If a fuse blows, it must be replaced with a fuse of the correct rating, and if it blows again, then the cause must be investigated.
MPH2027A
FUSE LINKS A fuse link is a wire that acts like a fuse, breaking down and causing an open circuit when the current that passes through it exceeds a certain amperage. For primary fuse protection the main supplies from the starter solenoid are fitted with fuse links.
20
21 CIRCUIT CONTROL DEVICES Some of the components in a circuit are used to interrupt and direct current flow either through an action of the operator or automatically. The current interrupters you are probably most familiar with are switches.
SWITCHES Switches are a vital part of an electric circuit, providing a method of controlling the circuit itself. One switch can control a number of different circuits at the same time. This is achieved by having several separate connections and/or multi--connector switches (several switch â&#x20AC;&#x2122;positionsâ&#x20AC;&#x2122;). There are several types of switch, and they may incorporate a warning light.
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13
Switches can be as simple as that used to turn on an implement lamp or as complex as the ones used to operate the starting and lighting systems. Checking the operation of switches is usually just a matter of testing for power going into the switch and for power leaving the switch at the appropriate contacts when the switch is operated. One of the most common type of switches is the pressure switch (fig. 23), a switch turned on or off by the pressure of a fluid. An example of this type of switch is the engine oil pressure switch, a simple on/off device that opens (or closes) when oil pressure rises above 0.7 bar. 23 FLASHERS Flashers work automatically to interrupt and connect the flow of current. Their operation is similar to that of the circuit breaker described earlier. In the flasher, a heating element warms a bimetallic strip. The strip bends, breaking contact with the power source. When it cools, the bimetallic strip once again makes contact and the process begins again.
24 DIODES Some components use a semiconductor material instead of moving parts to direct current. Diodes for example, allow current flow in one direction only. They are essential in converting the alternating current that an alternator produces to the direct current that the tractor electrical system components use.
25
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
RESISTANCE DEVICES A number of electrical components alter or make use of electricity through their resistance to current flow. Resistors are components which are generally used to regulate the supply of voltage and current to other electrical components. In some cases, the purpose of resistance in an electrical circuit is to provide light or heat. Lamps and cigar lighters are examples. Lamps convert electricity into light, and cigar lighters convert it into heat. Both lamps and lighters make use of the same physical principle, that is Ohms Law. 26 POTENTIOMETERS Potentiometers are variable resistors which are dependant on mechanical movement, i.e. Lateral float movement, to vary the resistance of the component and therefore alter the output voltage. In order to verify the correct operation of a potentiometer, the resistance should be measured at the minimum and maximum positions and a smooth and continuous change of resistance should be observed between. As the resistance varies with temperature, the test specifications are usually given at 20 °C.
27 ELECTROMAGNETIC DEVICES In general, they use the magnetic field created by flowing current to move metal parts within the components. The relay is an electromagnetic switch that uses a small amount of current to switch a larger amount on and off. When the operator closes a switch, current flows through the relayâ&#x20AC;&#x2122;s control circuit. In this circuit there are windings surrounding an iron core which is fixed in place (see Fig. 28). Current turns the iron core into an electromagnet. The core then attracts an arm which has a contact point on it. When the point on the arm contacts the stationary point, current flows through the power circuit. Relays are basically electrically operated switches. They are used to switch a circuit on/off in similar way to a manual switch.
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15
Two circuits are connected to the relay: • A work circuit, which is switched on/off by the relay, and provides the supply for the equipment to be operated, i.e., bulbs, solenoids, etc.; A control circuit, switched on/off by manual switches, used to operate the relay. The part of the relay which is connected to the control circuit consists of the winding of an electro--magnet. When the control circuit is switched off, the contacts are kept apart by a return spring. When the control circuit is switched on, a current flows through the coil and a magnetic force is produced. This force, which is stronger than the spring pressure, pulls the contacts of the relay together, causing the work circuit to operate. A switch--relay system has two main advantages over a simple switch: • The current that flows through the switch is not the same as the current required by the equipment to be operated, but is usually smaller: this allows the usage of smaller and less expensive switches; •
The distance from the supply, to the equipment, can be made as short as possible to minimise voltage drop. There are several types of relays. They can be normally open or normally closed. They may have internal electronic circuits to give special operating features. For example, they can turn the switch on/off at timed intervals (flasher relay), be sensitive to current, temperature, etc. The relay cover usually gives information about the features of the relay. On the relay cover there are usually 4 or 5 terminal markings: • 30: input terminal direct from battery positive, normally live. •
•
85: winding output terminal, usually to ground.
•
86: winding input terminal.
•
87: output terminal for normally closed contact.
•
87a: output terminal for normally open contact.
29
Brown relays are normally open relays, blue ones are normally closed.
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SOLENOID VALVES The solenoid valves (fig. 30) work in much the same way as relays, except that the iron core is not fixed in place. As a result, the windings in the control circuit cause the iron core to move. In the starting system, for example, the movement of this core is used to send large amounts of current to the starter motor. A solenoid is basically a winding around an iron core. In the centre of the core there is a plunger which is free to move through the core. When an electrical current passes through the winding an electro--magnetic force is produced which causes the plunger to move through the core. If the current is switched off, the magnetic force is stopped and the plunger is returned by a spring. The solenoid plunger may have different uses: the most common are moving a hydraulic spool or a mechanical lever. The use of solenoids to control hydraulic pressure instead of the hydraulic valves is highly recommended wherever there is a long distance between the control panel and the valve (more than 10 meters) or a fast action is required. A coil should: • Be non--sensitive to vibrations; • Be silent in operation • Have large frequency of activation (30--35 times per second) • It should be possible to fit it in any position. • Be insulated, in order to function correctly for a wide range of temperatures (from --40 to +85°C), and with high humidity conditions. The MOST COMMON FAULTS that can occur are: • Winding shorted: if a section of the winding allows the current to pass directly from positive (+) to negative (--) terminals without passing through the winding, this will cause the relevant circuit fuse to blow. • Broken winding: causing an open circuit, it will not allow the current to pass through the winding, so the solenoid will not operate. • Seized plunger (and/or connected components): the solenoid will only move the plunger if all components are free to move.
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17
PROPORTIONAL SOLENOID VALVES (PWM) Whenever it is necessary to provide proportional control to the solenoid valves, it is much better to use a principle of operation called pulse width modulation (PWM). PWM is a variable DC voltage signal that is used to control the solenoid valves. The voltage signal is pulsed on and off many times a second (at a constant frequency of 500 Hz) at a constant supply voltage of 12 V.
The processors contain transistors that are supplied with a constant input voltage which is switched on and off to achieve the variable input range. In this way the control module is able to limit the armature movement, so the hydraulic output flow of the solenoid is proportional to the average DC voltage. The lower voltage also allows the solenoid to operate with less residual magnetism and so the entire circuit will operate smoother. The variable DC voltage signal level is determined by varying the duration of the ON pulse relative to the OFF pulse (see Fig. 32). The ratio between the ON time and the cycle time is called duty cycle and is stated as a percentage of one complete cycle. Please refer to Fig. 32, diagrams 1 to 3 show the normal operating range of the PWM valve, and diagram 4 shows the initial 12V programming and fill time only. The diagrams in column A show the voltage signal that is sent to the valve, whereas column B shows the relevant spring pressure and column C the reading on a voltmeter connected to the solenoid valve. Diagram 1 shows the OFF position: no signal is directed to the valve, which means no spring pressure in the valve at all and results in a zero voltage reading. Increasing the duty cycle causes some pressure to be made on the circuit (Diagram 2), which results in a voltmeter reading increase. Diagram 3 shows the maximum signal that is used during the normal activity of the valve: its duty cycle is around 0.5, which results in a spring pressure for the half of its run and in an indication of a 6 volt average DC current. The electrical circuit to the solenoids can be checked by using a digital or analogue DC voltmeter, which will indicate the average voltage readings.
31
32
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
SENSORS A sensor is the primary component of a measurement chain that converts the input variable (temperature, capacitance, reluctance) into a signal suitable for measurement. The relationship between the input variable and the measured signal is a characteristic of the sensor. In the above mentioned measurement chain the signal is filtered and treated in order to adapt it to its use. It consists of three elements: the sensor itself; the converter, which converts the output signal from the sensor (in most of the cases into an electric signal); and the conditioner, which transforms the output signal from the converter in the most suitable form. Generally the term sensor indicates the entire measurement chain. TEMPERATURE SENSORS Generally based on a simple circuit with a thermistor. A thermistor is a resistor that changes its resistance according to the temperature. There are two groups of thermistors: NTC (Negative Temperature Coefficient) and PTC (Positive Temperature Coefficient). In the first case the higher the temperature, the lower is the resistance, and for the PTC the higher the temperature, the higher the resistance. The NTC are often used as sensors to indicate temperature change in fluids, such as the engine coolant fluid. An example of these type of senders is the coolant temperature sender. The changes in its resistance (which varies with temperature) are relayed to the Instrument Cluster, which operates the gauge and the warning indicators accordingly.
33
PRESSURE SENDER A pressure sender receives a supply signal and it varies it according to the (oil) pressure. An example is the oil pressure sender, which receives a 5 volt signal and varies it according to the oil pressure. The Instrument Cluster keeps track of these variations and changes its readouts and warnings accordingly.
34
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19
SPEED SENSOR The speed sensor is typically a reluctance sensor. An example is the axle speed sensor, which is fitted into the transmission and gets pulses off the gears, counting the gear teeth. The sensor uses a pickup coil. The action of the gear close to the pickup creates pulses which are relayed to the controller. The controller converts the frequency of the pulses into ground speed. Possible failures are due to vibration, open circuits.
35 FLUID LEVEL SENDER It operates by varying resistance through the movement of a float. An example is the fuel level sender.
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ELECTRONIC CONTROL UNITS The electronic control units (1) are the ”black boxes” that provide control on many of the functions of the tractor. These functions may vary according to the options that are fitted on the tractor. Inside these ”black boxes” there is a processor, the ”thinking part” of the control unit, and inside some of them there is one or more memories, which may allow the control unit to store calibration values, the configuration of the vehicle (which optional tools or devices have been installed) and the error codes.
A processor has a series of pins, which are electrical contacts (see Fig. 38). There are three main types of pin: for the inputs of the signals, for the outputs and for the processor supply. The processor, the memories and the link between them form the hardware of the control unit, its ”physical” part. Then some software is needed, to handle the communication between the processor and the memories and to manage the various signals going into and out of the processor. The software is designed to operate in a different way for every control unit, and is called functional code.
To provide a continuous control on components, the processor continuously scans all the inputs in a time-sharing mode, with a cycle lasting 10 ms. This means that all the components controlled by the processor are checked one by one, and that every component is checked 100 times per second. Control units are often blamed as responsible for most of the problems of modern tractors, while they are for certain among the most protected parts of the tractor. In fact, the pins of the control units are protected against spikes (high pulses) of current, and the signals are filtered by the hardware and by the software in input and in output to give the best handling of information.
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FAULT CODE DISPLAY FOR THE PANEL (ADIC) AND TRANSMISSION (XCM). All other fault codes are displayed on the analog digital instrument cluster (ADIC) dot matrix display (1) and the lower central display (2).
39 The disabling errors will be shown on the dot--matrix display of the control panel and will be visible for the driver.
40 Hidden and saved fault codes can be displayed by using the fault diagnosis mode of the ”H” menus and are not visible for the driver.
41
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Fault Code Symbols System
Symbol
System
Controller area network (CAN)
4WD
Gears
Diff lock
Power Take--Off
Control panel
Configuration errors
Electronic lift
Symbol
The ADIC will display a symbol accompanied by a four or five digit code to indicate a fault has occurred. The symbol represents the system in which the fault is detected and the code specifies the cause of the detected fault. The error codes are grouped by system using the following numbered ranges: • 1001--2000 (Electronic lift) •
2001--3000 (Transmission)
•
5001--6000 (Rear Power Take--Off)
•
6001--7000 (Four Wheel Drive)
•
7001--8000 (Differential lock)
•
14001--15000 (Control Panel)
H--MENU DIAGNOSTIC MODE The ”H” menu diagnostic mode can be used to access and clear the fault codes which may be stored in the various controllers. The H--menu diagnostic mode also contains many other useful functions which may be used to assist with diagnostics. Refer to the Diagnostic H Routines chapter in this Section.
42
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23
CONTROLLER AREA NETWORK (CAN) SYSTEM ADIC (HP -- HO) -- Analog--Digital Instrument Cluster. XCM (RJ) -- Multi Control Unit, used to control the transmission, power take--off, differential lock, four wheel drive and electronic lift systems. JB -- Keypad, used for the enhanced Analog--Digital Instrument Cluster (ADIC). The tractor utilises a CAN (Controller Area Network) in addition to the standard wiring harnesses. The CAN is a 2--wire system which uses a series of numeric values sent at very high speed to transmit data between the control unit and components. A CAN system has the advantage of being able to use one component for many applications without the need for hard wiring to each application, as in a conventional system. Depending on the model specification, control units are used to control a number of systems on the tractor.
ADIC HP -- HO
XCM RJ
JB 43
LOCATIONS OF THE CONTROL UNITS
The multi--control unit (XCM) (1) is located behind the control panel and can be accessed by removing the right-- and left--hand guards as well as the control panel itself.
44 If any of the control units need to be replaced, the following operations must be carried out: The H8 MENU function (cancellation of the resident non--volatile memory); also check that the self--configuration operation at the first start--up (after controller replacement) is correct; Calibration of the hydraulic clutches and electronic draft control H1 MENU.
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LIST OF ELECTRONIC LIFT ERROR CODES FAULT CODE 1002
Description of Fault Radar signal not present
E.C.R. (*) YES
1003
Speed sensor signal not present
YES
1004
Speed sensor signal too High
YES
1006
Slip control potentiometer signal too low
YES
1007
Slip control potentiometer signal too high
YES
1008
Raise / work switch failure
YES
1009
Both ext. sw. operated same time
YES
1010
Height limit pot signal too low
YES
1011
Height limit pot signal too high
YES
1012
Drop rate pot signal too low
YES
1013
Drop rate pot signal too high
YES
1014
R/H load sensing pin signal too low
YES
1015
R/H load sensing pin signal too high
YES
1016
L/H load sensing pin signal too low
YES
1017
L/H load sensing pin signal too high
YES
1018
Both load sensing pin disconnected
YES
1019
Load sensing pin voltage too low
YES
1020
Load sensing pin voltage too high
YES
1021
Sensitivity control potentiometer signal too low
YES
1022
Sensitivity control potentiometer signal too high
YES
1023
Control panel disconnected
YES
1024
Perform the hydraulic lift calibration procedure
NO
1025
Position control potentiometer control voltage too low
YES
1026
Position control potentiometer control voltage too high
YES
1027
Lift arm position sensing control voltage low
YES
1028
Lift arm position sensing control voltage high
YES
1029
Hydraulic control valve disconnected
YES
1030
Break in the ground circuit
YES
1031
Chassis harness disconnected
YES
1032
Draft control potentiometer control voltage high
YES
1033
Draft control potentiometer control voltage low
YES
1049
Wheel speed sensor open or short circuit
YES
1053
Controller 5 Volt reference shorted to positive voltage
YES
1054
Controller 5 Volt reference short to ground
YES
1059
Reference voltage to 8 volt load sensing pins, too high (> +9V), too low (< +7V)
YES
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1063
EDC hydraulic valve lower solenoid open circuit
YES
1064
EDC hydraulic valve raise solenoid open circuit
YES
1065
EDC Hydraulic valve lower solenoid short circuit
YES
1066
EDC Hydraulic valve raise solenoid short circuit
YES
1067
EDC control valve supply voltage low
YES
1068
Height limit calibration error
YES
1069
Slip control configuration error
NO
TRANSMISSION FAULT CODE LISTING FAULT CODE 2011
Clutch pedal potentiometer signal too low
E.C.R. (*) YES
2012
Clutch pedal potentiometer signal too high
YES
2014
Voltage from the gear neutral position switch is high
YES
2015
Voltage from the gear neutral position switch is low
YES
2016
Voltage from the range position switch (R1) is high
YES
2017
Voltage from the range position switch (R1) is low
YES
2018
Voltage from the range position switch (R2) is high
YES
2019
Voltage from the range position switch (R2) is low
YES
2021
Drive line harness disconnected
YES
2024
All the clutches must be calibrated
NO
2025
Engine speed (rpm) high
YES
2026
Clutch D not calibrated
NO
2027
Clutch C not calibrated
NO
2028
Clutch B not calibrated
NO
2029
Clutch A not calibrated
NO
2030
Critical code on transmission
NO
2033
Pressure on clutch A would not decrease
NO
2035
Wheel speed too high
YES
2036
Engine speed (rpm) low
YES
2037
Clutch disconnect switch open circuit
YES
2038
Clutch B solenoid valve short to + 12 volts
NO
2039
Clutch B solenoid valve open circuit or short to ground
NO
2040
Inconsistent gear lever status switches
YES
2041
Clutch A solenoid valve open circuit or short to ground
NO
2042
Clutch A solenoid valve short to + 12 volts
NO
2043
Pressure on clutch B would not decrease
NO
Description of Fault
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26 2047
Clutch disconnect switch set too high
YES
2048
Clutch disconnect switch set too low
NO
2049
Sensor for wheel speed too high (12X12 and 24X24 version)
YES
2049
Voltage from the wheel speed sensor too high (20X20 version)
YES
2051
Oil temperature sensor open circuit
YES
2052
Oil temperature sensor short circuit
YES
2053
5 volt reference voltage too high
NO
2054
5 volt reference voltage too low
NO
2055
Shuttle lever forward switch voltage high
YES
2056
Shuttle lever forward switch voltage low
YES
2057
Shuttle lever reverse switch voltage high
YES
2058
Shuttle lever reverse switch voltage low
YES
2059
Shuttle Lever sw. disagree
YES
2061
No seat safety switch transition in the last 25 hours of work
NO
2065
Clutch C solenoid valve open circuit or short to ground
NO
2066
Clutch D solenoid valve open circuit or short to ground
NO
2067
Clutch D solenoid valve short to + 12 volts
NO
2068
Clutch C solenoid valve short to + 12 volts
NO
2069
Wheel speed sensor voltage too low (12X12 and 24X24 version)
YES
2069
Wheel speed sensor voltage too low (20X20 version)
YES
2081
Clutch A safety pressure switch open circuit or short to ground
YES
2082
Clutch A safety pressure switch short circuit
YES
2083
Clutch B safety pressure switch open circuit or short to ground
YES
2084
Clutch B safety pressure switch short circuit
YES
2085
No supply to pressure switches for clutches A and B
NO
2090
YES
2092
Break in CAN communication between the ADIC and the XCM transmission control unit Short circuit to +12V from the clutch cut--out switch
2093
Short circuit to +12VF to the gear lever switch feed signal
YES
2094
Short circuit to ground to the gear lever switch feed signal
YES
2095
Clutch cut--out button jammed closed.
YES
2097
Short circuit to +12V to the discharge (dump) solenoid valve.
NO
2098
Short circuit to ground or circuit open to the discharge (dump) solenoid valve.
NO
2430
Creeper unit status switch voltage too low
YES
2431
Creeper unit status switch voltage too high
YES
2450
Configuration error
NO
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
27
REAR PTO FAULT CODE LISTING FAULT CODE 5007
E.C.R. (*) NO
Description of Fault PTO clutch solenoid valve short to + 12 volts
5008
PTO clutch solenoid valve open circuit or short to ground
NO
5033
Rear PTO cab normally closed switch open circuit
NO
5034
Open circuit or short to ground to the PTO switches on the mudguards
NO
5035
Short to + 12V from the PTO switches on the mudguards
NO
5037
Cab rear PTO switch jammed on (normally off)
NO
5043
Switch on mudguards jammed on
NO
FOUR WHEEL DRIVE ERROR CODE LISTING FAULT CODE 6023
Description of Fault Four--wheel drive clutch solenoid valve open circuit or short to ground
E.C.R. (*) NO
DIFFERENTIAL LOCK ERROR CODE LISTING FAULT CODE 7017
Description of Fault Differential lock solenoid valve open circuit or short to ground
E.C.R. (*) NO
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ANALOG--DIGITAL INSTRUMENT CLUSTER (ADIC) ERROR CODE LISTING FAULT CODE 14001
Description of Fault Rear power take off (PTO) speed sensor open circuit or short to high voltage
E.C.R. (*) YES
14002
Rear power take off (PTO) speed sensor short to ground
YES
14011
Engine speed sensor open circuit or short to high voltage
YES
14012
Engine speed sensor short to ground
YES
14015
5V supply Voltage too high
NO
14016
5V supply Voltage too low
NO
14041
Engine coolant temperature sensor open circuit or short to high voltage
NO
14042
Engine coolant temperature sensor short to ground
NO
14051
Fuel tank level sender open circuit or short to high voltage
YES
14052
Fuel tank level sender short to ground
YES
14061
Pneumatic brake pressure sensor shorted to + 12V or sensor not connected
NO
14091
Wheel speed sensor open circuit or short to high voltage
NO
14092
Wheel speed sensor short to ground
NO
14093
Seat switch signal short to +12V or open circuit
NO
14094
Seat switch signal short to ground
NO
14100
Pneumatic brake pressure sensor detected but not configured
YES
14101
Contaminated fuel sender disconnected
NO
14200 14900
Error with Electrically Erasable Programmable Read Only Memory (EEPROM) Control unit (XCM) disconnected
YES NO
14905
Instrument cluster keypad disconnected
NO
14911
Enhanced cluster without keypad
NO
14912
Basic cluster with keypad
NO
(*) Enter the HH programs of the control panel select the H3 program, enter the ECR, then select the options: E -- show only severe codes, F -- show all codes for 6 minutes of power then pass to â&#x20AC;&#x153;Eâ&#x20AC;?. With option E selected, the word: YES -- means that the code will not be shown on the display but only kept in memory, NO -- means the code will not be shown on the display.
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CALIBRATION U-- CODE LISTING Calibration Description of Fault code U19 Oil temperature <10 °C, calibration is not possible U20
Wrong sequence, operate the Power Shuttle control lever and the clutch control pedal
U21
Engine speed is too low, increase engine speed
U22
Engine speed is too high, reduce engine speed
U23
Shuttle lever is in neutral, shift lever to forward
U24
Wrong range selection (the III range is not engaged)
U25
Main gear lever is in neutral
U26
Clutch pedal is not up, release clutch pedal
U31
Wheel speed sensed
U33
The parking brake is not engaged
U34
Operator present seat switch off
U36
Calibration value too high
U37
Calibration value too low
U38
Range lever in neutral
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE U19 -- TRANSMISSION OIL TEMPERATURE IS BELOW 10 DEGREES CENTIGRADE Possible fault modes: 1. Transmission oil is very cold 2. Transmission oil temperature sensor open circuit 3. Oil temperature sensor faulty 4. Oil temperature sensor short to ground
ERROR CODE U20 -- INCORRECT SEQUENCE, CYCLE SHUTTLE LEVER AND PEDAL SWITCH Possible fault modes: 1. Operator has carried out the calibration incorrectly
ERROR CODE U21 -- ENGINE SPEED IS TOO LOW, INCREASE ENGINE SPEED Possible fault modes: 1. Operator has not set the correct engine speed 2. Open circuit between the engine speed sensor and the instrument cluster 3. Instrument cluster not powered 4. CAN circuit faulty NOTE: Use the HE menu ch. 18 in the instrument cluster to see if the engine speed is being detected.
ERROR CODE U22 -- ENGINE SPEED IS TOO HIGH, REDUCE ENGINE SPEED Possible fault modes: 1. Operator has not set the correct engine speed
ERROR CODE U23 -- SHUTTLE LEVER IS IN NEUTRAL, SHIFT LEVER TO FORWARD Possible fault modes: 1. Operator has not selected forward on the shuttle lever 2. Open circuit between the shuttle lever and the control unit (XCM) 3. 12V supply to the shuttle lever is open circuit NOTE: Use the H5 switch diagnostics of the RJ transmission control unit to detect if the switch is connected.
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ERROR CODE U24 -- INCORRECT RANGE SELECTED Possible fault modes: 1. Operator has not selected the correct range 2. The range switch (R1 or R2) is faulty 3. The gear linkage is out of adjustment NOTE: Use the H5 switch diagnostics of the RJ transmission control unit to detect if the switches (R1 and R2) are connected.
ERROR CODE U25 -- MAIN GEAR LEVER IS IN NEUTRAL Possible fault modes: 1. Operator has not selected a gear 2. The gear neutral switch is faulty 3. The gear linkage is out of adjustment NOTE: Use the H5 switch diagnostics of the RJ transmission control unit to detect if the switch (G) is connected.
ERROR CODE U26 -- CLUTCH PEDAL IS NOT UP, RELEASE CLUTCH PEDAL Possible fault modes: 1. Operator has not released the clutch pedal 2. The clutch pedal potentiometer linkage is sticking or faulty NOTE: Use the H9 in the transmission control unit to see if the clutch input is OK.
ERROR CODE U31 -- WHEEL SPEED DETECTED Possible fault modes: 1. The parking brake is not engaged 2. Brakes not working NOTE: If the brakes are okay, move the vehicle slightly forward and repeat the calibration.
ERROR CODE U33 -- HANDBRAKE IS NOT ENGAGED Possible fault modes: 1. The parking brake is not engaged 2. Open circuit between the parking brake switch and the instrument cluster 3. Parking brake switch faulty 4. 12V supply to the switch is open circuit NOTE: Use the H5 switch diagnostics of the instrument cluster to detect if the parking brake switch is connected.
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE U34 -- OPERATOR PRESENT SEAT SWITCH OFF Possible fault modes: 1. Operator is not sitting in the seat 2. Open circuit between the seat switch and the instrument cluster 3. Seat switch faulty 4. 12V supply to the switch is open circuit NOTE: Use the H5 switch diagnostics of the instrument cluster to detect if the seat switch is connected, if the switch has diagnostics then use the H9 diagnostics ch26.
ERROR CODE U36 -- CALIBRATION VALUE TOO HIGH Possible fault modes: 1. The speed does not drop 2. No or low oil pressure to the clutch 3. Mechanical failure breaking the torque path
ERROR CODE U37 -- CALIBRATION VALUE TOO LOW Possible fault modes: 1. Engine speed dropped too soon 2. Clutch pressure is not being controlled properly 3. Engine speed adjusted whilst completing calibration
ERROR CODE U38 -- RANGE LEVER IS IN NEUTRAL Possible fault modes: 1. Operator has not selected a range 2. The range switch (R1 or R2) is faulty 3. The gear linkage is out of adjustment NOTE: Use the H5 switch diagnostics to detect if the switch is connected.
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LIST OF ELECTRONIC LIFT ERROR CODES FAULT CODE 1002
Description of Fault Radar signal not present
E.C.R. (*) YES
1003
Speed sensor signal not present
YES
1004
Speed sensor signal too High
YES
1006
Slip control potentiometer signal too low
YES
1007
Slip control potentiometer signal too high
YES
1008
Raise / work switch failure
YES
1009
Both ext. sw. operated same time
YES
1010
Height limit pot signal too low
YES
1011
Height limit pot signal too high
YES
1012
Drop rate pot signal too low
YES
1013
Drop rate pot signal too high
YES
1014
R/H load sensing pin signal too low
YES
1015
R/H load sensing pin signal too high
YES
1016
L/H load sensing pin signal too low
YES
1017
L/H load sensing pin signal too high
YES
1018
Both load sensing pin disconnected
YES
1019
Load sensing pin voltage too low
YES
1020
Load sensing pin voltage too high
YES
1021
Sensitivity control potentiometer signal too low
YES
1022
Sensitivity control potentiometer signal too high
YES
1023
Control panel disconnected
YES
1024
Perform the hydraulic lift calibration procedure
NO
1025
Position control potentiometer control voltage too low
YES
1026
Position control potentiometer control voltage too high
YES
1027
Lift arm position sensing control voltage low
YES
1028
Lift arm position sensing control voltage high
YES
1029
Hydraulic control valve disconnected
YES
1030
Break in the ground circuit
YES
1031
Chassis harness disconnected
YES
1032
Draft control potentiometer control voltage high
YES
1033
Draft control potentiometer control voltage low
YES
1049
Wheel speed sensor open or short circuit
YES
1053
Controller 5 Volt reference shorted to positive voltage
YES
1054
Controller 5 Volt reference short to ground
YES
1059
Reference voltage to 8 volt load sensing pins, too high (> +9V), too low (< +7V)
YES
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EDC hydraulic valve lower solenoid open circuit
YES
1064
EDC hydraulic valve raise solenoid open circuit
YES
1065
EDC Hydraulic valve lower solenoid short circuit
YES
1066
EDC Hydraulic valve raise solenoid short circuit
YES
1067
EDC control valve supply voltage low
YES
1068
Height limit calibration error
YES
1069
Slip control configuration error
NO
(*) Enter the HH programs of the control panel select the H3 program, enter the ECR, then select the options: E -- show only severe codes, F -- show all codes for 6 minutes of power then pass to â&#x20AC;&#x153;Eâ&#x20AC;?. With option E selected, the word: YES -- means that the code will not be shown on the display but only kept in memory, NO -- means the code will not be shown on the display.
NOTE: For the location of the components, connectors and the wiring diagrams, please refer to the end of the troubleshooting section from page 78 to page 86.
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ERROR CODE 1002 -- RADAR SIGNAL NOT PRESENT Possible fault modes: 1. Faulty connectors 2. Fuse F4 (5A) faulty 3. Radar faulty 4. Wiring fault 5. Control unit (XCM) trouble 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 radar SEN--227, the main cab--transmission connector C02 and the connector of the control unit (XCM) MOD--1/3 (1B). 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 radar power supply. A. If a fault is indicated with fuse F4 (5A) replace it, then continue to step 3. B. If the fuse is okay, continue to the next step. 3. Check for an open circuit. A. Disconnect the connector of the control unit (XCM) MOD--1/3 (1B) and the connector for the radar SEN--227. Check between the connector: MOD--1/3 (1B) pin 19 wire 0.5 (RN), and SEN--227 pin 3 wire 1.0 (RN) MOD--1/3 (1B) pin 33 wire 0.5 (MV), and SEN--227 pin 2 wire 1.0 (MV). If an open circuit is indicated, repair or replace the harness as required. B. Check between the connector: SEN--227 pin 1 and ground. If an open circuit is indicated, repair or replace the harness as required. C. Turn the key OFF, check whether +12Volt is indicated on the connector SEN--227 pin. 4 wire 1.0 (LB) If an open circuit is indicated, repair or replace the harness as required. 4. Check for a short to ground. A. Check between the connector: SEN--227 pin 2, wire 1.0 (MV) and ground. SEN--227 pin 3 wire 1.0 (RN) and ground. SEN--227 pin 4 wire 1.0 (LB) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, continue to the next step. 5. Check the position of the radar. A. If the radar is pointing at the tractor wheel or excessively vibrating, point the radar at the ground and tighten the fixings. B. If the radar mounting and position is okay, remove and replace the radar assembly. C. If the error is still present, download the correct level of software. If the error is repeated, remove and replace the control unit (XCM).
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 1003 -- NO SIGNAL FROM SPEED SENSOR Possible fault modes: 1. Faulty connectors 2. Faulty speed sensor 3. Wiring fault 4. Control unit (XCM) trouble 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 speed sensor connector SEN--217, transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (1B). 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 speed sensor. A. If the speed sensor is loose in the parking brake housing or damaged, re--tighten or remove and replace the speed sensor as required. B. If the speed sensor is okay, continue to step 3. 3. Check the speed pickup gear. A. Remove the speed sensor and check for damage to the speed pickup gear inside the parking brake housing. If any damage is indicated, disassemble the housing and replace the speed pickup gear. B. If the speed pickup gear is okay, continue to step 4. 4. Check the speed sensor. A. Disconnect the connector of the speed sensor SEN--217. Measure the resistance between the connector SEN--217 pin 2, wire 1.0 (BR) and SEN--217 pin 1, wire 1.0 (HB). If the resistance indicated is not approximately 680 Âą 15% Ohm, remove and replace the speed sensor. B. If the value is okay, continue to step 5. 5. Check for an open circuit. A. Disconnect the connector of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (1B). Check between the connector: SEN--217 pin 1, wire 1.0 (HB) and MOD--1/3 (1B) pin 34, wire 0.5 (HB) SEN--217 pin 2, wire 1.0 (BR) and MOD--1/3 (1A) pin 23, wire 1.0 (BR) If an open circuit is indicated, repair or replace the harness as required. B. If the error is still present, download the correct level of software. If the error is repeated, remove and replace the control unit (XCM).
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ERROR CODE 1004 -- SPEED SENSOR SIGNAL TOO HIGH Possible fault modes: 1. Faulty connectors 2. Faulty speed sensor 3. Wiring fault 4. Control unit (XCM) trouble 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 speed sensor connector SEN--217, the connector of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (1B) and the transmission -- cab main connector C--2. 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 wheel speed sensor. A. Disconnect the connector SEN--217. Measure the resistance between the wheel speed sensor terminals. If the resistance indicated is not approximately 680 ± 15% Ohm , remove and replace the speed sensor. B. If the wheel speed sensor is okay, continue to step 3. 3. Check there is a short to positive. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: SEN--217 pin 1, wire 1.0 (HB) and ground. SEN--217 pin 2, wire 1.0 (BR) and ground. If a short to positive is indicated, turn the key OFF, disconnect the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (1B) try again if a short circuit is indicated with positive voltage, 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 (XCM).
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 1006 -- SLIP CONTROL POTENTIOMETER SIGNAL TOO LOW (SHORT OR OPEN CIRCUIT) Possible fault modes: 1. Faulty connector 2. Faulty slip 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 slip control potentiometer in H9, ch. 37. A. Turn the slip control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 84 to 14, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 37 wiggle the harness and the EDC control panel connector MOD--53, the connectors MOD--1/3 (1B) and MOD--1/3 (1A) of the controller to check for an intermittent circuit. The values of ch 37 will change if an intermittent circuit is indicated; Repair or replace as necessary. 2. Check the slip control potentiometer. A. Remove the EDC control panel and disconnect the connector MOD--53. While turning the slip control knob fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel side between: MOD--53 pin 8 and MOD--53 pin 6 MOD--53 pin 7 and MOD--53 pin 6 If the resistances indicated are not between 80 and 340 ohm, replace the control panel. B. If the EDC control panel is okay, continue to step 3. 3. Check for a short to ground. A. Check between (wire side): MOD--53 pin 6 wire 0.5 (LG) and ground MOD--53 pin 8 wire 0.5 (S) 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 4. 4. Check for an open circuit. A. Disconnect the connectors MOD--1/3 (1B) and MOD--1/3 (1A) of the controller. Check between: MOD--1/3 (1A) pin 23 wire 1.0 (1BR) and MOD--53 pin 7 wire 0.5 (BR) MOD--1/3 (1B) pin 7 wire 0.5 (LG) and MOD--53 pin 6 wire 0.5 (LG) MOD--1/3 (1B) pin 17 wire 0.5 (S) and MOD--53 pin 8 wire 0.5 (S) 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.
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ERROR CODE 1007 -- SLIP CONTROL POTENTIOMETER SIGNAL TOO HIGH (SHORT TO + 12 VOLT) Possible fault modes: 1. Faulty connector 2. Faulty slip 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 slip control potentiometer in H9, ch. 37. A. Turn the slip control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 84 to 14, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 37 wiggle the harness and the EDC control panel connector MOD--53, the connectors MOD--1/3 (1B) and MOD--1/3 (1A) of the controller wiring to check for an intermittent circuit. The values of ch 37 will change if an intermittent circuit is indicated; Repair or replace as necessary. 2. Check the slip control potentiometer. A. Remove the EDC control panel and disconnect the connector MOD--53. While turning the slip control knob fully clockwise and then fully counter clockwise, measure the resistance between the component side of connector: MOD--53 pin 8 and MOD--53 pin 6 MOD--53 pin 7 and MOD--53 pin 6 If the resistances indicated are not between 80 and 340 ohm, replace the control panel. B. If the EDC control panel is okay, continue to step 3. 3. Check for a short to +8 or +12 Volts. A. Turn the key start ON. Measure the voltage, with the panel disconnected, between the connector: MOD--53 pin 8 wire 0.5 (S) and ground. If the voltage indicated is greater than +5 volts, repair or replace the harness as required. B. If the voltage indicated is approximately +5 volts, continue to step 4. 4. Check for a short circuit with positive voltage. A. Measure the voltage between the connector: MOD--53 pin 6 Wire 0.5 (LG) 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.
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 1008 -- RAISE / LOWER SWITCH FAILURE Possible fault modes: 1. Faulty connector 2. Faulty raise/work switch 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 raise/work switch in H5. A. The display will show d0. Move the fast raise/work switch between the raise and work positions several times, and check the display. If the display does not change, continue to step 8. B. If the display passes from d0 to d3, d4 and then d5, the switch and the circuit are okay. If the display shows d0 and d3 then d5, continue to step 2. C. If the display shows d0 and d4 then d5, continue to step 5. 2. Check the raise/work switch. A. Disconnect the connector MOD--54 of the lift/work switch. With the switch in the raise position, check between the connector: MOD--54 pin F and the connector MOD--54 pin E MOD--54 pin F and the connector MOD--54 pin H If an open circuit is indicated, replace the raise/work switch. B. If the raise/work switch is okay, continue to step 3. 3. Check for an open circuit. A. Disconnect the connectors MOD--1/3 (1B) and MOD--1/3 (3A) of the controller. Check between the connector: MOD--54 pin E wire 0.5 (MB) and MOD--1/3 (1B) pin 20 wire 0.5 (MB) MOD--54 pin H wire 0.5 (A) and MOD--1/3 (3A) pin 6 wire 0.5 (A) 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 a short circuit or a short to ground. A. Check between: MOD--54 pin E wire 0.5 (MB) and MOD--54 pin F wire 0.5 (RV) MOD--54 pin E wire 0.5 (MB) and ground MOD--54 pin F wire 0.5 (RV) and ground MOD--54 pin H wire 0.5 (A) and MOD--54 pin F wire 0.5 (RV) MOD--54 pin H wire 0.5 (A) and ground If a short circuit or a short to ground 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. 5. Check the raise/work switch. A. With the switch in the work position, check between the connector: MOD--54 pin G and the connector MOD--54 pin F MOD--54 pin F and the connector MOD--54 pin H If an open circuit is indicated, replace the raise/work switch. B. If the switch is okay, continue to step 6. 6. Check for an open circuit. A. Disconnect the connectors MOD--1/3 (1B) and MOD--1/3 (3A) of the controller. Check between the connector: MOD--54 pin G wire 0.5 (VN) and MOD--1/3 (1B) pin 18 wire 0.5 (VN) MOD--54 pin H wire 0.5 (A) and MOD--1/3 (3A) pin 6 wire 0.5 (A) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 7. 87679925A1 - 02 - 2008
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7. Check for a short circuit or a short to ground. A. Check between: MOD--54 pin F wire 0.5 (RV) and MOD--54 pin G wire 0.5 (VN) MOD--54 pin F wire 0.5 (RV) and ground MOD--54 pin G wire 0.5 (VN) and ground MOD--54 pin H wire 0.5 (A) and MOD--54 pin F wire 0.5 (RV) MOD--54 pin H wire 0.5 (A) and ground If a short circuit or a short to ground 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. 8. Check for an open circuit. A. Turn the Keystart OFF. Disconnect the connector MOD--54 of the lift/work switch. Check between the connector: MOD--54 pin F wire 0.5 (RV) and F4 (5A) wire 1.5 (RV) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, continue to step 9. 9. Check the raise/work switch. A. Check between: MOD--54 pin F and MOD--54 pin E MOD--54 pin F and MOD--54 pin H with the raise/work switch kept in the position for raising MOD--54 pin F and MOD--54 pin G MOD--54 pin F and MOD--54 pin H with the raise/work switch kept in the position for lowering If an open circuit is indicated in either test, remove and replace the switch. B. If the switch is okay, continue to step 10. 10. Check for a short circuit. A. Disconnect the connectors MOD--1/3 (1B) and MOD--1/3 (3A) of the controller. Check between the connector: MOD--1/3 (1B) pin 18 wire 0.5 (VN) and MOD--1/3 (1B) pin 20 wire 0.5 (MB) MOD--1/3 (1B) pin 18 wire 0.5 (VN) and MOD--1/3 (3A) pin 6 wire 0.5 (A) MOD--1/3 (1B) pin 20 wire 0.5 (MB) and MOD--1/3 (3A) pin 6 wire 0.5 (A) If a short circuit is indicated, repair the short between the connectors MOD--1/3 (1B) pin 18 and pin 20 and (MB) and MOD--1/3 (3A) pin 6 of the controller and the connector MOD--54 of the raise/work switch or replace the wiring harness as required. B. If a short circuit is not indicated, continue to step 11. 11. Check for an open circuit. A. Check between the connector: MOD--54 pin E wire 0.5 (MB) and MOD--1/3 (1B) pin 20 wire 0.5 (MB) MOD--54 pin G wire 0.5 (VN) and MOD--1/3 (1B) pin 18 wire 0.5 (VN) MOD--54 pin H wire 0.5 (A) and MOD--1/3 (3B) pin 6 wire 0.5 (A) 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.
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ERROR CODE 1009 -- BOTH EXTERNAL SWITCHES OPERATED AT SAME TIME 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 HPL fender switches are not sticking in the raise or lower position. A. If the switches are sticking, clean, repair or replace as required. B. If the fender switches are not sticking, continue to step 2. 2. Check the HPL fender switches have not been operated simultaneously. A. Clear the error codes. Test the system for normal operation. If error code 1009 is still displayed, continue to step 3. 3. Check the connector SW--167 of the HPL switch mounted on the LH fender, the connector SW--164 of the HPL switch mounted on the RH fender and the connector MOD--1/3 (1B) 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 4. 4. Check for a short circuit with positive voltage. A. Disconnect the connectors SW--164 and SW--167. Turn the key start ON. Measure the voltage between connector: SW--164 pin 4 wire 0.5 (RB) and ground SW--164 pin 5 wire 0.5 (RL) and ground SW--167 pin 4 wire 0.5 (RB) and ground SW--167 pin 5 wire 0.5 (RL) 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 the L/H HPL fender switch for a short circuit. A. While operating the HPL fender switch mounted on the LH fender in the raise and then lower position, check between the connector: SW--167 pin 5 wire 0.5 (RL) and SW--167 pin 4 wire 0.5 (RB) If a short circuit is indicated, replace the HPL switch mounted on the LH fender. B. If the switch is okay, continue to step 6. 6. Check the R/H HPL fender switch for a short circuit. A. While operating the HPL fender switch mounted on the RH fender in the raise and then lower position, check between the connector: SW--164 pin 5 wire 0.5 (RL) and SW--164 pin 4 wire 0.5 (RB). If a short circuit is indicated, replace the R/H HPL fender switch. B. If the switch is okay, download the correct level of software. If the fault re--occurs, remove and replace the controller.
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ERROR CODE 1010 -- HEIGHT LIMIT POTENTIOMETER SIGNAL TOO LOW (SHORT OR OPEN CIRCUIT) 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 84 to 14, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 35 wiggle the harness and the EDC control panel connector MOD--53, the connectors MOD--1/3 (1B) and MOD--1/3 (1A) of the controller wiring 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 height limit control potentiometer. A. Remove the EDC control panel and disconnect the connector MOD--53. While turning the height limit control knob fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel side between: MOD--53 pin 8 and MOD--53 pin 2 MOD--53 pin 7 and MOD--53 pin 2 If the resistances indicated are not between 90 and 360 ohm (with slip control) and between 170 and 520 ohm (without slip control), replace the control panel. B. If the EDC control panel is okay, continue to step 3. 3. Check for a short to ground. A. Check between: MOD--53 pin 2 wire 0.5 (SN) and ground MOD--53 pin 8 wire 0.5 (S) 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 4. 4. Check for an open circuit. A. Disconnect the connectors MOD--1/3 (1B) and MOD--1/3 (1A) of the controller. Check between: MOD--1/3 (1A) pin 23 wire 1.0 (BR) and MOD--53 pin 7 wire 0.5 (BR) MOD--1/3 (1B) pin 5 wire 0.5 (SN) and MOD--53 pin 2 wire 0.5 (SN) MOD--1/3 (1B) pin 17 wire 0.5 (S) and MOD--53 pin 8 wire 0.5 (S) 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.
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ERROR CODE 1011 -- HEIGHT LIMIT POTENTIOMETER SIGNAL TOO HIGH (SHORT TO + 12 VOLT) 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 slip control potentiometer in H9, ch. 35. A. Turn the slip control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 84 to 14, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 35 wiggle the harness and the EDC control panel connector MOD--53, the connectors MOD--1/3 (1B) and MOD--1/3 (1A) of the controller wiring 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 height limit control potentiometer. A. Remove the EDC control panel and disconnect the connector MOD--53. While turning the height limit control knob fully clockwise and then fully counter clockwise, measure the resistance between: MOD--53 pin 8 and MOD--53 pin 2 MOD--53 pin 7 and MOD--53 pin 2 If the resistances indicated are not between 90 and 360 ohm (with slip control) and between 170 and 520 ohm (without slip control), replace the control panel. B. If the EDC control panel is okay, continue to step 3. 3. Check for a short to +8 or +12 Volts. A. Turn the key start ON. Measure the voltage, with the panel disconnected, between the connector MOD--53 pin 8 wire 0.5 (S) and ground. If the voltage indicated is greater than +5 volts, repair or replace the harness as required. B. If the voltage indicated is approximately +5 volts, continue to step 4. 4. Check for a short circuit with positive voltage. A. Measure the voltage between the connector: MOD--53 pin 2 wire 0.5 (SN) 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.
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ERROR CODE 1012 -- DROP RATE POTENTIOMETER SIGNAL TOO LOW (SHORT OR OPEN CIRCUIT) Possible fault modes: 1. Faulty connector 2. Faulty drop rate 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 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 84 to 14, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 34 wiggle the harness and the EDC control panel connector MOD--53, the connectors MOD--1/3 (1B) and MOD--1/3 (1A) of the controller wiring 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 drop rate control potentiometer. A. Remove the EDC control panel and disconnect the connector MOD--53. While turning the drop rate control knob fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel side between: MOD--53 pin 8 and MOD--53 pin 1 MOD--53 pin 7 and MOD--53 pin 1 If the resistances indicated are not between 90 and 360 ohm (with slip control) and between 170 and 520 ohm (without slip control), replace the EDC control panel. B. If the EDC control panel is okay, continue to step 3. 3. Check for a short to ground. A. Check between (wire side): MOD--53 pin 1 wire 0.5 (GR) and ground MOD--53 pin 8 wire 0.5 (S) 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 4. 4. Check for an open circuit. A. Disconnect the connectors MOD--1/3 (1B) and MOD--1/3 (1A) of the controller. Check between: MOD--1/3 (1A) pin 23 wire 1.0 (1BR) and MOD--53 pin 7 wire 0.5 (BR) MOD--1/3 (1B) pin 4 wire 0.5 (GR) and MOD--53 pin 1 wire 0.5 (GR) MOD--1/3 (1B) pin 17 wire 0.5 (S) and MOD--53 pin 8 wire 0.5 (S) 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.
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ERROR CODE 1013 -- DROP RATE POTENTIOMETER SIGNAL TOO HIGH (SHORT TO + 12 VOLT) Possible fault modes: 1. Faulty connector 2. Faulty drop rate 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 drop rate control potentiometer in H9, ch. 34. A. Turn the slip control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 84 to 14, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 34 wiggle the harness and the EDC control panel connector MOD--53, the connectors MOD--1/3 (1B) and MOD--1/3 (1A) of the controller wiring 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 drop rate control potentiometer. A. Remove the EDC control panel and disconnect the connector MOD--53. While turning the drop rate control knob fully clockwise and then fully counter clockwise, measure the resistance between: MOD--53 pin 8 and MOD--53 pin 1 MOD--53 pin 7 and MOD--53 pin 1 If the resistances indicated are not between 90 and 360 ohm (with slip control) and between 170 and 520 ohm (without slip control), replace the control panel. B. If the EDC control panel is okay, continue to step 3. 3. Check for a short to +8 or +12 Volts. A. Turn the key start ON. Measure the voltage, with the panel disconnected, between the connector MOD--53 pin 8 wire 0.5 (S) and ground. If the voltage indicated is greater than +5 volts, repair or replace the harness as required. B. If the voltage indicated is approximately +5 volts, continue to step 4. 4. Check for a short circuit with positive voltage. A. Measure the voltage between the connector: MOD--53 pin 1 wire 0.5 (GR) 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.
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ERROR CODE 1014 -- R/H LOAD SENSING PIN SIGNAL TOO LOW (SHORT OR OPEN CIRCUIT) Possible fault modes: 1. Faulty connector 2. Faulty load sensing pin 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 right--hand load sensing pin connector SEN--221, transmission -- cab main connector C--2 and the connectors MOD--1/3 (1B) and MOD--1/3 (1A) 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 2. 2. Check the load sensing pin in H9, ch 38. A. Where possible, remove any implements to ensure the load sensing pins are not under any draft loading. If the value displayed is approximately 42, check for an intermittent circuit to the load sensing pin; repair or replace the harness as required. If the error re--occurs and no intermittent circuit is indicated, download the correct level of software. If the fault re--occurs, remove and replace the controller. B. If the value displayed in H9 channel 38 is not approximately 42, continue to step 3. 3. Replace the load sensing pin. A. Turn the Keystart OFF. Remove and replace the load sensing pin (If a new pin is not available interchange the left and right hand load sensing pins). If the error is cleared, remove and replace the faulty sensing pin. B. If the error re--occurs, continue to step 4. 4. Check for a short to ground. A. Disconnect the connector MOD--1/3 (1B) and MOD--1/3 (1A) the connectors SEN--221 and SEN--225 of both right--hand load sensing pins. Check between: SEN--221 pin 2 wire 1.0 (HV) and ground SEN--221 pin 3 wire 1.0 (1B) 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: SEN--221 pin 1 wire 1.0 (BR) and MOD--1/3 (1A) pin 23 wire 1.0 (BR). SEN--221 pin 2 wire 1.0 (HV) and MOD--1/3 (1B) pin 9 wire 1.0 (HV) SEN--221 pin 3 wire 1.0 (B) and MOD--1/3 (1B) pin 25 wire 1.0 (B) 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.
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ERROR CODE 1015 -- R/H LOAD SENSING PIN SIGNAL TOO HIGH (SHORT TO + 12 VOLT) Possible fault modes: 1. Faulty connector 2. Faulty load sensing pin 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 right--hand load sensing pin connector SEN--221, transmission -- cab main connector C--2 and the connectors MOD--1/3 (1B) and MOD--1/3 (1A) 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 2. 2. Check the load sensing pin in H9, ch 38. A. Where possible, remove any implements to ensure the load sensing pins are not under any draft loading. If the value displayed is approximately 42, check for an intermittent circuit to the load sensing pin; repair or replace the harness as required. If the error re--occurs and no intermittent circuit is indicated, download the correct level of software. If the fault re--occurs, remove and replace the controller. B. If the value displayed in H9 channel 38 is not approximately 42, continue to step 3. 3. Replace the load sensing pin. A. Turn the Keystart OFF. Remove and replace the load sensing pin (If a new pin is not available interchange the left and right hand load sensing pins). If the error is cleared, remove and replace the faulty sensing pin. B. If the error re--occurs, continue to step 4. 4. Check for a short to +12 volts. A. Disconnect the connectors MOD--1/3 (1B) and MOD--1/3 (1A) and the connectors SEN--221 and SEN--225 of both load sensing pins. Turn the key start ON. Check between: SEN--221 pin 1 wire 1.0 (BR) and ground. SEN--221 pin 2 wire 1.0 (HV) and ground. SEN--221 pin 3 wire 1.0 (B) 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.
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ERROR CODE 1016 -- L/H LOAD SENSING PIN SIGNAL TOO LOW (SHORT OR OPEN CIRCUIT) Possible fault modes: 1. Faulty connector 2. Faulty load sensing pin 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 left--hand load sensing pin connector SEN--225, transmission -- cab main connector C--2 and the connectors MOD--1/3 (1B) and MOD--1/3 (1A) 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 2. 2. Check the load sensing pin in H9, ch 39. A. Where possible, remove any implements to ensure the load sensing pins are not under any draft loading. If the value displayed is approximately 42, check for an intermittent circuit to the load sensing pin; repair or replace the harness as required. If the error re--occurs and no intermittent circuit is indicated, download the correct level of software. If the fault re--occurs, remove and replace the controller. B. If the value displayed in H9 channel 39 is not approximately 42, continue to step 3. 3. Replace the load sensing pin. A. Turn the Keystart OFF. Remove and replace the load sensing pin (If a new pin is not available interchange the left and right hand load sensing pins). If the error is cleared, remove and replace the faulty sensing pin. B. If the error re--occurs, continue to step 4. 4. Check for a short to ground. A. Disconnect the connectors MOD--1/3 (1B) and MOD--1/3 (1A) and the connectors SEN--221 and SEN--225 of both the right--hand load sensing pins. Check between: SEN--225 pin 2 wire 1.0 (HV) and ground SEN--225 pin 3 wire 1.0 (B) 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: SEN--225 pin 1 wire 1.0 (BR) and MOD--1/3 (1A) pin 23 wire 1.0 (BR) SEN--225 pin 2 wire 1.0 (HV) and MOD--1/3 (1B) pin 10 wire 1.0 (CV) SEN--225 pin 3 wire 1.0 (B) and MOD--1/3 (1B) pin 25 wire 1.0 (B) 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.
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ERROR CODE 1017 -- L/H LOAD SENSING PIN SIGNAL TOO HIGH (SHORT TO + 12 VOLT) Possible fault modes: 1. Faulty connector 2. Faulty load sensing pin 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 left--hand load sensing pin connector SEN--225, transmission -- cab main connector C--2 and the connectors MOD--1/3 (1B) and MOD--1/3 (1A) 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 2. 2. Check the load sensing pin in H9, ch 39. A. Where possible, remove any implements to ensure the load sensing pins are not under any draft loading. If the value displayed is approximately 42, check for an intermittent circuit to the load sensing pin; repair or replace the harness as required. If the error re--occurs and no intermittent circuit is indicated, download the correct level of software. If the fault re--occurs, remove and replace the controller. B. If the value displayed in H9 channel 39 is not approximately 42, continue to step 3. 3. Replace the load sensing pin. A. Turn the Keystart OFF. Remove and replace the load sensing pin (If a new pin is not available interchange the left and right hand load sensing pins). If the error is cleared, remove and replace the faulty sensing pin. B. If the error re--occurs, continue to step 4. 4. Check for a short to +12 volts. A. Disconnect the connectors MOD--1/3 (1B) and MOD--1/3 (1A) and the connectors SEN--221 and SEN--225 of both load sensing pins. Turn the key start ON. Check between: SEN--225 pin 1 wire 1.0 (BR) and ground. SEN--225 pin 2 wire 1.0 (CV) and ground. SEN--225 pin 3 wire 1.0 (B) 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.
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ERROR CODE 1018 -- BOTH LOAD SENSING PINS DISCONNECTED 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 the transmission -- cab main connector C--2, the connectors MOD--1/3 (1B) and MOD--1/3 (1A) of the controller and the connectors SEN--221 and SEN--225 of both load sensing pins. 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 2. 2. Visually check the harness to both pins for any damage. A. If the harness is damaged, repair or replace as required. B. If no visible damage to the harness is indicated, continue to step 3. 3. Check for an open circuit. A. Disconnect the connectors MOD--1/3 (1B) and MOD--1/3 (1A) of the controller and the connectors SEN--221 and SEN--225 of both load sensing pins. Check between: SEN--221 pin 1 wire 1.0 (BR) and MOD--1/3 (1A) pin 23 wire 1.0 (BR). SEN--221 pin 2 wire 1.0 (HV) and MOD--1/3 (1B) pin 9 wire 1.0 (HV) SEN--221 pin 3 wire 1.0 (B) and MOD--1/3 (1B) pin 25 wire 1.0 (B) SEN--225 pin 1 wire 1.0 (BR) and MOD--1/3 (1A) pin 10 wire 1.0 (CV) SEN--225 pin 2 wire 1.0 (CV) and MOD--1/3 (1B) pin 9 wire 1.0 (HV) SEN--225 pin 3 wire 1.0 (B) and MOD--1/3 (1B) pin 25 wire 1.0 (B) 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.
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ERROR CODE 1019 -- LOAD SENSING PIN VOLTAGE TOO LOW (SHORT OR OPEN CIRCUIT) Possible fault modes: 1. Faulty load sensing pin 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 the +8 volt sensor supply in H9, ch 22. A. If the value displayed is approximately 79, check for an intermittent circuit to the load sensing pin; repair or replace the harness as required. If the error re--occurs and no intermittent circuit is indicated, download the correct level of software. If the fault re--occurs, remove and replace the controller. B. If the value displayed is not approximately 79, continue to step 2. 2. Check for a short to ground. A. Disconnect the connectors SEN--221 and SEN--225 of both load sensing pins. Check between: SEN--221 pin 3 wire 1.0 (B) and ground SEN--225 pin 3 wire 1.0 (B) 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 3. 3. Check for an open circuit. A. Disconnect the connectors MOD--1/3 (1B) and MOD--1/3 (1A) of the controller. Check between: SEN--221 pin 3 wire 1.0 (B) and MOD--1/3 (1B) pin 25 wire 1.0 (B) SEN--221 pin 1 wire 1.0 (BR) and MOD--1/3 (1A) pin 23 wire 1.0 (BR) SEN--225 pin 3 wire 1.0 (B) and MOD--1/3 (1B) pin 25 wire 1.0 (B) SEN--225 pin 1 wire 1.0 (BR) and MOD--1/3 (1A) pin 23 wire 1.0 (BR) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, continue to step 4. 4. Replace the load sensing pin(s). A. Remove and replace the load sensing pin(s). B. If the error re--occurs, refit the old load sensing pins and download the correct level of software. If the fault re--occurs, remove and replace the controller.
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ERROR CODE 1020 -- LOAD SENSING PIN VOLTAGE TOO HIGH (SHORT TO + 12 VOLT) Possible fault modes: 1. Faulty connector 2. Faulty load sensing pin 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 +8 volt sensor supply in H9, ch 22. A. If the value displayed is approximately 79, check for an intermittent circuit to the load sensing pin; repair or replace the harness as required. If the error re--occurs and no intermittent circuit is indicated, download the correct level of software. If the fault re--occurs, remove and replace the controller. B. If the value displayed is not approximately 79, continue to step 2. 2. Check for a short to +12 volts. A. Disconnect the connectors MOD--1/3 (1B) and MOD--1/3 (1A) of the controller and the connectors SEN--221 and SEN--225 of both load sensing pins. Turn the key start ON. Check between: SEN--221 pin 3 wire 1.0 (B) and ground SEN--221 pin 2 wire 1.0 (HV) and ground SEN--221 pin 1 wire 1.0 (BR) and ground SEN--225 pin 3 wire 1.0 (B) and ground SEN--225 pin 2 wire 1.0 (CV) and ground SEN--225 pin 1 wire 1.0 (BR) and ground If a voltage is indicated, repair or replace the harness as required. B. If harness okay, continue to step 3. 3. Replace the load sensing pin(s). A. Remove and replace the load sensing pin(s). B. If the error re--occurs, refit the old load sensing pins and download the correct level of software. If the fault re--occurs, remove and replace the controller.
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ERROR CODE 1021 -- SENSITIVITY CONTROL POTENTIOMETER SIGNAL TOO LOW (SHORT OR OPEN CIRCUIT) Possible fault modes: 1. Faulty connector 2. Faulty draft sensitivity 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 drop rate control potentiometer in H9, ch 36. A. Turn the draft sensitivity control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 84 to 14, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 36 wiggle the harness and the EDC control panel connector MOD--53 and the controller harness connectors MOD--1/3 (1B) and MOD--1/3 (1A) 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 draft sensitivity control potentiometer. A. Remove the EDC control panel and disconnect the connector MOD--53. While turning the load sensitivity control knob fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel side between: MOD--53 pin 8 and MOD--53 pin 5 MOD--53 pin 7 and MOD--53 pin 5 If the resistances indicated are not between 90 and 360 ohm (with slip control) and between 170 and 520 ohm (without slip control), replace the EDC control panel. B. If the EDC control panel is okay, continue to step 3. 3. Check for a short to ground. A. Check between: MOD--53 pin 5 wire 0.5 (R) and ground MOD--53 pin 8 wire 0.5 (S) 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 4. 4. Check for an open circuit. A. Disconnect the connectors MOD--1/3 (1B) and MOD--1/3 (1A) of the controller. Check between: MOD--1/3 (1A) pin 23 wire 1.0 (BR) and MOD--53 pin 7 wire 0.5 (BR) MOD--1/3 (1B) pin 6 wire 0.5 (R) and MOD--53 pin 5 wire 0.5 (R) MOD--1/3 (1B) pin 17 wire 0.5 (S) and MOD--53 pin 8 wire 0.5 (S) 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.
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ERROR CODE 1022 -- SENSITIVITY CONTROL POTENTIOMETER SIGNAL TOO HIGH (SHORT TO + 12 VOLT) Possible fault modes: 1. Faulty connector 2. Faulty draft sensitivity 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 draft sensitivity control potentiometer in H9, ch. 36. A. Turn the draft sensitivity control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 84 to 14, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 34 wiggle the harness and the EDC control panel connector MOD--53, the connectors MOD--1/3 (1B) and MOD--1/3 (1A) of the controller wiring 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 draft sensitivity potentiometer. A. Remove the EDC control panel and disconnect the connector MOD--53. While turning the drop rate control knob fully clockwise and then fully counter clockwise, measure the resistance between: MOD--53 pin 8 and MOD--53 pin 5 MOD--53 pin 7 and MOD--53 pin 5 If the resistances indicated are not between 90 and 360 ohm (with slip control) and between 170 and 520 ohm (without slip control), replace the control panel. B. If the EDC control panel is okay, continue to step 3. 3. Check for a short to +8 or +12 Volts. A. Turn the key start ON. Measure the voltage, with the panel disconnected, between the connector: MOD--53 pin 8 wire 0.5 (S) and ground If the voltage indicated is greater than +5 volts, repair or replace the harness as required. B. If the voltage indicated is approximately +5 volts, continue to step 4. 4. Check for a short circuit with positive voltage. A. Measure the voltage between the connector: MOD--53 pin 5 wire 0.5 (R) 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.
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ERROR CODE 1023 -- CONTROL PANEL DISCONNECTED 1. Faulty connector 2. Faulty potentiometer panel 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 EDC potentiometer panel connector MOD--53, the connectors MOD--1/3 (1B) and MOD--1/3 (1A) 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 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 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.
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ERROR CODE 1024 -- CALIBRATE THE HYDRAULIC LIFT 1. 2. 3. 4.
Replace arm lift potentiometer Replace solenoid valve Replace control unit 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. Perform the hydraulic lift calibration procedure NOTE: For the calibration procedure, please refer to chapter 10 in this section.
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ERROR CODE 1025 -- POSITION CONTROL POTENTIOMETER CONTROL VOLTAGE TOO LOW (SHORT OR OPEN CIRCUIT) Possible fault modes: 1. Faulty connector 2. Faulty position 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 position control potentiometer for any damage. A. If the potentiometer is damaged, remove and replace the potentiometer. B. If the potentiometer is okay, continue to step 2. 2. Check the position control potentiometer in H9, Channel 33. A. Fully lower and then raise the position control potentiometer. If the values displayed are not between 25 to 74, continue to step 3. B. If the values displayed are okay, while still in H9 Channel 33, wiggle the harness and the EDC control unit connector MOD--1/3 (1B) and MOD--1/3 (1A) and the EDC control panel connector MOD--54 to check for an intermittent circuit. Channel 33 values will change if an intermittent circuit is detected; repair or replace as necessary. 3. Check the position control potentiometer. A. Disconnect the connector MOD--54 of the EDC control panel. While moving the position control potentiometer from the minimum to maximum position, measure the resistance between the component side of connector: MOD--54 pin A and MOD--54 pin C MOD--54 pin A and MOD--54 pin D If the indicated values are not between 100 and 600 ohm, remove and replace the EDC control unit. B. If the EDC control unit is okay, continue to step 4. 4. Check for a short to ground. A. Check between: MOD--54 pin A wire 0.5 (LR) and ground MOD--54 pin C wire 0.5 (S) 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. Disconnect the connectors MOD--1/3 (1B) and MOD--1/3 (1A) of the controller. Check the EDC control panel for an open circuit. A. Check between: MOD--54 pin A wire 0.5 (LR) and MOD--1/3 (1B) pin 3 wire 0.5 (LR) MOD--54 pin C wire 0.5 (S) and MOD--1/3 (1B) pin 17 wire 0.5 (S) MOD--54 pin D wire 0.5 (BR) and MOD--1/3 (1A) pin 23 wire 1.0 (BR) If an open circuit is indicated, remove and replace the EDC control panel. B. If the harness is okay, download the correct level of software. If the fault re--occurs, remove and replace the controller.
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ERROR CODE 1026 -- POSITION CONTROL POTENTIOMETER CONTROL VOLTAGE TOO HIGH (SHORT TO + 12 VOLT) Possible fault modes: 1. Faulty connector 2. Faulty position 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 position control potentiometer for any damage. A. If the potentiometer is damaged, remove and replace the potentiometer. B. If the potentiometer is okay, continue to step 2. 2. Check the position control potentiometer in H9, Channel 33. A. Fully lower and then raise the position control potentiometer. If the values displayed are not between 25 to 74, continue to step 3. B. If the values displayed are okay, while still in H9 Channel 33, wiggle the harness and the EDC control unit connector MOD--1/3 (1B) and MOD--1/3 (1A) and the EDC control panel connector MOD--54 to check for an intermittent circuit. Channel 33 values will change if an intermittent circuit is detected; repair or replace as necessary. 3. Check the position control potentiometer. A. Disconnect the connector MOD--54. While moving the position control potentiometer from the minimum to maximum position, measure the resistance between the component side of connector: MOD--54 pin A and MOD--54 pin C MOD--54 pin A and MOD--54 pin D If the indicated values are not between 100 and 600 ohm, remove and replace the EDC control unit. B. If the EDC control unit is okay, continue to step 4. 4. Check for a short to +8 or +12 Volts. A. Turn the key start ON. Measure the voltage between the connector: MOD--54 pin C wire 0.5 (S) and ground If the voltage indicated is greater than +5 volts, repair or replace the harness as required. B. If the voltage indicated is approximately +5 Volts, continue to step 5. 5. Check for a short circuit with positive voltage A. Measure the voltage between the connector: MOD--54 pin A wire 0.5 (LR) and ground If a voltage is indicated, remove and replace the EDC control panel. B. If the harness is okay, download the correct level of software. If the fault re--occurs, remove and replace the controller.
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ERROR CODE 1027 -- LIFT ARM POSITION SENSING CONTROL VOLTAGE LOW (SHORT OR OPEN CIRCUIT) Possible fault modes: 1. Faulty connector 2. Faulty lift arm position sensing 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 lift arm position sensing potentiometer and itâ&#x20AC;&#x2122;s linkage for any damage. A. If the potentiometer or linkage is damaged, repair or replace as required. B. If the potentiometer and the linkage is okay, continue to step 2. 2. Check the lift arm position sensing potentiometer in H9, Channel 32. A. Fully lower then raise the arms of the hydraulic lift (check that the vertical tie rods of the quick coupler do not limit the movement of the arms). If the values displayed are not between 79 to 6, continue to step 3. B. If the values displayed are okay, while still in H9 channel 32, wiggle the harness, the lift arm position potentiometer connector SEN--224, the transmission -- cab main connector C--2 and the controller connectors MOD--1/3 (1A) and MOD--1/3 (1B) to check for an intermittent circuit. Channel 32 values will change if an intermittent circuit is detected; repair or replace as necessary. 3. Check the lift arm position sensing potentiometer. A. Disconnect the connector SEN--224 and remove the potentiometer. While turning the potentiometer, measure the resistance between the component side of connector: SEN--224 pin 2 and SEN--224 pin 3 SEN--224 pin 2 and SEN--224 pin 1 If the indicated resistances are not within the range between 1.0 and 4.0 kohm, replace the lift arm position sensing potentiometer. B. If the values are okay, refit the potentiometer and continue to step 4. 4. Check for a short to ground. A. Check between (wire side): SEN--224 pin 2 wire 1.0 (BL) and ground SEN--224 pin 3 wire 1.0 (S) 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. Disconnect the connector MOD--1/3 (1A) and MOD--1/3 (1B) of the controller. Check between: SEN--224 pin 1 wire 1.0 (BR) and MOD--1/3 (1A) pin 23 wire 1.0 (BR) SEN--224 pin 2 wire 1.0 (BL) and MOD--1/3 (1B) pin 2 wire 1.0 (BL) SEN--224 pin 3 wire 1.0 (S) and MOD--1/3 (1B) pin 17 wire 0.5 (S) 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.
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ERROR CODE 1028 -- LIFT ARM POSITION SENSING CONTROL VOLTAGE HIGH (SHORT TO + 12 VOLT) Possible fault modes: 1. Faulty connector 2. Faulty lift arm position sensing 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 lift arm position sensing potentiometer and itâ&#x20AC;&#x2122;s linkage for any damage. A. If the potentiometer or linkage is damaged, repair or replace as required. B. If the potentiometer and the linkage is okay, continue to step 2. 2. Check the lift arm position sensing potentiometer in H9, Channel 32. A. Fully lower then raise the arms of the hydraulic lift (check that the vertical tie rods of the quick coupler do not limit the movement of the arms). If the values displayed are not between 79 to 6, continue to step 3. B. If the values displayed are okay, while still in H9 channel 32, wiggle the harness, the lift arm position potentiometer connector SEN--224, the transmission -- cab main connector C--2 and the controller connectors MOD--1/3 (1A) and MOD--1/3 (1B) to check for an intermittent circuit. Channel 32 values will change if an intermittent circuit is detected; repair or replace as necessary. 3. Check the lift arm position sensing potentiometer. A. Disconnect the connector SEN--224 and remove the potentiometer. While turning the potentiometer, measure the resistance between the component side of connector: SEN--224 pin 2 and SEN--224 pin 3 SEN--224 pin 2 and SEN--224 pin 1 If the indicated resistances are not within the range between 1.0 and 4.0 kohm, replace the lift arm position sensing potentiometer. B. If the values are okay, refit the potentiometer and continue to step 4. 4. Check for a short to +8 or +12 Volts. A. Turn the key start ON. Measure the voltage between the connector: SEN--224 pin 3 wire 1.0 (S) and ground If the voltage indicated is greater than +5 volts, repair or replace the harness as required. B. If the voltage indicated is approximately +5 Volts, continue to step 5. 5. Check for a short circuit with positive voltage A. Measure the voltage between the connector: SEN--224 pin 2 wire 1.0 (BL) and ground If a voltage is indicated, remove and replace the EDC control panel. B. If the harness is okay, download the correct level of software. If the fault re--occurs, remove and replace the controller.
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ERROR CODE 1029 -- HYDRAULIC CONTROL VALVE DISCONNECTED Possible fault modes: 1. Faulty connector 2. Wiring harness faulty 3. Faulty hydraulic control valve solenoid 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 the hydraulic control valve solenoid connectors SOL--222 and SOL--223, the transmission -- cab main connector C2 and the connectors MOD--1/3 (1A) and MOD--1/3 (2) 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. Visibly check the harness any damage. A. Check the harness from the controller connectors MOD--1/3 (1A) and MOD--1/3 (2) to the hydraulic control valve connectors SOL--222 and SOL--223 via the main connector C2 for damage. If damage to the harness 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.
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ERROR CODE 1030 -- BREAK IN THE GROUND CIRCUIT 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 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 the controller connector MOD--1/3 (1A), transmission -- cab main connector C--2, clutch pedal potentiometer connector RES--156, oil temperature sensor connector SEN--201, theoretical speed sensor connector SEN--217, EDC mouse connector MOD--54, arms lift potentiometer connector SEN--224, potentiometer panel MOD--53, and the right and left draft sensing pins SEN--221 and SEN--225. 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 for an open circuit. A. Disconnect the connectors MOD--1/3 (1A), MOD--54, RES--156, SEN--201, SEN--217, SEN--224, MOD--53, SEN--221 and SEN--225. Check between: MOD--1/3 (1A) wire 1.0 (BR) and MOD--54 pin D wire 0.5 (BR) MOD--1/3 (1A) wire 1.0 (BR) and RES--156 pin 1 wire 0.5 (BR) MOD--1/3 (1A) wire 1.0 (BR) and SEN--201 pin A wire 1.0 (BR) MOD--1/3 (1A) wire 1.0 (BR) and SEN--217 pin 2 wire 1.0 (BR) MOD--1/3 (1A) wire 1.0 (BR) and SEN--224 pin 1 wire 1.0 (BR)) MOD--1/3 (1A) wire 1.0 (BR) and MOD--53 pin 7 wire 0.5 (BR)) MOD--1/3 (1A) wire 1.0 (BR) and SEN--221 pin 1 wire 1.0 (BR)) MOD--1/3 (1A) wire 1.0 (BR) and SEN--225 pin 1 wire 1.0 (BR)) 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.
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ERROR CODE 1031 -- CHASSIS HARNESS DISCONNECTED 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 the chassis harness connectors C--2. 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 chassis harness connector is 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.
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ERROR CODE 1032 -- DRAFT CONTROL POTENTIOMETER CONTROL VOLTAGE HIGH (SHORT TO + 12 VOLT) Possible fault modes: 1. Faulty connector 2. Faulty draft 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 draft control potentiometer for any damage. A. If the potentiometer is damaged, remove and replace the potentiometer. B. If the potentiometer is okay, continue to step 2. 2. Check the draft control potentiometer in H9 Channel 40. A. Fully lower and then raise the draft control potentiometer. If the values displayed are not between 14 and 89, continue to step 3. B. If the values displayed are okay, while still in H9 Channel 40, wiggle the harness, the EDC control unit connector MOD--1/3 (1B) and MOD--1/3 (1A) and the EDC control panel connector MOD--54 to check for an intermittent circuit. Channel 33 values will change if an intermittent circuit is detected; Repair or replace as necessary. 3. Check the draft control potentiometer. A. Disconnect the connector MOD--54. While moving the position control potentiometer from the minimum to maximum position, measure the resistance between the component side of connector: MOD--54 pin B and MOD--54 pin C MOD--54 pin B and MOD--54 pin D If the indicated values are not between 100 and 600 ohm, remove and replace the EDC control unit. B. If the EDC control unit is okay, continue to step 4. 4. Check for a short to +8 or +12 Volts. A. Turn the key start ON. Measure the voltage between the connector: MOD--54 pin C wire 0.5 (S) and ground If the voltage indicated is greater than +5 volts, repair or replace the harness as required. B. If the voltage indicated is approximately +5 Volts, continue to step 5. 5. Check for a short circuit with positive voltage A. Measure the voltage between the connector: MOD--54 pin B wire 0.5 (SB) and ground If a voltage is indicated, remove and replace the EDC control panel. B. If the harness is okay, download the correct level of software. If the fault re--occurs, remove and replace the controller.
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ERROR CODE 1033 -- DRAFT CONTROL POTENTIOMETER CONTROL VOLTAGE LOW (SHORT OR OPEN CIRCUIT) Possible fault modes: 1. Faulty connector 2. Faulty draft 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 position control potentiometer for any damage. A. If the potentiometer is damaged, remove and replace the potentiometer. B. If the potentiometer is okay, continue to step 2. 2. Check the position control potentiometer in H9, Channel 40. A. Fully lower and then raise the position control potentiometer. If the values displayed are not between 14 and 89, continue to step 3. B. If the values displayed are okay, while still in H9 Channel 40, wiggle the harness, the EDC control unit connector MOD--1/3 (1B) and MOD--1/3 (1A) and the EDC control panel connector MOD--54 to check for an intermittent circuit. Channel 33 values will change if an intermittent circuit is detected; Repair or replace as necessary. 3. Check the draft control potentiometer. A. Disconnect the connector MOD--54 of the EDC control panel. While moving the position control potentiometer from the minimum to maximum position, measure the resistance between the component side of connector: MOD--54 pin B and MOD--54 pin C MOD--54 pin B and MOD--54 pin D If the indicated values are not between 100 and 600 ohm, remove and replace the EDC control unit. B. If the EDC control unit is okay, continue to step 4. 4. Check for a short to ground. A. Check between: MOD--54 pin B wire 0.5 (SB) and ground MOD--54 pin C wire 0.5 (S) 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. Disconnect the connectors MOD--1/3 (1B) and MOD--1/3 (1A) of the controller. Check the EDC control panel for an open circuit. A. Check between: MOD--54 pin B wire 0.5 (SB) and MOD--1/3 (1B) pin 3 wire 0.5 (SB) MOD--54 pin C wire 0.5 (S) and MOD--1/3 (1B) pin 17 wire 0.5 (S) MOD--54 pin D wire 0.5 (BR) and MOD--1/3 (1A) pin 23 wire 1.0 (BR) If an open circuit is indicated, remove and replace the EDC control panel. B. If the harness is okay, download the correct level of software. If the fault re--occurs, remove and replace the controller.
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ERROR CODE 1049 -- WHEEL SPEED SENSOR OPEN OR SHORT CIRCUIT Possible causes include: 1. 2. 3. 4.
Faulty connector Faulty wheel speed sensor Wiring harness faulty 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 wheel speed sensor connector SEN--217, the controller connectors MOD--1/3 (1B) and MOD--1/3 (3A) and the transmission -- cab main connector C--2 of the in--line harness. 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 2. 2. Check the wheel speed sensor. A. Disconnect the connector C046. Measure the resistance between: SEN--217 pin 1 and 2. If the resistance indicated is not between 0.80K Ohms -- 1.2K Ohms at 20 degrees centigrade, remove and replace the wheel speed sensor. B. If the wheel speed sensor is okay, continue to step 3. 3. Check for an open circuit. A. Disconnect the connectors MOD--1/3 (1B) and MOD--1/3 (3A) of the controller. Check between: SEN--217 pin 1 wire 1.0 (HB) and MOD--1/3 (1B) pin 34 wire 0.5 (HB) SEN--217 pin 2 wire 1.0 (BR) and MOD--1/3 (3A) pin 23 wire 1.0 (BR) 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 a short to ground. A. Check between: SEN--217 pin 1 wire 1.0 (HB) and ground SEN--217 pin 2 wire 1.0 (BR) 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 of software. If the fault re--occurs, remove and replace the controller.
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ERROR CODE 1053 -- CONTROLLER 5 VOLT REFERENCE SHORTED TO POSITIVE VOLTAGE Possible fault modes: 1. Wiring fault 2. Control unit (XCM) trouble 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 the +5 volt sensor supply reference in H9, ch 21. A. If the value displayed is not approximately 49, continue to step 3. B. If the value displayed is approximately 49, while still in H9, ch 5 wiggle the harness, the EDC control unit connectors MOD--1/3 (1B) and MOD--1/3 (3A), the EDC control panel connector MOD--54 and MOD--53, the connector SEN--224 of the arm lift potentiometer C--2 of the transmission--cab main wiring, the shuttle lever connector SW--79, the range and gear lever position sensing button connectors SW--209, SW--210 and SW--211, the clutch pedal potentiometer connector RES--156 to check for an intermittent circuit. Channel 5 values will change if an intermittent circuit is detected; Repair or replace as necessary. 3. Check for a short to +8 or +12 Volts. A. Disconnect the connector of the control unit (XCM) MOD--1/3 (1B). Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: MOD--1/3 (1B) pin 17, wire 0.5 (S) 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 (XCM).
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ERROR CODE 1054 -- CONTROLLER 5 VOLT REFERENCE SHORTED TO GROUND Possible fault modes: 1. Wiring fault 2. Control unit (XCM) trouble 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 the +5 Volt sensor supply reference in H9 Channel 21. A. If the value displayed is not approximately 49, continue to step 3. B. If the value displayed is approximately 49, while still in H9, ch 5 wiggle the harness, the EDC control unit connectors MOD--1/3 (1B) and MOD--1/3 (3A), the EDC control panel connector MOD--54 and MOD--53, the connector SEN--224 of the arm lift potentiometer C--2 of the transmission--cab main wiring, the shuttle lever connector SW--79, the range and gear lever position sensing button connectors SW--209, SW--210 and SW--211, the clutch pedal potentiometer connector RES--156 to check for an intermittent circuit. Channel 5 values will change if an intermittent circuit is detected; Repair or replace as necessary. 3. Check for a short to ground. A. Disconnect the connector MOD--1/3 (1B). Check between the connector: MOD--1/3 (1B) pin 17 wire 0.5 (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 of software. If the fault re--occurs, remove and replace the controller.
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ERROR CODE 1059 -- REFERENCE VOLTAGE TO 8 VOLT LOAD SENSING PINS, TOO HIGH (> +9V), TOO LOW (< +7V) 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 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 the +8 volt sensor supply reference in H9, ch 22. A. If the value displayed is not approximately 79, continue to step 3. B. If the value displayed is approximately 79, while still in H9, ch 22, wiggle the harness, draft pin connector SEN--221 and SEN--225, connectors MOD--1/3 (1B) and MOD--1/3 (3A) and the transmission -- cab main connector C--2, to check for an intermittent circuit. Channel 22 values will change if an intermittent circuit is detected; Repair or replace as necessary. 3. Check for a short to + 12 Volt. A. Disconnect the connectors SEN--221 and SEN--225. Turn the key ON, check between: SEN--221 pin 3 wire 1.0 (B) and ground SEN--224 pin 3 wire 1.0 (B) and ground If a short to +12 Volt is detected, turn the key OFF. Disconnect the connector of the controller MOD--1/3 (1B). Turn key ON. If a voltage is still indicated, repair or replace the harness as required. B. If there is no short to + 12 Volt, continue to step 4. 4. Check for a short to ground. A. Check between: SEN--221 pin 3 wire 1.0 (B) and ground SEN--224 pin 3 wire 1.0 (B) 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 open circuit. A. Check between: SEN--221 pin 3 wire 1.0 (B) and MOD--1/3 (1B) pin 25 wire 1.0 (B) SEN--224 pin 3 wire 1.0 (B) and MOD--1/3 (1B) pin 25 wire 1.0 (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 fault re--occurs, remove and replace controller.
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ERROR CODE 1063 -- EDC HYDRAULIC VALVE LOWER SOLENOID OPEN CIRCUIT Possible fault modes: 1. Faulty connector 2. Faulty EDC valve lower solenoid 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 EDC valve lowering solenoid connector SOL--223, the transmission -- cab main connector C--2 and the connectors MOD--1/3 (1A) and MOD--1/3 (2) 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 2. 2. Check the EDC valve lower solenoid. A. Disconnect the connector SOL--223 of the EDC valve lowering solenoid valve. Measure the resistance between the terminals of the solenoid valve. If the resistance indicated is not approximately 2 Ohms, remove and replace the EDC valve lower solenoid. B. If the solenoid valve is okay continue to step 2. 3. Check for a short to ground. A. Check between the connector: SOL--223 pin 1 wire 1.0 (A) 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 4. 4. Check for a short to ground. A. Disconnect the connector MOD--1/3 (2) of the controller. Check between the connector: SOL--223 pin 2 wire 1.0 (AR) 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. Disconnect the connector MOD--1/3 (1A) of the controller. Check between: SOL--223 pin 2 wire 1.0 (AR) and MOD--1/3 (2) pin 5 wire 1.0 (AR) SOL--223 pin 1 wire 1.0 (A) and MOD--1/3 (1A) pin 12 wire 1.0 (A) If an open circuit is indicated, repair or replace the harness as required. C. If the harness is okay, download the correct level of software. If the fault re--occurs, remove and replace the controller.
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ERROR CODE 1064 -- EDC HYDRAULIC VALVE RAISE SOLENOID OPEN CIRCUIT Possible fault modes: 1. Faulty connector 2. Faulty EDC valve raise solenoid 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 EDC valve raising solenoid connector SOL--222, the transmission -- cab main connector C--2 and the connectors MOD--1/3 (1A) and MOD--1/3 (2) 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 2. 2. Check the EDC valve raise solenoid. A. Disconnect the connector SOL--222 of the EDC valve lifting solenoid valve. Measure the resistance between the terminals of the solenoid valve. If the resistance indicated is not approximately 2 Ohms, remove and replace the EDC valve lower solenoid. B. If the solenoid valve is okay continue to step 2. 3. Check for a short to ground. A. Check between the connector: SOL--222 pin 1 wire 1.0 (SB) 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 4. 4. Check for a short to ground. A. Disconnect the connector MOD--1/3 (2) of the controller. Check between the connector: SOL--222 pin 2 wire 1.0 (AG) 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. Disconnect the connector MOD--1/3 (1A) of the controller. Check between: SOL--222 pin 2 wire 1.0 (AG) and MOD--1/3 (2) pin 4 wire 1.0 (AG) SOL--222 pin 1 wire 1.0 (SB) and MOD--1/3 (1A) pin 5 wire 1.0 (SB) If an open circuit is indicated, repair or replace the harness as required. C. If the harness is okay, download the correct level of software. If the fault re--occurs, remove and replace the controller.
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ERROR CODE 1065 -- EDC HYDRAULIC VALVE LOWER SOLENOID SHORT CIRCUIT Possible fault modes: 1. Faulty connector 2. Faulty EDC valve lower solenoid 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 EDC valve lowering solenoid connector SOL--223, the transmission -- cab main connector C--2 and the connectors MOD--1/3 (1A) and MOD--1/3 (2) 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 2. 2. Check the EDC valve lower solenoid. A. Disconnect the connector SOL--223 of the EDC valve lowering solenoid valve. Measure the resistance between the terminals of the solenoid valve. If the resistance indicated is not approximately 2 Ohms, remove and replace the EDC valve lower solenoid. B. If the solenoid valve is okay, continue to step 3. 3. Check for a short circuit with positive voltage. A. Turn the key start ON. Measure the voltage between the connector: SOL--223 pin 2 wire 1.0 (AR) 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. 4. Check for a short circuit with positive voltage. A. Turn the Keystart OFF. Disconnect the connector MOD--1/3 (1A) of the controller. Turn the key start ON. Measure the voltage between the connector: SOL--223 pin 1 wire 1.0 (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.
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 1066 -- EDC HYDRAULIC VALVE RAISE SOLENOID SHORT CIRCUIT Possible fault modes: 1. Faulty connector 2. Faulty EDC valve raise solenoid 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 EDC valve raising solenoid connector SOL--222, the transmission -- cab main connector C--2 and the connectors MOD--1/3 (1A) and MOD--1/3 (2) 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 2. 2. Check the EDC valve raise solenoid. A. Disconnect the connector SOL--222 of the EDC valve lifting solenoid valve. Measure the resistance between the terminals of the solenoid valve. If the resistance indicated is not approximately 2 Ohms, remove and replace the EDC valve lower solenoid. B. If the solenoid valve is okay, continue to step 3. 3. Check for a short circuit with positive voltage. A. Turn the key start ON. Measure the voltage between the connector: SOL--222 pin 2 wire 1.0 (AG) 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. 4. Check for a short circuit with positive voltage. A. Turn the Keystart OFF. Disconnect the connector MOD--1/3 (1A) of the controller. Turn the key start ON. Measure the voltage between the connector: SOL--222 pin 1 wire 1.0 (SB) 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.
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
75
ERROR CODE 1067 -- EDC CONTROL VALVE SUPPLY VOLTAGE LOW Possible fault modes: 1. Wiring harness faulty 2. 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 +12 Volt reference voltage in H9, ch 4. A. If the value displayed is approximately 45, continue to test for error codes 1063, 1064, 1065 and 1066. B. If the value displayed is not approximately 45, continue to step 2. 2. Check for +12 Volts at fuse F04 (5A). A. Turn the key start ON. Measure the voltage at fuse F04 (5A). If the voltage indicated is approximately +12 volt, continue to step 3. B. If the voltage indicated is not okay, check the supply from the battery to fuse F04 (5A). 3. Check for an open circuit. A. Turn the Keystart OFF. Disconnect the connector MOD--1/3 (1A) of the controller. Check between the connector: MOD--1/3 (1A) pin 20 wire 1.0 (RV) and F04 (5A) wire 1.5 (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.
87679925A1 - 02 - 2008
76
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 1068 -- HEIGHT LIMIT CALIBRATION ERROR Possible fault modes: 1. Calibration was done incorrectly Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. NOTE: If the height limit control has not been turned fully clockwise to the maximum height position, this error code will be displayed. 1. Turn the height limit control to the maximum height position when performing the hydraulic lift calibration procedure. NOTE: For the calibration procedure, please refer to chapter 10 ”HH MENU AND CALIBRATIONS” in this section.
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
77
ERROR CODE 1069 -- SLIP CONTROL CONFIGURATION ERROR Possible fault modes: 1. Slip option present but not configured Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Enter the H3 diagnostics program, select the lift option, enter ch 3 with the hours or minutes buttons, select ”YES” then save with the brightness control button.
87679925A1 - 02 - 2008
78
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 WIRING DIAGRAMS 17 -- 18
MPM1174A
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Pin
Col.
Sect.
Pin
Col.
Sect.
1
C
1.0
14
R
1.0
2
C
1.0
15
G
0.75
3
--
--
16
V
0.75
4
AG
1.0
17
--
--
5
SB
1.0
18
--
--
6
LR
1.0
19
N
1.0
7
GR
1.0
20
RV
1.0
8
RN
0.5
21
--
--
9
MN
0.5
22
--
--
10
--
--
23
BR
1.0
11
LG
1.0
24
--
--
12
A
1.0
25
N
1.0
13
--
--
26
N
1.0
79
7
1
26
20
MOD--1/3 (1A)
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
Pin
Col.
Sect.
Pin
Col.
Sect.
1
ZB
0.5
14
--
--
2
--
--
15
--
--
3
MN
0.5
16
--
--
4
VB
0.5
17
--
--
5
MB
0.5
18
C
0.5
6
A
0.5
19
--
--
7
H
0.5
20
--
--
8
SB
0.5
21
--
--
9
--
--
22
--
--
10
L
0.5
23
--
--
11
CA
0.5
24
CB
0.5
12
H
0.5
25
--
--
13
MZ
0.5
26
MN
0.5
7
1
26
20
MOD--1/3 (3A)
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
80
Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
18
VN
0.5
2
BL
0.5
19
RN
0.5
3
LR
0.5
20
MB
0.5
4
GR
0.5
21
BV
0.5
5
SN
0.5
22
HN
0.5
1
9
6
R
0.5
23
N
0.5
10
17
7
LG
0.5
24
B
0.5
18
25
26
34
8
SB
0.5
25
B
1.0
9
HV
1.0
26
--
--
10
GV
1.0
27
--
--
11
--
--
28
NB
0.5
12
H
0.5
29
RL
0.5
13
MB
0.5
30
RB
0.5
14
M
0.5
31
--
--
15
--
--
32
--
--
16
--
--
33
MV
0.5
17
S
0.5
34
HB
0.5
MOD--1/3 (1B)
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
14
--
--
2
--
--
15
--
--
3
--
--
16
--
--
4
AG
1.0
17
--
--
5
AR
1.0
18
--
--
6
--
--
19
CL
0.5
7
--
--
20
--
--
8
--
--
21
N
0.5
9
--
--
22
--
--
10
--
--
23
--
--
11
S
0.5
24
SN
0.5
12
--
--
25
SB
0.5
13
--
--
26
N
0.5
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
87679925A1 - 02 - 2008
7
1
26
20
MOD--1/3 (2)
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Pin
Col.
Sect.
Pin
Col.
Sect.
1
BG
0.5
26
HB
0.5
2
BN
1.0
27
HN
0.5
3
AG
1.0
28
H
1.0
4
AN
1.0
29
MB
0.5
5
LG
1.0
30
MN
0.5
6
LN
1.0
31
VB
0.5
7
LR
1.0
32
NG
1.0
8
LV
1.0
33
BR
1.0
9
GR
1.0
34
ZB
1.0
10
GV
1.0
35
ZB
11
AV
1.0
36
12
RG
1.0
13
--
--
81
41
31
21
11
1
42
32
22
12
2
43
33
23
13
3
1.0
44
34
24
14
4
S
1.0
45
35
25
15
5
37
--
--
46
36
26
16
6
47
37
27
17
7
38
RV
1.0
48
38
28
18
8
49
39
29
19
9
50
40
30
20
10
14
L
1.0
39
RN
0.5
15
B
1.0
40
MV
0.5
16
GN
1.0
41
--
--
17
G
1.5
42
SB
1.0
18
R
1.0
43
AG
1.0
19
BV
0.5
44
A
1.0
20
NB
0.5
45
AR
1.0
21
--
--
46
S
0.5
22
--
--
47
B
1.0
23
--
--
48
BL
0.5
24
SN
1.0
49
GV
1.0
25
M
0.5
50
HV
1.0
C--2
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE Pin
Col.
Sect.
Pin
Col.
Sect.
1
GR
0.5
5
R
0.5
2
SN
0.5
6
LG
0.5
3
--
--
7
BR
0.5
4
--
--
8
S
0.5
MOD--53
5
8
1
4
For model with cab, version with Power Shuttle and Electronic Lift
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
82
Pin
Col.
Sect.
Pin
Col.
Sect.
A
LR
0.5
E
MB
0.5
B
SB
0.5
F
RV
0.5
C
S
0.5
G
VN
0.5
D
BR
0.5
H
A
0.5
For model with cab, version with Power Shuttle and Electronic Lift
Pin
Col.
Sect.
Pin
Col.
Sect.
1
BR
0.5
3
S
0.5
2
H
0.5
--
--
--
For model with cab, version with Power Shuttle and Electronic Lift
MOD--54
E
F
G
H
D
C
B
A
RES--156
3
2
1
For model without cab, standard version
Pin
Col.
Sect.
Pin
Col.
Sect.
1
RV
0.5
4
RB
0.5
2
--
--
5
RL
0.5
SW--164
1
For model with cab, version with Power Shuttle and Electronic Lift 4
Pin
Col.
Sect.
Pin
Col.
Sect.
1
RV
0.5
4
RB
0.5
2
--
--
5
RL
0.5
3
--
--
--
--
--
5
SW--167
1
For model with cab, version with Power Shuttle and Electronic Lift
87679925A1 - 02 - 2008
4
5
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Pin
Col.
Sect.
1
HB
1.0
2
BR
1.0
Pin
Col.
Sect.
83
SEN--217
For model fitted with Power Shuttle and Electronic Lift
Pin
Col.
Sect.
1
BR
1.0
3
B
1.0
2
HV
1.0
--
--
--
Pin
Col.
Sect.
1
SB
1.0
2
AG
1.0
Pin
Col.
Sect.
3
3
2
For model fitted with Power Shuttle and Electronic Lift
SEN--221
1
Sect.
2
Col.
1
Pin
SOL--222
For model fitted with Power Shuttle and Electronic Lift
Pin
Col.
Sect.
1
A
1.0
2
AR
1.0
Pin
Col.
Sect.
SOL--223
For model fitted with Power Shuttle and Electronic Lift
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Pin
Col.
Sect.
Pin
Col.
Sect.
1
BR
1.0
3
S
1.0
2
BL
1.0
--
--
--
SEN--224
1
For model fitted with Power Shuttle and Electronic Lift
Sect.
Pin
Col.
Sect.
1
BR
1.0
3
B
1.0
2
GV
1.0
--
--
--
SEN--225
Pin
Col.
Sect.
Pin
Col.
Sect.
1
N
1.0
3
RN
1.0
2
MV
1.0
4
RV
1.0
3
2
1
87679925A1 - 02 - 2008
SEN--227
4
For model fitted with Power Shuttle and Electronic Lift
3
3
2
1
For model fitted with Power Shuttle and Electronic Lift
1
Col.
2
Pin
3
3
2
2
1
84
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
85
POWER SHUTTLE CIRCUIT -- DIAGRAM 17
MPM0760
87679925A1 - 02 - 2008
86 ELECTRONIC LIFT CIRCUIT (EDC) -- DIAGRAM 18
MPM0761
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
87
TRANSMISSION FAULT CODE LISTING FAULT CODE 2011
Clutch pedal potentiometer signal too low
E.C.R. (*) YES
2012
Clutch pedal potentiometer signal too high
YES
2014
Voltage from the gear neutral position switch is high
YES
2015
Voltage from the gear neutral position switch is low
YES
2016
Voltage from the range position switch (R1) is high
YES
2017
Voltage from the range position switch (R1) is low
YES
2018
Voltage from the range position switch (R2) is high
YES
2019
Voltage from the range position switch (R2) is low
YES
2021
Drive line harness disconnected
YES
2024
All the clutches must be calibrated
NO
2025
Engine speed (rpm) high
YES
2026
Clutch D not calibrated
NO
2027
Clutch C not calibrated
NO
2028
Clutch B not calibrated
NO
2029
Clutch A not calibrated
NO
2030
Critical code on transmission (**)
NO
2033
Pressure on clutch A would not decrease
NO
2035
Wheel speed too high
YES
2036
Engine speed (rpm) low
YES
2037
Clutch disconnect switch open circuit
YES
2038
Clutch B solenoid valve short to + 12 volts
NO
2039
Clutch B solenoid valve open circuit or short to ground
NO
2040
Inconsistent gear lever status switches
YES
2041
Clutch A solenoid valve open circuit or short to ground
NO
2042
Clutch A solenoid valve short to + 12 volts
NO
2043
Pressure on clutch B would not decrease
NO
2047
Clutch disconnect switch set too high
YES
2048
Clutch disconnect switch set too low
NO
2049
Wheel speed sensor voltage too high (12X12 and 24X24 version)
YES
2049
Voltage from the wheel speed sensor too high (20X20 version) (**)
YES
2051
Oil temperature sensor open circuit
YES
2052
Oil temperature sensor short circuit
YES
2053
5 volt reference voltage too high
NO
2054
5 volt reference voltage too low
NO
2055
Shuttle lever forward switch voltage high
YES
2056
Shuttle lever forward switch voltage low
YES
Description of Fault
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
88 2057
Shuttle lever reverse switch voltage high
YES
2058
Shuttle lever reverse switch voltage low
YES
2059
Shuttle Lever sw. disagree
YES
2061
No seat safety switch transition in the last 25 hours of work
NO
2065
Clutch C solenoid valve open circuit or short to ground
NO
2066
Clutch D solenoid valve open circuit or short to ground
NO
2067
Clutch D solenoid valve short to + 12 volts
NO
2068
Clutch C solenoid valve short to + 12 volts
NO
2069
Wheel speed sensor voltage too low (12X12 and 24X24 version)
YES
2069
Wheel speed sensor voltage too low (20X20 version) (**)
YES
2081
Clutch A safety pressure switch open circuit or short to ground
YES
2082
Clutch A safety pressure switch short circuit
YES
2083
Clutch B safety pressure switch open circuit or short to ground
YES
2084
Clutch B safety pressure switch short circuit
YES
2085
No supply to pressure switches for clutches A and B
NO
2090
YES
2092
Break in CAN communication between the ADIC and the XCM transmission control unit Short circuit to +12V from the clutch cut--out switch
2093
Short circuit to +12VF to the gear lever switch feed signal
YES
2094
Short circuit to ground to the gear lever switch feed signal
YES
2095
Clutch cut--out button jammed closed.
YES
2097
Short circuit to +12V to the discharge (dump) solenoid valve
NO
2098
Short circuit to ground or circuit open to the discharge (dump) solenoid valve
NO
2430
Creeper unit status switch voltage too low (**)
YES
2431
Creeper unit status switch voltage too high (**)
YES
2450
Configuration error (**)
NO
YES
(*) Enter the HH programs of the control panel select the H3 program, enter the ECR, then select the options: E -- show only severe codes, F -- show all codes for 6 minutes of power then pass to â&#x20AC;&#x153;Eâ&#x20AC;?. With option E selected, the word: YES -- means that the code will not be shown on the display but only kept in memory, NO -- means the code will not be shown on the display. (**) For the workflow for resolving these problems, see from page 235 onwards. NOTE: For the location of the components, connectors and the wiring diagrams, please refer to the end of the troubleshooting section from page 148 to page 167.
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
89
ERROR CODE 2011 -- CLUTCH PEDAL POTENTIOMETER SIGNAL LOW Cause: Short to ground or open circuit between the clutch pedal potentiometer and the control unit (XCM), or the potentiometer is faulty. Effects: If the error code occurs while driving it will disable the transmission. Cycling the shuttle lever will re--enable the transmission. The tractor may be used with the shuttle lever. If the clutch pedal is depressed the transmission will be disabled again until the shuttle lever has been cycled. Possible fault modes: 1. Faulty connectors 2. Clutch pedal potentiometer fault 3. Wiring fault 4. Control unit (XCM) trouble 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 1. A. Cycle clutch pedal. If the values displayed do not change continuously between 79 and 12, continue to step 2. B. If the values displayed are okay, while still in H9 channel 1, wiggle the harness, the clutch pedal potentiometer connector RES--156 and the connectors of the control unit (XCM) MOD1/3 (1A), MOD1/3 (3A) and MOD1/3 (1B) to check for an intermittent circuit. Channel 1 values will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check connectors RES--156, MOD1/3 (1A), MOD1/3 (3A) and MOD1/3 (1B). 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 the connector RES--156. While operating the clutch pedal, measure the resistance between the component side of connector: RES--156 pin 2 and pin 3 must indicate between 0.9 kOhm and 3.7 kOhm RES--156 pin 2 and pin 1 must indicate between 3.7 kOhm and 0.9 kOhm 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 MOD1/3 (1A), MOD1/3 (3A) and MOD1/3 (1B). Check between: RES--156 pin 1, wire 0.5 (BR) and MOD1/3 (1A) pin 23, wire 1.0 (BR) RES--156 pin 2, wire 0.5 (H) and MOD1/3 (3A) pin 7, wire 0.5 (H) RES--156 pin 3, wire 0.5 (S) and MOD1/3 (1B) pin 17, wire 0.5 (S) 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: RES--156 pin 2, wire 0.5 (H) 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 (XCM).
87679925A1 - 02 - 2008
90
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 2012 -- CLUTCH PEDAL POTENTIOMETER SIGNAL HIGH Cause: Short to ground or open circuit between the clutch pedal potentiometer and the control unit (XCM), or the potentiometer ground is an open circuit or the potentiometer is faulty. Effects: If the error code occurs while driving it will disable the transmission. Cycling the shuttle lever will re--enable the transmission. The tractor may be used with the shuttle lever. If the clutch pedal is depressed the transmission will be disabled again until the shuttle lever has been cycled. Possible fault modes: 1. Faulty connectors 2. Clutch pedal potentiometer fault 3. Wiring fault 4. Control unit (XCM) trouble 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 1. A. Cycle clutch pedal. If the values displayed do not change continuously between 79 and 12, continue to step 2. B. If the values displayed are okay, while still in H9 channel 1, wiggle the harness, the clutch pedal potentiometer connector RES--156 and the connectors of the control unit (XCM) MOD1/3 (1A), MOD1/3 (3A) and MOD1/3 (1B) to check for an intermittent circuit. Channel 1 values will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check connectors RES--156, MOD1/3 (1A), MOD1/3 (3A) and MOD1/3 (1B). 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 the connector RES--156. While operating the clutch pedal, measure the resistance between the component side of connector: RES--156 pin 2 and pin 3 must indicate between 0.9 kOhm and 3.7 kOhm RES--156 pin 2 and pin 1 must indicate between 3.7 kOhm and 0.9 kOhm 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 there is a short to positive. A. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between connector: RES--156 pin 2, wire 0.5 (H) and ground RES--156 pin 1, wire 0.5 (BR) and ground If 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 Volts. A. With the keystart ON. Measure the voltage between the connector: RES--156 pin 3, wire 0.5 (S) and ground If the indicated voltage is not approximately + 5 Volt, repair or replace the harness as required. B. If the voltage indicated is approximately +5 Volts, continue to step 6. 6. Check for an open circuit. A. Turn ignition switch to OFF position. Check between: RES--156 pin 1, wire 0.5 (BR) and ground 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 (XCM).
87679925A1 - 02 - 2008
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91
ERROR CODE 2014 -- VOLTAGE FROM THE GEAR NEUTRAL POSITION SWITCH IS HIGH Cause: Short to a voltage between the gear neutral position switch and the control unit (XCM), or the switch is faulty. Effects: Gear lever neutral position cannot be detected and is assumed to be in gear. A start request will be processed with the shuttle lever, but only if there is no wheel speed sensor error, otherwise the transmission will be disabled. Possible fault modes: 1. Faulty connectors 2. Faulty gear neutral position switch 3. Wiring fault 4. Control unit (XCM) trouble 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 neutral switch in H9, Channel 16. A. Operate the gear lever. If the values displayed do not change to approximately 67 in neutral and 30 in gear, continue to step 2. B. If the values displayed are okay, while still in H9 channel 16, wiggle the harness, the gear lever neutral switch connector SW--209, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (3A) and MOD--1/3 (1B) to check for an intermittent circuit. Channel 16 values will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check the gear neutral switch connector SW--209, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (3A) and MOD--1/3 (1B). 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 gear neutral position switch. A. Disconnect the connector SW--209. Measure the resistance between: SW--209 pin 1 and pin 2. With the gear lever in neutral, should indicate 560 Ohms. SW--209 pin 1 and pin 2. With the gear lever in gear, should indicate 2.76 kOhms. If the resistances indicated are not okay, remove and replace the gear neutral position switch. B. If the gear neutral position switch is okay, continue to step 4. 4. Check there is a short to positive. A. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: SW--209 pin 2, wire 1.0 (VB) and ground If 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 Volts. A. With the keystart ON. Measure the voltage between the connector: SW--209 pin 1, wire 1.0 (S) and ground If the indicated voltage is not approximately + 5 Volt, repair or replace the harness as required. B. If the voltage is approximately +5 Volts, download the correct level of software. If the error is repeated, remove and replace the control unit (XCM).
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ERROR CODE 2015 -- VOLTAGE FROM THE GEAR NEUTRAL POSITION SWITCH IS LOW Cause: Short to ground between the gear neutral position switch and the control unit (XCM), or the switch is faulty. Effects: Gear lever neutral position cannot be detected and is assumed to be in gear. A start request will be processed with the shuttle lever, but only if there is no wheel speed sensor error, otherwise the transmission will be disabled. Possible fault modes: 1. Faulty connectors 2. Faulty gear neutral position switch 3. Wiring fault 4. Control unit (XCM) trouble 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 neutral switch in H9, Channel 16. A. Operate the gear lever. If the values displayed do not change to approximately 67 in neutral and 30 in gear, continue to step 2. B. If the values displayed are okay, while still in H9 channel 16, wiggle the harness, the gear lever neutral switch connector SW--209, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (3A) and MOD--1/3 (1B) to check for an intermittent circuit. Channel 16 values will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check the gear neutral switch connector SW--209, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (3A) and MOD--1/3 (1B). 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 gear neutral position switch. A. Disconnect the connector SW--209. Measure the resistance between: SW--209 pin 1 and pin 2. With the gear lever in neutral, should indicate 560 Ohms. SW--209 pin 1 and pin 2. With the gear lever in gear, should indicate 2.76 kOhms. If the resistances indicated are not okay, remove and replace the gear neutral position switch. B. If the gear neutral position switch is okay, continue to step 4. 4. Check for an open circuit. A. Disconnect the connector MOD--1/3 (3A) and MOD--1/3 (1B). Check between: SW--209 pin 1, wire 1.0 (S) and MOD--1/3 (1B) pin 17, wire 0.5 (S) SW--209 pin 2, wire 1.0 (VB) and MOD--1/3 (3A) pin 4, wire 0.5 (VB) 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--1/3 (3A) pin 4, wire 0.5 (VB) 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 (XCM).
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ERROR CODE 2016 -- VOLTAGE FROM THE RANGE POSITION SWITCH (R1) IS HIGH Cause: Short to a voltage between the range position switch (R1) and the control unit (XCM), or the switch is faulty. Effects: Gear lever range position cannot be detected and is assumed to be in gear. A start request will be processed with the shuttle lever, but only if there is no wheel speed sensor error, otherwise the transmission will be disabled. Possible fault modes: 1. Faulty connectors 2. Faulty range position switch (R1) 3. Wiring fault 4. Control unit (XCM) trouble 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 (R1) in H9, channel 17. A. Operate the range lever. If the values displayed do not change to approximately 67 on engaging range II and III and 30 on engaging I and neutral, continue to step 2. B. If the values displayed are okay, while still in H9 channel 17, wiggle the harness, the range position switch connector (R1) SW--210, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (3A) and MOD--1/3 (1B) to check for an intermittent circuit. Channel 17 values will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check the range position switch connector (R1) SW--210, inline harness connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (3A) and MOD--1/3 (1B). 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 the range position switch (R1). A. Disconnect the connector SW--210. Measure the resistance between: SW--210 pin 1 and pin 2. With the gear lever in medium or high range, should indicate 560 Ohms. SW--210 pin 1 and pin 2. With the gear lever in neutral or low range, should indicate 2.76 kOhms. If the resistances indicated are not okay, remove and replace the range position switch. B. If the range position switch is okay, continue to step 3. 4. Check there is a short to positive. A. Turn key ON. Measure the voltage between the connector: SW--210 pin 2, wire 1.0 (MB) and ground If 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 Volts. A. With the keystart ON. Measure the voltage between the connector: SW--210 pin 1, wire 1.0 (S) and ground If the indicated voltage is not approximately + 5 Volt, repair or replace the harness as required. B. If the voltage is approximately +5 Volts, download the correct level of software. If the error is repeated, remove and replace the control unit (XCM).
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ERROR CODE 2017 -- VOLTAGE FROM THE RANGE POSITION SWITCH (R1) IS LOW Cause: Short to ground or open circuit between the range position switch (R1) and the control unit (XCM), or the switch is faulty. Effects: Gear lever range position cannot be detected and is assumed to be in gear. A start request will be processed with the shuttle lever, but only if there is no wheel speed sensor error, otherwise the transmission will be disabled. Possible fault modes: 1. Faulty connectors 2. Faulty range position switch (R1) 3. Wiring fault 4. Control unit (XCM) trouble 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 (R1) in H9, channel 17. A. Operate the range lever. If the values displayed do not change to approximately 67 on engaging range II and III and 30 on engaging I and neutral, continue to step 2. B. If the values displayed are okay, while still in H9 channel 17, wiggle the harness, the range position switch connector (R1) SW--210, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (3A) and MOD--1/3 (1B) to check for an intermittent circuit. Channel 17 values will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check the range position switch connector (R1) SW--210, inline harness connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (3A) and MOD--1/3 (1B). 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 the range position switch (R1). A. Disconnect the connector SW--210. Measure the resistance between: SW--210 pin 1 and pin 2. With the gear lever in medium or high range, should indicate 560 Ohms. SW--210 pin 1 and pin 2. With the gear lever in neutral or low range, should indicate 2.76 kOhms. If the resistances indicated are not okay, remove and replace the range position switch. B. If the range position switch is okay, continue to step 3. 4. Check for an open circuit. A. Disconnect the connectors MOD--1/3 (3A) and MOD--1/3 (1 B). Check between: SW--210 pin 1, wire 1.0 (S) and MOD--1/3 (1B) pin 17, wire 0.5 (S) SW--210 pin 2, wire 1.0 (MB) and MOD--1/3 (3A) pin 5, wire 0.5 (MB) 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--1/3 (3A) pin 5, wire 0.5 (MB) 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 (XCM).
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ERROR CODE 2018 -- VOLTAGE FROM THE RANGE POSITION SWITCH (R2) IS HIGH Cause: Short to a voltage between the range position switch (R2) and the control unit (XCM), or the switch is faulty. Effects: Gear lever range position cannot be detected and is assumed to be in gear. A start request will be processed with the shuttle lever, but only if there is no wheel speed sensor error, otherwise the transmission will be disabled. Possible fault modes: 1. Faulty connectors 2. Faulty range position switch (R2) 3. Wiring fault 4. Control unit (XCM) trouble 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 (R2) in H9, channel 18. A. Operate the range lever. If the values displayed do not change to approximately 67 on engaging range I and III and 30 on engaging range II and neutral, continue to step 2. B. If the values displayed are okay, while still in H9 channel 18, wiggle the harness, the range position switch connector (R1) SW--211, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (3A) and MOD--1/3 (1B) to check for an intermittent circuit. Channel 18 values will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check the range position switch connector (R2) SW--211, inline harness connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (3A) and MOD--1/3 (1B). 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 the range position switch (R2). A. Disconnect the connector SW--211. Measure the resistance between: SW--211 pin 1 and pin 2. With the gear lever in low or high range, should indicate 560 Ohms. SW--211 pin 1 and pin 2. With the gear lever in neutral or medium range, should indicate 2.76 kOhms. If the resistances indicated are not okay, remove and replace the range position switch. B. If the range position switch is okay, continue to step 3. 4. Check there is a short to positive. A. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: SW--211 pin 2, wire 1.0 (MN) and ground If 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 Volts. A. With the keystart ON. Measure the voltage between the connector: SW--211 pin 1, wire 1.0 (S) and ground If the indicated voltage is not approximately + 5 Volt, repair or replace the harness as required. B. If the voltage is approximately +5 Volts, download the correct level of software. If the error is repeated, remove and replace the control unit (XCM).
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ERROR CODE 2019 -- VOLTAGE FROM THE RANGE POSITION SWITCH (R2) IS LOW Cause: Short to ground or open circuit between the range position switch (R2) and the control unit (XCM), or the switch is faulty. Effects: Gear lever range position cannot be detected and is assumed to be in gear. A start request will be processed with the shuttle lever, but only if there is no wheel speed sensor error, otherwise the transmission will be disabled. Possible fault modes: 1. Faulty connectors 2. Faulty range position switch (R2) 3. Wiring fault 4. Control unit (XCM) trouble 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 (R2) in H9, channel 18. A. Operate the range lever. If the values displayed do not change to approximately 67 on engaging range I and III and 30 on engaging range II and neutral, continue to step 2. B. If the values displayed are okay, while still in H9 channel 18, wiggle the harness, the range position switch connector (R1) SW--211, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (3A) and MOD--1/3 (1B) to check for an intermittent circuit. Channel 18 values will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check the range position switch connector (R2) SW--211, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (3A) and MOD--1/3 (1B). 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 the range position switch (R2). A. Disconnect the connector SW--211. Measure the resistance between: SW--211 pin 1 and pin 2. With the gear lever in low or high range, should indicate 560 Ohms. SW--211 pin 1 and pin 2. With the gear lever in neutral or medium range, should indicate 2.76 kOhms. If the resistances indicated are not okay, remove and replace the range position switch. B. If the range position switch is okay, continue to step 3. 4. Check for an open circuit. A. Disconnect the connectors MOD--1/3 (3A) and MOD--1/3 (1B). Check between: SW--211 pin 1, wire 1.0 (S) and MOD--1/3 (1B) pin 17, wire 0.5 (S) SW--211 pin 2, wire 1.0 (MN) and MOD--1/3 (3A) pin 5, wire 0.5 (MN) 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. 5. Check for a short to ground. A. Check between connector MOD--1/3 (3A) pin 26, wire 0.5 (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 (XCM).
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ERROR CODE 2021 -- TRANSMISSION HARNESS DISCONNECTED Effects: Transmission disabled. 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--2. 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.
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ERROR CODE 2024 -- ALL CLUTCHES REQUIRE CALIBRATION Effects: Clutch feathering will be poor, jerky or sluggish. Possible fault modes: 1. Transmission not calibrated 2. Control unit (XCM) trouble 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 (XCM), or since using H8, delete the EEPROM memory and run the transmission calibration procedure. 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 (XCM).
NOTE: For a description of calibration, please refer to Section 55 Chapter 10.
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ERROR CODE 2025 -- ENGINE SPEED (RPM) HIGH Cause: Engine speed is sent from the instrument cluster (ADIC) on the CAN. This error is only detected if the engine rev/min exceeds 3500 rev/min for over 3 seconds. Short to positive or open circuit between the engine speed sensor and the control unit (XCM), or the sensor is faulty. Effects: Tractor drives but may be unable to perform calibration(s). Possible fault modes: 1. Faulty connectors 2. Faulty engine speed sensor 3. Wiring fault 4. Control unit (XCM) trouble 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--315, ADIC connector MOD--27 (1) and the transmission -- cab 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. Disconnect the connector SEN--315. Check the connector between: SEN--315 pins 1 and 2 If the indicated resistance is not between 850 and 950 Ohm at 20 degrees centigrade, 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 connector MOD--27 (1). Check between: SEN--315 pin 2, wire 1.0 (HB) and MOD--27 (1) pin 3, wire 1.0 (HB) SEN--315 pin 1, wire 1.0 (MG) and MOD--27 (1) pin 22, wire 1.0 (MG) 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 there is a short to positive. A. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: SEN--315 pin 2, wire 1.0 (HB) and ground If a short to positive 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 (XCM).
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ERROR CODE 2026 -- CLUTCH D NOT CALIBRATED Effects: Poor performance of the uncalibrated clutch. Possible fault modes: 1. Transmission not calibrated 2. Clutch D solenoid valve trouble 3. Hydraulic circuit trouble 4. Mechanical failure 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 (XCM), or since using H8, delete the EEPROM memory and run the transmission calibration procedure. 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 calibration, please refer to Section 55 Chapter 10.
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ERROR CODE 2027 -- CLUTCH C NOT CALIBRATED Effects: Poor performance of the uncalibrated clutch. Possible fault modes: 1. Transmission not calibrated 2. Clutch C solenoid valve trouble 3. Hydraulic circuit trouble 4. Mechanical failure 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 (XCM), or since using H8, delete the EEPROM memory and run the transmission calibration procedure. 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 calibration, please refer to Section 55 Chapter 10.
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ERROR CODE 2028 -- CLUTCH B NOT CALIBRATED Effects: Poor performance of the uncalibrated clutch. Possible fault modes: 1. Transmission not calibrated 2. Clutch B solenoid valve trouble 3. Hydraulic circuit trouble 4. Mechanical failure 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 (XCM), or since using H8, delete the EEPROM memory and run the transmission calibration procedure. 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 calibration, please refer to Section 55 Chapter 10.
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ERROR CODE 2029 -- CLUTCH A NOT CALIBRATED Effects: Poor performance of the uncalibrated clutch. Possible fault modes: 1. Transmission not calibrated 2. Clutch A solenoid valve trouble 3. Hydraulic circuit trouble 4. Mechanical failure 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 (XCM), or since using H8, delete the EEPROM memory and run the transmission calibration procedure. 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 calibration, please refer to Section 55 Chapter 10.
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ERROR CODE 2033 -- PRESSURE ON CLUTCH A WOULD NOT DECREASE Cause: The pressure of clutch A does not drop below 3 bar after a change from forward to reverse. Effects: Transmission is disabled. Possible fault modes: 1. Clutch A solenoid valve trouble 2. Faulty pressure switch 3. Hydraulic circuit trouble 4. Control unit (XCM) trouble 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 error codes 2041, 2042, 2081 and 2082. A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. If any other error codes are still displayed, continue to these tests. B. If only error code 2033 is still displayed, continue with step 2. 2. Check the clutch solenoid valve connector SOL--202, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3B). 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 the clutch A solenoid. A. Disconnect the connector SOL--202. Measure the resistance between the connector: SOL--202 pin A and pin B If the resistance indicated is not approximately 10 Ohm, remove and replace the clutch solenoid valve. B. If the resistance is okay, continue to step 4. 4. Check for a short circuit. A. Disconnect the connectors MOD--1/3 (1A) and MOD--1/3 (3B). Check between the connector: MOD--1/3 (1A) pin 4, wire 1.0 (AG) and MOD--1/3 (3B) pin 1, wire 1.0 (AN) If a short circuit is indicated, repair or replace the harness as required. B. If the harness is okay, continue to step 5. 5. Check the clutch A solenoid for a mechanical fault. A. If the clutch A solenoid valve is sticking, remove and replace the solenoid assembly. B. If the solenoid valve is okay, continue to step 6. 6. Check the hydraulic system pressure. A. If the pressure indicated is approximately 16 bar, download the correct level of software. If the error is repeated, remove and replace the control unit (XCM). B. If the pressure indicated is less than approximately 11 bar, continue with the hydraulic troubleshooting procedure.
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ERROR CODE 2035 -- WHEEL SPEED TOO HIGH Cause: The advance speed sensor connector is disconnected or in short circuit to ground. Effects: The tractor runs but may function irregularly. Possible fault modes: 1. Faulty connectors 2. Faulty speed sensor 3. Wiring fault 4. Control unit (XCM) trouble 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 speed sensor connector SEN--217, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (1B). 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 speed sensor. A. Disconnect the connector SEN--217. Measure the resistance between: SEN--217 pin 1 and 2 If the resistance indicated is not approximately 700 Ohm, remove and replace the speed sensor. B. If the resistance is okay, continue to step 3. 3. Check for a short to ground. A. Check between the connector: SEN--217 pin 1, wire 1.0 (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 error is repeated, remove and replace the control unit (XCM).
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ERROR CODE 2036 -- ENGINE SPEED (RPM) LOW Cause: Engine speed is sent from the instrument cluster (ADIC) on the CAN. This error is only detected if the engine rev/min is below 500 rev/min, the wheel speed sensor detects the tractor is moving and the clutches are at full pressure for over 60 seconds. Short to positive or open circuit between the engine speed sensor and the control unit (XCM), or the sensor is faulty. Effects: Tractor drives but may be unable to perform calibrations. Possible fault modes: 1. Faulty connectors 2. Faulty engine speed sensor 3. Wiring fault 4. Control unit (XCM) trouble 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--315, instrument cluster (ADIC) connector MOD--27 (1) and the transmission -- cab 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. Disconnect the connector SEN--315. Check the connector: SEN--315 between pins 1 and 2 If the indicated resistance is not between 850 and 950 Ohm at 20 degrees centigrade, 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 connector MOD--27 (1). Check between: SEN--315 pin 2, wire 1.0 (HV) and MOD--27 (1) pin 3, wire 1.0 (HV) SEN--315 pin 1, wire 1.0 (NG) and MOD--27 (1) pin 22, wire 1.0 (NG) 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 there is a short to positive. A. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: SEN--315 pin 2, wire 1.0 (HV) and ground If a short to positive 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 (XCM).
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ERROR CODE 2037 -- CLUTCH DISCONNECT SWITCH OPEN CIRCUIT Cause: Clutch disconnect switch is open above 30% of the clutch pedal position as indicated by the potentiometer. Open circuit between the clutch disconnect switch and the control unit (XCM), or the switch is faulty. Effects: Transmission disabled. Possible fault modes: 1. Faulty connectors 2. Incorrect clutch disconnect switch adjustment 3. Clutch disconnect switch faulty 4. Wiring fault 5. Control unit (XCM) trouble 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 1. 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 closed 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--35 and the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (1B) 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--35, shuttle lever assembly connector SW--79, and the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (1B). 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 the connector SW--35. Check between the component side of connector: SW--35 pin 2 and SW--35 pin 3 should indicate a closed circuit with the pedal released and an open circuit with the pedal depressed. SW--35 pin 1 and SW--35 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 + 12 Volts. A. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: SW--35 pin 4, wire 0.5 (R) and ground If the indicated voltage is not approximately + 12 Volt, repair or replace the harness as required. B. If approximately +12 Volts is indicated continue to step 5.
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5. Check for an open circuit. A. Turn ignition switch to OFF position. Disconnect the connectors SW--79, MOD--1/3 (1A) and MOD--1/3 (1B). Check between: SW--35 pin 1, wire 0.5 (B) and MOD--1/3 (1B) pin 24, wire 0.5 (B) SW--35 pin 2, wire 0.5 (B) and MOD--1/3 (1B) pin 24, wire 0.5 (B) SW--35 pin 3, wire 0.5 (RN) and MOD--1/3 (1A) pin 8, wire 0.5 (RN) SW--35 pin 2, wire 0.5 (B) and SW--79 pin 7, wire 0.5 (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 (XCM).
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ERROR CODE 2038 -- CLUTCH B SOLENOID VALVE SHORT TO +12 VOLTS Cause: Short circuit to + 12 Volt between the solenoid valve of clutch B and the control unit (XCM), or the control unit (XCM) is faulty. Effects: Transmission is disabled. The tractor is not operative. Possible fault modes: 1. Faulty connectors 2. Wiring fault 3. Control unit (XCM) trouble 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 B solenoid valve connector SOL--203, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3B). 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 volts. A. Disconnect the connector SOL--203. Turn the ignition key switch ’ON’. Measure the voltage between connector: SOL--203 pin 1, wire 1.0 (LN) and ground SOL--203 pin 2, wire 1.0 (LG) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connectors MOD--1/3 (1A) and MOD--1/3 (3B). Turn the ignition key switch ’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 (XCM).
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ERROR CODE 2039 -- CLUTCH B SOLENOID VALVE OPEN CIRCUIT OR SHORT TO GROUND Cause: Short to ground or open circuit between the clutch B solenoid valve and the control unit (XCM), or the solenoid valve is faulty. Effects: Clutch B is disabled. Tractor will only drive in forward gears. Possible Failure modes: 1. Faulty connectors 2. Clutch B solenoid valve trouble 3. Wiring fault 4. Control unit (XCM) trouble 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 B solenoid valve connector SOL--203, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3B). 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 clutch B solenoid. A. Disconnect the connector SOL--203. Measure the resistance in the connector: SOL--203 between pins 1 and 2 If the resistance indicated is not approximately 10 Ohm, remove and replace the clutch solenoid valve. B. If the resistance is okay, continue to step 3. 3. Check the clutch B solenoid for a short to ground. A. Check between the component side of connector: SOL--203 pin 1 and ground SOL--203 pin 2 and ground If a short to ground is indicated, remove and replace the clutch 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--1/3 (1A) and MOD--1/3 (3B). Check between: SOL--203 pin 1, wire 1.0 (LN) and ground SOL--203 pin 2, wire 1.0 (LG) 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--203 pin 1, wire 1.0 (LN) and MOD--1/3 (3B) pin 2, wire 1.0 (LN) SOL--203 pin 2, wire 1.0 (LG) and MOD--1/3 (1A) pin 11, wire 1.0 (LG) 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 (XCM).
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ERROR CODE 2040 -- INCONSISTENT RANGE LEVER STATUS SWITCHES (R1 AND R2) Cause: With the machine running, switches R1 and R2 both off for longer than 3sec. Effects: The control unit detects the lever is in neutral even if this has a range engaged, displays the code 2040 and does not disable the transmission. Possible fault modes: 6. Switches faulty 7. Controller (XCM) trouble Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Ensure that the switches are connected, not damaged, the pins are in the correct position and that the connection to the connector is tight. Repair or replace as necessary. A. Check the switches: (R1) SW--210 Pin 1 wire 1.0 (S) ! C--2 pin 36 wire 1.0 (S) ! MOD--1/3 (1B) pin 17 wire 0.5 (S) 5 volt supply switch Pin 2 wire 1.0 (MB) ! C--2 pin 31 wire 0.5 (MB) ! MOD--1/3 (3A) pin 5 wire 0.5 (MB) signal to the control unit. (R2) SW--211 Pin 1 wire 1.0 (S) ! C--2 pin 36 wire 1.0 (S) ! MOD--1/3 (1B) pin 17 wire 0.5 (S) 5 volt supply switch. Pin 2 wire 1.0 (MN) ! C--2 pin 30 wire 0.5 (MN) ! MOD--1/3 (3A) pin 26 wire 0.5 (MN) signal to the control unit. Repeat the adjustment, described in sect. 21 Chap. 3 (for the ”Power shuttle 12X12” transmission) and 4 (for the ”Power shuttle transmission with Dual Command (2 Speed Power Shift) functions”), or with the diagnostics program: H5 ! code d34 for R1 and code d50 for R2 H7 ! option transmission channel ch1 H9 ! channel 17 for R1 and channel 18 for R2. NOTE: With some diagnostics programs it is possible to move the tractor. It is wise to test in motion and on ground that is not level but rather broken. The jolting produced and the vibration of the gear levers must not be enough to accidentally switch over the switches, even for a short time, thus causing this fault code. B. If the switches are okay, download the correct level of software. NOTE: Before replacing the control unit (XCM) with this error code, which moreover does not disable the transmission, repeat the adjustment in sect. 21 Chap. 3 or 4, certainly the fact that the switches change status during the movement is eliminated. Physical breakage of the switches will display codes 2016 and 2017 for R1, 2017 and 2018 for R2 at the next start, when they will be replaced (especially if the transmission is disabled) or, if they are okay, the control unit replaced.
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ERROR CODE 2041 -- CLUTCH A SOLENOID VALVE OPEN CIRCUIT OR SHORT TO GROUND Cause: Short to ground or open circuit between the clutch A solenoid valve and the control unit (XCM), or the solenoid valve is faulty. Effects: Clutch A is disabled. Possible fault modes: 1. Faulty connectors 2. Clutch A solenoid valve trouble 3. Wiring fault 4. Control unit (XCM) trouble 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 A solenoid valve connector SOL--202, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD 1/3 (1A) and MOD 1/3 (3B). 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 clutch A solenoid. A. Disconnect the connector SOL--202. Measure the resistance between the connector: SOL--202 pin 1 and 2 If the resistance indicated is not approximately 10 Ohm, remove and replace the clutch solenoid valve. B. If the resistance is okay, continue to step 3. 3. Check the clutch A solenoid for a short to ground. A. Check between the component side of connector: SOL--202 pin 1 and ground SOL--202 pin 2 and ground If a short to ground is indicated, remove and replace the clutch 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 1/3 (1A) and MOD 1/3 (3B). Check between: SOL--202 pin 1, wire 1.0 (AN) and ground SOL--202 pin 2, wire 1.0 (AG) 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--202 pin 1, wire 1.0 (AN) and MOD 1/3 (3B) pin 1, wire 1.0 (AN) SOL--202 pin 2, wire 1.0 (AG) and MOD 1/3 (1A) pin 4, wire 1.0 (AG) 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 (XCM).
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ERROR CODE 2042 -- CLUTCH A SOLENOID VALVE SHORT TO +12 VOLTS Cause: Short circuit to + 12 Volt between the solenoid valve of clutch A and the control unit (XCM), or the control unit (XCM) is faulty. Effects: Transmission is disabled. The tractor is not operative. Possible fault modes: 1. Faulty connectors 2. Wiring fault 3. Control unit (XCM) trouble 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 A solenoid valve connector SOL--202, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD 1/3 (1A) and MOD 1/3 (3B). 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 volts. A. Disconnect SOL--202. Turn the ignition key switch ’ON’. Measure the voltage between connector: SOL--202 pin 1, wire 1.0 (AN) and ground SOL--202 pin 2, wire 1.0 (AG) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connectors MOD 1/3 (1A) and MOD 1/3 (3B). Turn the ignition key switch ’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 (XCM).
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ERROR CODE 2043 -- PRESSURE ON CLUTCH B WOULD NOT DECREASE Cause: The pressure of clutch B does not drop below 3 bar after a change from reverse to forward. Effects: Transmission is disabled. Possible fault modes: 1. Clutch B solenoid valve trouble 2. Faulty pressure switch 3. Hydraulic circuit trouble 4. Control unit (XCM) trouble 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 error codes 2038, 2039, 2083 and 2084. A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. If any other error codes are still displayed, continue to these tests. B. If only error code 2043 is still displayed, continue with step 2. 2. Check the clutch B solenoid valve connector SOL--203, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3B). 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 clutch B solenoid. A. Disconnect the connector SOL--203. Measure the resistance between the connector: SOL--203 pin 1 and pin 2 If the resistance indicated is not approximately 10 Ohm, remove and replace the clutch solenoid valve. B. If the resistance is okay, continue to step 3. 4. Check for a short circuit. A. Disconnect the connectors MOD--1/3 (1A) and MOD--1/3 (3B). Check between the connector: MOD--1/3 (1A) pin 11, wire 1.0 (LG) and MOD--1/3 (3B) pin 2, wire 1.0 (LN) If a short circuit is indicated, repair or replace the harness as required. B. If the harness is okay, continue to step 5. 5. Check the clutch B solenoid for a mechanical fault. A. If the clutch B solenoid valve is sticking, remove and replace the solenoid assembly. B. If the solenoid is okay, continue to step 3. 6. Check the hydraulic system pressure. A. If the pressure indicated is approximately 16 bar, download the correct level of software. If the error is repeated, remove and replace the control unit (XCM). B. If the pressure indicated is less than approximately 11 bar, continue with the hydraulic troubleshooting procedure.
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ERROR CODE 2047 -- CLUTCH DISCONNECT SWITCH SET TOO HIGH Cause: The error is detected if the clutch pedal position is above 15%, the shuttle lever is not in neutral and there is no +12 volts at connector MOD--1/3 (1A) pin 8 for over 1 second. Effects: Tractor drives but has jerky take off. Possible fault modes: 1. Faulty connectors 2. Incorrect clutch pedal potentiometer calibration 3. Incorrect clutch disconnect switch adjustment 4. Clutch disconnect switch faulty 5. Control unit (XCM) trouble 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 error code 2037. A. If error code 2037 is displayed, clear the error code and test the system for normal operation. If 2037 is still displayed, continue to this test. B. If the fault is still present, continue with step 2. 2. Check the clutch pedal potentiometer in H7 channel 1. A. Cycle clutch pedal. If the values displayed do not change continuously between 0 to 99, perform the clutch potentiometer calibration procedure. B. If the values displayed are okay, continue to step 3. 3. Check the clutch disconnect switch adjustment. A. Position the forward/reverse shuttle lever into gear. Depress the clutch pedal. While still in H7, check that the disconnect switch operates between open and closed, indicated by ”O” or ”C”, when the pedal is raised, before 15%. Adjust the disconnect switch as required. B. If the disconnect switch is adjusted correctly, continue to step 4. 4. Check the clutch disconnect switch connector SW--35 and the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (1B). 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 5. 5. Check the clutch disconnect switch. A. Disconnect the connector SW--35. Check between the component side of connector: SW--35 pin 2 and SW--35 pin 3 should indicate a closed circuit with the pedal released and an open circuit with the pedal depressed. SW--35 pin 1 and SW--35 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, download the correct level of software. If the error is repeated, remove and replace the control unit (XCM).
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ERROR CODE 2048 -- CLUTCH DISCONNECT SWITCH SET TOO LOW Cause: The error is detected if the clutch pedal position is below 5% and there is +12 volts at connector MOD--1/3 (1A) pin 8 for over 1 second. Short to +12 volts between clutch disconnect switch and the control unit (XCM), or the clutch disconnect switch is faulty or incorrectly adjusted. Effects: Tractor drives but has jerky take off. Possible fault modes: 1. Faulty connectors 2. Incorrect clutch pedal potentiometer calibration 3. Incorrect clutch disconnect switch adjustment 4. Clutch disconnect switch faulty 5. Wiring fault 6. Control unit (XCM) trouble 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 error code 2037. A. If error code 2037 is displayed, clear the error code and test the system for normal operation. If 2037 is still displayed, continue to this test. B. If the fault is still present, continue with step 2. 2. Check the clutch pedal potentiometer in H7 Channel 0. A. Cycle clutch pedal. If the values displayed do not change continuously between 0 to 99, perform the clutch potentiometer calibration procedure. B. If the values displayed are okay, continue to step 3. 3. Check the clutch disconnect switch adjustment. A. Position the forward/reverse shuttle lever into gear. Depress the clutch pedal. While still in H7, check that the disconnect switch operates between open and closed, indicated by ”O” or ”C”, when the pedal is being raised between 5 -- 15%. Adjust the disconnect switch as required. B. If the disconnect switch is adjusted correctly, continue to step 4. 4. Check the clutch disconnect switch connector SW--35 and the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (1B). 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 5. 5. Check the clutch disconnect switch. A. Disconnect the connector SW--35. Check between the component side of connector: SW--35 pin 2 and SW--35 pin 3 should indicate a closed circuit with the pedal released and an open circuit with the pedal depressed. SW--35 pin 1 and SW--35 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 with step 6. 6. Check for a short to +12 volts. A. Disconnect C126. Turn the ignition key switch ’ON’. Measure the voltage between the connector: SW--35 pin 3, wire 0.5 (RN) and ground.
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SW--35 pin 3, wire 0.5 (RN) and ground. If a voltage is indicated, turn the key--start OFF. Disconnect the connector MOD--1/3 (1B). Turn the ignition key switch â&#x20AC;&#x2DC;ONâ&#x20AC;&#x2122;. 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 (XCM).
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ERROR CODE 2049 -- WHEEL SPEED SENSOR VOLTAGE TOO HIGH (12X12 AND 24X24 VERSION) Cause: Short to a positive voltage or an open circuit between the advance speed sensor and the control unit (XCM), or the sensor is faulty. Effects: Shuttle shifting may not function correctly and a delay in upshifts may occur. Possible fault modes: 1. Faulty connector 2. Faulty speed sensor 3. Wiring fault 4. Control unit (XCM) trouble 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 speed sensor connector SEN--217, the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (1B) and the transmission -- cab main connector C--2. 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 2. 2. Check the wheel speed sensor. A. Disconnect the connector SEN--217. Measure the resistance between the wheel speed sensor terminals. If the resistance indicated is not between 646 Ohm and 714 Ohm, remove and replace the speed sensor. B. If the wheel speed sensor is okay, continue to step 3. 3. Check for an open circuit. A. Disconnect the connectors MOD--1/3 (1A) and MOD--1/3 (1B). Check between: SEN--217 pin 1, wire 1.0 (HB) and MOD--1/3 (1B) pin 34 wire 0.5 (HB). SEN--217 pin 2, wire 1.0 (BR) and MOD--1/3 (1A) pin 23, wire 1.0 (BR) 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 there is a short to positive. A. Turn the ignition key switch â&#x20AC;&#x2DC;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: SEN--217 pin 1, wire 1.0 (HB) and ground If a short to positive is indicated, repair or replace the harness as required. B. If the harness is okay, continue to download the correct level of software. If the error is repeated, remove and replace the control unit (XCM).
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FAULT CODE 2051 -- OIL TEMPERATURE SENSOR OPEN CIRCUIT Cause: Short to a positive voltage or an open circuit between the oil temperature sensor and the control unit (XCM), the sensor is faulty, or the oil temperature is below --30 degrees Centigrade. Effects: Cold oil temperature is assumed. If the oil is cold, sluggish shifting and a higher than normal clutch pedal bite point will be indicated. Possible fault modes: 1. Oil temperature 2. Faulty connectors 3. Oil temperature sensor faulty 4. Wiring fault 5. Control unit (XCM) trouble 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 2. A. The value will change dependant on temperature, at 40°C 75% is displayed; if the reading is incorrect, continue to step 2. B. If the values displayed are okay, while still in H9 channel 2, wiggle the harness, the transmission oil temperature sensor connector SEN--201, the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (1B) and the transmission -- cab main connector C--2 to check for an intermittent circuit. Channel 2 values will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check the temperature sensor connector SEN--201, the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (1B) and inline harness connector C--2. 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 the connector SEN--201. Measure the resistance between the temperature sensor terminals. If the indicated resistance is not between 460 Ohm and 540 Ohm 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--1/3 (1A) and MOD--1/3 (1B). Check between: SEN--201 pin B, wire 1.0 (M) and MOD--1/3 (1B) pin 14, wire 0.5 (M) SEN--201 pin A, wire 1.0 (BR) and MOD--1/3 (1A) pin 23, wire 1.0 (BR) 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 there is a short to positive. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: SEN--201 pin B, wire 1.0 (M) and ground If a short to positive 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 (XCM).
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ERROR CODE 2052 -- OIL TEMPERATURE SENSOR SHORT CIRCUIT Cause: Short to ground between the oil temperature sensor and the control unit (XCM), the sensor is faulty, or the oil temperature is above 130 degrees Centigrade. Effects: It is presumed that the oil is hot. If the oil is cold, sluggish shifting and a higher than normal clutch pedal bite point will be indicated. Possible fault modes: 1. Oil temperature 2. Faulty connectors 3. Oil temperature sensor faulty 4. Wiring fault 5. Control unit (XCM) trouble 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 2. A. The value will change dependant on temperature, at 40°C 75% is displayed; if the reading is incorrect, continue to step 2. B. If the values displayed are okay, while still in H9 channel 2, wiggle the harness, the transmission oil temperature sensor connector SEN--201, the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (1B) and the transmission -- cab main connector C--2 to check for an intermittent circuit. Channel 2 values will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check the temperature sensor connector SEN--201, the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (1B) and the transmission -- cab main connector C--2. 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 in the temperature sensor. A. Disconnect the connector SEN--201. Check the connector between: SEN--201 pin A and B If a short circuit is indicated, remove and replace the temperature sensor. B. If a short circuit is not indicated, continue to step 4. 4. Check the temperature sensor for a short to ground. A. Check between the component side of connector: SEN--201 pin A and ground SEN--201 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--1/3 (1A) and MOD--1/3 (1B). Check between the connector: SEN--201 pin B, wire 1.0 (M) 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 (XCM).
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ERROR CODE 2053 -- 5 VOLT REFERENCE VOLTAGE TOO HIGH Cause: Short to +12 Volt on the + 5 Volt supply voltage to the switches of the shuttle lever, clutch pedal potentiometer, gear neutral and range, lift arms height potentiometer and lift control panels. Effects: Transmission is critically disabled. Possible fault modes: 1. Wiring fault 2. Control unit (XCM) trouble 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 the +5 volt sensor supply reference in H9, ch 21. A. If the value displayed is not approximately 49, continue to step 3. B. If the value displayed is approximately 49, while still in H9, ch 5 wiggle the harness and the control unit (XCM) connectors MOD--1/3 (1B) and MOD--1/3 (3A), the EDC control panel connector MOD--54 and MOD--53, the connector SEN--224 of the arm lift potentiometer C--2 of the transmission--cab main wiring, the shuttle lever connector SW--79, the range and gear lever position sensing button connectors SW--209, SW--210 and SW--211, the clutch pedal potentiometer connector RES--156 to check for an intermittent circuit. Channel 5 values will change if an intermittent circuit is detected; Repair or replace as necessary. 3. Check for a short to +8 or +12 Volts. A. Disconnect the connector of the control unit (XCM) MOD--1/3 (1B). Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: MOD--1/3 (1B) pin 17, wire 0.5 (S) 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 (XCM).
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ERROR CODE 2054 -- + 5 VOLT REFERENCE VOLTAGE TOO LOW Cause: Short to ground or break in the circuit of the + 5 Volt supply voltage to the switches of the shuttle lever, clutch pedal potentiometer, gear neutral and range, lift arms height potentiometer and lift control panels. Effects: Transmission is critically disabled. Possible fault modes: 1. Wiring fault 2. Control unit (XCM) trouble 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 the +5 Volt sensor supply reference in H9 Channel 21. A. If the value displayed is not approximately 49, continue to step 3. B. If the value displayed is approximately 49, while still in H9, ch 5 wiggle the harness, the EDC control unit connectors MOD--1/3 (1B) and MOD--1/3 (3A), the EDC control panel connector MOD--54 and MOD--53, the connector SEN--224 of the arm lift potentiometer C--2 of the transmission--cab main wiring, the shuttle lever connector SW--79, the range and gear lever position sensing button connectors SW--209, SW--210 and SW--211, the clutch pedal potentiometer connector RES--156 to check for an intermittent circuit. Channel 5 values will change if an intermittent circuit is detected; Repair or replace as necessary. 3. Check for a short to ground. A. Disconnect the connector MOD--1/3 (1B). Check between the connector: MOD--1/3 (1B) pin 17 wire 0.5 (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 of software. If the fault re--occurs, remove and replace the controller.
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ERROR CODE 2055 -- SHUTTLE LEVER FORWARD SWITCH VOLTAGE HIGH Cause: Short to a positive voltage between the shuttle lever forward switch and the control unit (XCM), or the shuttle lever assembly is faulty. Effects: There will be a short delay recognising that forward has been selected. Possible fault modes: 1. Faulty connectors 2. Faulty shuttle lever assembly 3. Wiring fault 4. Control unit (XCM) trouble 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. Turn the ignition key switch ’ON’. Move the shuttle lever into forward. If the display does not change to d22, continue to step 2. B. If the display does change to d22, 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--79. Move the shuttle lever forward and measure the resistance in the connector: SW--79 between pin 1 and SW--79 pin 2 If the resistance indicated is not approximately 0.56 kOhm, and then in neutral approximately 2.76 kOhm, 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 Volts. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: SW--79 pin 1, wire 0.5 (AB) and ground If the indicated voltage is greater than + 5 Volt, repair or replace the harness as required. B. If the voltage indicated is approximately +5 Volts, continue to step 4. 4. Check there is a short to positive. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: SW--79 pin 2, wire 0.5 (H) and ground If 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 (XCM).
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ERROR CODE 2056 -- SHUTTLE LEVER FORWARD SWITCH VOLTAGE LOW Cause: Open circuit or short to ground between the switch of the forward gear, of the shuttle lever and the control unit (XCM), or the shuttle lever assembly is faulty. Effects: There will be a short delay recognising that forward has been selected. Possible fault modes: 1. Faulty connectors 1. Faulty shuttle lever assembly 2. Wiring fault 3. Control unit (XCM) trouble 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. Turn the ignition key switch ’ON’. Move the shuttle lever into forward. If the display does not change to d22, continue to step 2. B. If the display does change to d22, 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--79. Move the shuttle lever to reverse and measure the resistance between the connector: SW--79 pin 1 and SW--79 pin 2 If the resistance indicated is not approximately 0.56 kOhm, and in neutral approximately 2.76 kOhm, remove and replace the shuttle lever assembly. B. If the shuttle lever switch is okay, continue to step 3. 3. Check for + 5 Volts. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: SW--79 pin 1, wire 0.5 (S) and ground If the indicated voltage is not approximately + 5 Volt, repair or replace the harness as required. B. If the voltage indicated is approximately +5 Volts, continue to step 4. 4. Check for an open circuit. A. Turn ignition switch to OFF position. Disconnect the connector of the control unit (XCM) MOD--1/3 (1B). Check in the connector: MOD--1/3 (1B) between pin 12, wire 0.5 (H) and SW--79 pin 2, wire 0.5 (H) 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--1/3 (1B) between pin 12, wire 0.5 (H) 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 (XCM).
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ERROR CODE 2057 -- SHUTTLE LEVER REVERSE SWITCH VOLTAGE HIGH Cause: Short to a positive voltage between the shuttle lever reverse switch and the control unit (XCM), or the shuttle lever assembly is faulty. Effects: There will be a short delay recognising that reverse has been selected. Possible fault modes: 1. Faulty connectors 2. Faulty shuttle lever assembly 3. Wiring fault 4. Control unit (XCM) trouble 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. Turn the ignition key switch ’ON’. Move the shuttle lever into reverse. If the display does not change to d23, continue to step 2. B. If the display does change to d23, 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--79. Move the shuttle lever to reverse and measure the resistance between the connector: SW--79 pin 1, and SW--79 pin 3 If the resistance indicated is not approximately 0.56 kOhm, and in neutral approximately 2.76 kOhm, 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 Volts. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: SW--79 pin 1, wire 0.5 (S) and ground If the indicated voltage is greater than + 5 Volt, repair or replace the harness as required. B. If the voltage indicated is approximately +5 Volts, continue to step 4. 4. Check there is a short to positive. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: SW--79 pin 3, wire 0.5 (MB) and ground If 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 (XCM).
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ERROR CODE 2058 -- SHUTTLE LEVER REVERSE SWITCH VOLTAGE LOW Cause: Open circuit or short to ground between the switch of the reverse gear, of the shuttle lever and the control unit (XCM), or the shuttle lever assembly is faulty. Effects: There will be a short delay recognising that reverse has been selected. Possible fault modes: 1. Faulty connectors 1. Faulty shuttle lever assembly 2. Wiring fault 3. Control unit (XCM) trouble 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. Turn the ignition key switch ’ON’. Move the shuttle lever into reverse. If the display does not change to d23, continue to step 2. B. If the display does change to d23, 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--79. Move the shuttle lever to reverse and measure the resistance between the connector: SW--79 pin 1 and SW--79 pin 3 If the resistance indicated is not approximately 0.56 kOhm, and in neutral approximately 2.76 kOhm, remove and replace the shuttle lever assembly. B. If the shuttle lever switch is okay, continue to step 3. 3. Check for + 5 Volts. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: SW--79 pin 1, wire 0.5 (S) and ground If the indicated voltage is not approximately + 5 Volt, repair or replace the harness as required. B. If the voltage indicated is approximately +5 Volts, continue to step 4. 4. Check for an open circuit. A. Turn ignition switch to OFF position. Disconnect the connector of the control unit (XCM) MOD--1/3 (1B). Check in the connector: MOD--1/3 (1B) between pin 13, wire 0.5 (MB) and SW--79 pin 3, wire 0.5 (MB) 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--1/3 (1B) between pin 13, wire 0.5 (MB) 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 (XCM).
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ERROR CODE 2059 -- SHUTTLE LEVER SWITCHES DISAGREE Cause: Open circuit between the neutral switch and the control unit (XCM), or the shuttle lever assembly is faulty. Effects: Transmission is disabled. Possible fault modes: 1. Faulty connectors 2. Faulty shuttle lever assembly 3. Wiring fault 4. Control unit (XCM) trouble 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 2055, 2056, 2057 or 2058 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--79 and the connector of the control unit (XCM) MOD--1/3 (1B). 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 an open circuit. A. Disconnect the connectors SW--79 and MOD--1/3 (1B). Check for an open circuit between connector: SW--79 pin 7, wire 0.5 (B) and MOD--1/3 (1B) pin 24, wire 0.5 (B) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the shuttle lever assembly.
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FAULT CODE 2061 -- NO SEAT SAFETY SWITCH TRANSITION IN THE LAST 25 HOURS OF WORK. Cause: The gearbox control unit, via CAN, has not seen the seat switch change over in the last 25 cumulative hours of work. Effects: The tractor can be used, but starting without using the clutch pedal is not possible. Possible fault modes: 1. Switch trouble (jammed on or off). 2. Wiring short or open circuit. 3. Connectors disconnected. 4. Control unit (XCM) trouble NOTE: This fault code can trigger after manually increasing the work hours on the dashboard. 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 (with diagnostics) in H9 channel 26 of the control unit (ADIC). A. Turn the ignition key switch ’ON’. Get up and then sit down again. The display will show respectively 450
585 and 292 450. B. If the display shows 450 585 (operator standing) and 292 450 (seated) in H5, check that the connectors and the pins are tight and stable, continue to step 2 of the switch (with diagnostics). 2. Check the operator present switch (with diagnostics). A. Disconnect the operator present connector SW--59. Check the resistance between the two pins, with operator seated (∼ 500 ohm), with operator standing (∼ 2000 ohm). B. If the operator present switch is okay, continue with step 3. 1. Check the operator present switch (without diagnostics) in H9 of the control unit (ADIC). A. Turn the ignition key switch ’ON’. Get up and then sit down again. The display will show from d0 to d26. B. If the display shows d26, still in H5, check that the connectors and the pins are tight and stable, continue to step 2 of the switch (without diagnostics). 2. Check the operator present switch (without diagnostics). A. Disconnect the operator present connector SW--59. Check whether there is continuity between the two pins of the switch SW--59, with the driver seated and with the driver standing. B. If the operator present switch is okay, continue with step 3. 3. Check for an open circuit. A. Disconnect the connectors SW--59 and MOD--27 (1) and MOD--27 (3) of the control unit (ADIC). Check for an open circuit between connector: SW--59 pin 1, wire 0.5 (Z) and MOD--27 (3) pin 1, wire 0.5 (Z). SW--59 pin 2, wire 0.5 (LR) and MOD--27 (1) pin 22, cavo1 (NG). If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, continue to step 4. 4. Check for a short circuit. A. Check for a short circuit between the connectors, of the operator present switch: SW--59 pin 1, wire 0.5 (Z) and pin 2, wire 0.5 (LR) If a short circuit is indicated, repair as required. B. If the system is okay, download the correct software release. If the error is repeated, remove and replace the control unit (XCM).
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ERROR CODE 2065 -- CLUTCH C SOLENOID VALVE OPEN CIRCUIT OR SHORT TO GROUND Cause: Short to ground or open circuit between the clutch C solenoid valve and the control unit (XCM), or the solenoid valve is faulty. Effects: The tractor can be used, but HIGH and LOW cannot be engaged. Possible fault modes: 1. Faulty connectors 2. Clutch C solenoid valve trouble 3. Wiring fault 4. Control unit (XCM) trouble 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 solenoid valve connector SOL--204, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3B) 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 clutch C solenoid. A. Disconnect the connector SOL--204. Measure the resistance between the connector: SOL--204 pin 1 and pin 2 If the resistance indicated is not approximately 10 Ohm, remove and replace the clutch solenoid valve. B. If the resistance is okay, continue to step 3. 3. Check the clutch C solenoid for a short to ground. A. Check between the component side of connector: SOL--204 pin 1 and ground SOL--204 pin 2 and ground If a short to ground is indicated, remove and replace the clutch 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 connector SOL--204. Check between: SOL--204 pin 1, wire 1.0 (LV) and ground SOL--204 pin 2, wire 1.0 (LR) 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--204 pin 1, wire 1.0 (LV) and MOD--1/3 (3B) pin 3, wire 1.0 (LV) SOL--204 pin 2, wire 1.0 (LR) and MOD--1/3 (1A) pin 6, wire 1.0 (LR) 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 (XCM).
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ERROR CODE 2066 -- CLUTCH D SOLENOID VALVE OPEN CIRCUIT OR SHORT TO GROUND Cause: Short to ground or open circuit between the clutch D solenoid valve and the control unit (XCM), or the solenoid valve is faulty. Effects: The tractor can be used, but HIGH and LOW cannot be engaged. Possible fault modes: 1. Faulty connectors 2. Clutch D solenoid valve trouble 3. Wiring fault 4. Control unit (XCM) trouble 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 solenoid valve connector D SOL--205, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3B). 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 clutch D solenoid. A. Disconnect the connector SOL--205. Measure the resistance in the connector SOL--205 between pins 1 and 2 If the resistance indicated is not approximately 10 Ohm, remove and replace the clutch solenoid valve. B. If the resistance is okay, continue to step 3. 3. Check the clutch D solenoid for a short to ground. A. Check between the component side of connector: SOL--205 pin 1 and ground SOL--205 pin 2 and ground If a short to ground is indicated, remove and replace the clutch 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 connector SOL--205. Check between: SOL--205 pin 1, wire 1.0 (GV) and ground SOL--205 pin 2, wire 1.0 (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. 5. Check for an open circuit. A. Check between: SOL--205 pin 1, wire 1.0 (GV) and MOD--1/3 (3B) pin 4, wire 1.0 (GV) SOL--205 pin 2, wire 1.0 (GR) and MOD--1/3 (1A) pin 7, wire 1.0 (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 (XCM).
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ERROR CODE 2067 -- CLUTCH D SOLENOID VALVE SHORT TO +12 VOLTS Cause: Short circuit to + 12 Volt between the solenoid valve of clutch D and the control unit (XCM), or the control unit (XCM) is faulty. Effects: Transmission is disabled. The tractor is not operative. Possible fault modes: 1. Faulty connectors 2. Wiring fault 3. Control unit (XCM) trouble 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 solenoid valve connector D SOL--205, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3B). 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 volts. A. Disconnect SOL--205. Turn the ignition key switch ’ON’. Measure the voltage between connector: SOL--205 pin 1, wire 1.0 (GV) and ground SOL--205 pin 2, wire 1.0 (GR) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3B). Turn the ignition key switch ’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 (XCM).
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ERROR CODE 2068 -- CLUTCH D SOLENOID VALVE SHORT TO +12 VOLTS Cause: Short circuit to + 12 Volt between the solenoid valve of clutch C and the control unit (XCM), or the control unit (XCM) is faulty. Effects: Transmission is disabled. The tractor is not operative. Possible fault modes: 1. Faulty connectors 2. Wiring fault 3. Control unit (XCM) trouble 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 C solenoid valve connector SOL--204, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3B). 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 volts. A. Disconnect SOL--204. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between connector: SOL--204 pin 1, wire 1.0 (LV) and ground SOL--204 pin 2, wire 1.0 (LR) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3B). Turn ignition switch to OFF position. 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 (XCM).
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ERROR CODE 2069 -- WHEEL SPEED SENSOR VOLTAGE TOO LOW (12X12 AND 24X24 VERSION) Cause: Short to ground between the advance speed sensor and the control unit (XCM), or the sensor is faulty. Effects: Shuttle shifting may not function correctly and a delay in upshifts may occur. Possible fault modes: 1. Faulty connector 2. Faulty speed sensor 3. Wiring fault 4. Control unit (XCM) trouble 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 speed sensor connector SEN--217, the connectors of the control unit (XCM) MOD--1/3 (1B) and MOD--1/3 (1A) and the transmission -- cab main connector C--2. 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 2. 2. Check the wheel speed sensor for a short circuit. A. Disconnect the connector SEN--217. Check the connector between: SEN--217 pins 1 and 2 If a short circuit is indicated, remove and replace the wheel speed sensor. B. If a short circuit is not indicated, continue to step 3. 3. Check the wheel speed sensor for a short to ground. A. Check between the component side of connector: SEN--217 pin 1 and ground SEN--217 pin 2 and ground If short to ground is indicated, remove and replace the wheel speed sensor. B. If the speed sensor is okay, continue to step 4. 4. Check for a short to ground.. A.Disconnect the connector MOD--1/3 (1B). Check between the connector: SEN--217 pin 1, wire 1.0 (HB) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, continue to download the correct level of software. If the error is repeated, remove and replace the control unit (XCM).
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ERROR CODE 2081 -- CLUTCH A SAFETY PRESSURE SWITCH OPEN CIRCUIT OR SHORT TO GROUND Cause: Short to ground or open circuit between the clutch A safety pressure switch and the control unit (XCM), or the pressure switch is faulty. During ignition, when the clutch fluid reaches the pressure switch with a pressure of > 11 bar, it sends a signal to the control unit (XCM) to enable clutch engagement. Effects: Pressure information is not available to the control unit (XCM). The tractor is not operative. Possible fault modes: 1. Faulty connector 2. Fuse F18 (5A) faulty 3. Faulty pressure switch 4. Hydraulic circuit trouble 5. Wiring fault 6. Control unit (XCM) trouble 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 safety pressure switch connector SEN--206, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (1B) and MOD 1/3 (3B). 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 2. 2. Check the pressure switch for a closed circuit. A. Disconnect the connector SEN--206. Check for a closed circuit between the pressure switch terminals. If a closed circuit is not indicated, remove and replace the pressure switch. B. If a closed circuit is indicated, continue to step 3. 3. Check the pressure switch for an open circuit. A. Start the engine. Check for an open circuit between the switch terminals. If an open circuit is not indicate, continue to step 4. B. If an open circuit is indicated, continue to step 5. 4. Check the hydraulic system pressure. A. If the pressure indicated is approximately 16 bar, remove and replace the pressure switch. B. If the pressure indicated is less than approximately 11 bar, continue with the hydraulic troubleshooting procedure. 5. Check fuse F18 (5A). A. Turn the starter switch to the â&#x20AC;&#x153;OFFâ&#x20AC;? position. If a fault is indicated with fuse F18 (5A), continue to step 6. B. If the fuse is okay, continue to step 8. 6. Check the pressure switch for a short to ground. A. Check between each of the switch terminals and ground. If a short to ground is indicated, remove and replace the pressure switch. B. If a short to ground is not indicated, continue to step 7. 7. Check for a short to ground. A. Disconnect the connector MOD--1/3 (1B). Check between: SEN--206 terminal, wire 1.0 (ZB) and ground
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SEN--206 terminal, wire 1.0 (BV) 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 (XCM). 8. Check for + 12 Volts. A. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: SEN--206 terminal, wire 1.0 (ZB) and ground If the indicated voltage is not approximately + 12 Volt, repair or replace the harness as required. B. If +12 Volts is indicated, continue to step 9. 9. Check for an open circuit. A. Turn ignition switch to OFF position. Disconnect the connector MOD--1/3 (1B). Check between the connector: SEN--206 terminal, wire 1.0 (BV) and MOD--1/3 (1B) pin 21, wire 0.5 (BV) 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 (XCM).
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ERROR CODE 2082 -- CLUTCH A SAFETY PRESSURE SWITCH SHORT CIRCUIT Cause: Short to a voltage between the clutch A safety pressure switch and the control unit (XCM), or the pressure switch is faulty. During ignition, when the clutch fluid reaches the pressure switch with a pressure of > 11 bar, it sends a signal to the control unit (XCM) to enable clutch engagement. Effects: Pressure information is not available to the control unit (XCM). The tractor is not operative. Possible fault modes: 1. Faulty connectors 2. Faulty pressure switch 3. Hydraulic circuit trouble 4. Wiring fault 5. Control unit (XCM) trouble 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 safety pressure switch connector SEN--206, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (1B) and MOD 1/3 (3B). 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 pressure switch for an open circuit. A. Disconnect the connector SEN--206. Start the engine. Check for an open circuit between the switch terminals. If an open circuit is not indicated, continue to step 3. B. If an open circuit is indicated, continue to step 4. 3. Check the hydraulic system pressure. A. If the pressure indicated is approximately 16 bar, remove and replace the pressure switch. B. If the pressure indicated is less than approximately 11 bar, continue with the hydraulic troubleshooting procedure. 4. Check there is a short to positive. A. Disconnect SEN--206. Turn the ignition key switch ’ON’. Measure the voltage between the connector: SEN--206 terminal, wire 1.0 (BV) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connector MOD--1/3 (1B). Turn the ignition key switch ’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 (XCM).
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137
ERROR CODE 2083 -- CLUTCH B SAFETY PRESSURE SWITCH OPEN CIRCUIT OR SHORT TO GROUND Cause: Short to ground or open circuit between the clutch B safety pressure switch and the control unit (XCM), or the pressure switch is faulty. During ignition, when the clutch fluid reaches the pressure switch with a pressure of > 11 bar, it sends a signal to the control unit (XCM) to enable clutch engagement. Effects: Pressure information is not available to the control unit (XCM). The tractor is not operative. Possible fault modes: 1. Faulty connectors 2. Fuse F18 (5A) faulty 3. Faulty pressure switch 4. Hydraulic circuit trouble 5. Wiring fault 6. Control unit (XCM) trouble 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 safety pressure switch connector SEN--207, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (1B) and MOD 1/3 (3B). 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 pressure switch for a closed circuit. A. Disconnect the connector SEN--207. Check for a closed circuit between the pressure switch terminals. If a closed circuit is not indicated, remove and replace the pressure switch. B. If a closed circuit is indicated, continue to step 3. 3. Check the pressure switch for an open circuit. A. Start the engine. Check for an open circuit between the switch terminals. If an open circuit is not indicate, continue to step 4. B. If an open circuit is indicated, continue to step 5. 4. Check the hydraulic system pressure. A. If the pressure indicated is approximately 16 bar, remove and replace the pressure switch. B. If the pressure indicated is less than approximately 11 bar, continue with the hydraulic troubleshooting procedure. 5. Check fuse F18 (5A). A. Turn ignition switch to OFF position. If a fault is indicated with fuse F18 (5A), continue to step 6. B. If the fuse is okay, continue to step 8. 6. Check the pressure switch for a short to ground. A. Check between each of the switch terminals and ground. If a short to ground is indicated, remove and replace the pressure switch. B. If a short to ground is not indicated, continue to step 7. 7. Check for a short to ground. A. Disconnect the connector MOD--1/3 (1B). Check between: SEN--207 terminal, wire 1.0 (NB) and ground.
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
SEN--207 terminal, wire 1.0 (ZB) 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 (XCM). 8. Check for + 12 Volts. A. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: SEN--207 terminal, wire 1.0 (ZB) and ground If the indicated voltage is not approximately + 12 Volt, repair or replace the harness as required. B. If +12 Volts is indicated, continue to step 9. 9. Check for an open circuit. A. Turn ignition switch to OFF position. Disconnect the connector SEN--207. Check between the connector: SEN--207 terminal, wire 1.0 (NB) and MOD--1/3 (1B) pin 28, wire 1.0 (NB) 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 (XCM).
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139
ERROR CODE 2084 -- CLUTCH B SAFETY PRESSURE SWITCH SHORT CIRCUIT Cause: Short to a voltage between the clutch B safety pressure switch and the control unit (XCM), or the pressure switch is faulty. During ignition, when the clutch fluid reaches the pressure switch with a pressure of > 11 bar, it sends a signal to the control unit (XCM) to enable clutch engagement. Effects: Pressure information is not available to the control unit (XCM). The tractor is not operative. Possible fault modes: 1. Faulty connectors 2. Faulty pressure switch 3. Hydraulic circuit trouble 4. Wiring fault 5. Control unit (XCM) trouble 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 safety pressure switch connector SEN--207, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (1B) and MOD 1/3 (3B). 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 pressure switch for an open circuit. A. Disconnect the connector SEN--207. Start the engine. Check for an open circuit between the switch terminals. If an open circuit is not indicated, continue to step 3. B. If an open circuit is indicated, continue to step 4. 3. Check the hydraulic system pressure. A. If the pressure indicated is approximately 16 bar, remove and replace the pressure switch. B. If the pressure indicated is less than approximately 11 bar, continue with the hydraulic troubleshooting procedure. 4. Check there is a short to positive. A. Disconnect SEN--207. Turn the ignition key switch ’ON’. Measure the voltage between the connector: SEN--207 terminal, wire 1.0 (NB) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connector MOD--1/3 (1B). Turn the ignition key switch ’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 (XCM).
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 2085 -- NO SUPPLY TO PRESSURE SWITCHES FOR CLUTCHES A AND B -BLOWN FUSE Cause: The +12 V supply voltage to the control unit (XCM) is less than + 6 Volt at MOD--1/3 (3A) pin 1. Clutch A and B safety pressure switches not supplied. Effects: The control unit detects no current from the pressure switches of clutches A and B, as a result it considers clutches A and B closed; it ignores this unlikely situation and generates a code that can be displayed even in situations of error code reduction. Possible fault modes: 1. Fuse F18 (5A) blown. 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 fuse F18 (5A). A Replace it. B. If the error is repeated, remove and replace the control unit (XCM).
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141
FAULT CODE 2090 -- BREAK IN CAN COMMUNICATION BETWEEN THE ADIC AND THE TRANSMISSION CONTROL UNIT (XCM) Cause: No exchange of fault codes and information between the controllers. Possible fault modes: 1. Broken wiring. 2. Faulty connectors 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. Disconnect the connectors from the various controllers: MOD--1/3 (1A) from the transmission control unit (XCM), pin 15 and 16 MOD--27 (3) from the dashboard control unit (ADIC), pin 25 and 26 MOD--166 from the JB keypad control unit, pin 2 and 3 if this is fitted, also check the diagnostics connector C--117, pin C and D 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 continuity of the wiring: A. Check continuity on the cable CAN--A--L. MOD--1/3 (1A) from the transmission control unit (XCM), pin 16 to the JB keypad MOD--166 pin 2 MOD--1/3 (1A) from the transmission control unit (XCM), pin 16 to the dashboard (ADIC) MOD--27 (3) pin 25 MOD--1/3 (1A) from the transmission control unit (XCM), pin 16 to the diagnostics connector C--117 pin D check continuity on the cable CAN--A--H. MOD--1/3 (1A) from the transmission control unit (XCM), pin 15 to the JB keypad MOD--166 pin 3 MOD--1/3 (1A) from the transmission control unit (XCM), pin 15 to the dashboard (ADIC) MOD--27 (3) pin 26 MOD--1/3 (1A) from the transmission control unit (XCM), pin 15 to the diagnostics connector C--117 pin C B. If there is continuity, go ahead with step 3. 3. Check the terminators of the CAN line: A. Measure the resistance of the terminators: MOD--1/3 (1A) between pin 16 and pin 15 MOD--27 (3) between pin 25 and pin 26 the resistance is 120 ohm. B. If the terminators are okay, go ahead with step 4. 4. Check the total resistance of the CAN line: A. Reconnect all the controllers Measure the resistance on the diagnostic connector: C--117, between pins D and pin C the resistance is approximately 60 ohm. B. If the total resistance of the terminators is okay, download the correct software release. If the error is repeated, remove and temporarily replace the control unit (XCM) and, if the error is repeated again, fit the control unit back on and replace the dashboard control unit (ADIC),
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
FAULT CODE 2092 -- SHORT CIRCUIT TO +12V FROM THE CLUTCH CUT--OUT SWITCH Cause: Short to voltage between the clutch cut--out switch and the control unit (XCM). Effects: Switch disabled, amber warning light on. Possible fault modes: 1. Wiring fault. 2. Faulty connectors 3. Controller (XCM) trouble Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Disconnect the connector of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3A) and the connector for the push--buttons on the gear lever SW--13. 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 there is a short to positive. A. Disconnect SW--13. Turn the ignition key switch ’ON’. Measure the voltage between the connector: SW--13 pin 4, wire 0.5 (SB) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connector MOD--1/3 (3A). Turn the ignition key switch ’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 (XCM).
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143
FAULT CODE 2093 -- SHORT TO +12VF TO THE GEAR LEVER SWITCH SUPPLY SIGNAL Cause: Short to +12VF between the control unit (XCM) and gear lever switches. Effects: Switches disabled, amber warning light on. Possible fault modes: 1. Wiring fault. 2. Faulty connectors 3. Controller (XCM) trouble Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Disconnect the connector of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3A) and the connector for the push--buttons on the gear lever SW--13. 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 there is a short to +12VF. A. Disconnect SW--13. Turn the ignition key switch ’ON’. Measure the voltage between the connector: SW--13 pin 3, wire 0.5 (MN) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connector MOD--1/3 (1A). Turn the ignition key switch ’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 (XCM).
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
FAULT CODE 2094 -- SHORT TO GROUND TO THE GEAR LEVER SWITCH SUPPLY SIGNAL Cause: Short to ground between the control unit (XCM) and gear lever switches. Effects: Switches disabled, amber warning light on. Possible fault modes: 1. Wiring fault. 2. Faulty connectors 3. Controller (XCM) trouble Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Disconnect the connector of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3A) and the connector for the push--buttons on the gear lever SW--13. 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 SW--13. With a tester switched onto measuring continuity, test between connector: SW--13 pin 3, wire 0.5 (MN) and ground If continuity is indicated, disconnect the connector MOD--1/3 (1A) if continuity 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 (XCM).
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145
ERROR CODE 2095 -- CLUTCH CUT--OUT SWITCH (NORMALLY OPEN) STUCK CLOSED Cause: The control unit (XCM) detects the clutch cut--out switch has been turned on for a time of 15 sec. Effects: The clutch disabling function stays off until the next ”key OFF” (switching off the machine), the display shows CP and the amber warning light is on. Possible fault modes: 1. Switch faulty. 2. Clutch cut--out switch wiring shorted. 3. Controller (XCM) trouble 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 cut--out switch: A. Disconnect the connector of the clutch cut--out switch SW--13. Cycling the switch, test between: SW--13 pin 4 and SW--13 pin 3 A closed circuit must be indicated with the button pressed, an open circuit with the button released. If the switch operation is not as indicated, remove and replace the clutch cut--out switch. B. If the switch is okay, continue with step 2. 2. Check for a short circuit. A. Disconnect the connector of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3A). Check between the connector: MOD--1/3 (3A) pin 8, wire 0.5 (SB) and MOD--1/3 (1A) pin 9, wire 0.5 (MN) 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 error is repeated, remove and replace the control unit (XCM).
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 2097 -- SHORT TO +12 VOLTS OF THE DUMP SOLENOID VALVE Cause: Short circuit to + 12 Volt between the dump solenoid valve and the control unit (XCM), or the control unit (XCM) is faulty. Effects: The transmission is not disabled. The tractor functions and the dashboard turns on the red stop warning light, the error is also visible in fault code reduction mode. Possible fault modes: 1. Faulty connectors 2. Wiring fault 3. Control unit (XCM) trouble 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 solenoid valve connector SOL--204, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3B). 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 volts. A. Disconnect SOL--204. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between connector: SOL--204 pin 1, wire 1.0 (LV) and ground SOL--204 pin 2, wire 1.0 (LR) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connector MOD--1/3 (1A) and MOD--1/3 (3B). Turn ignition switch to OFF position. 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 (XCM).
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147
ERROR CODE 2098 -- DUMP SOLENOID VALVE OPEN CIRCUIT OR SHORT TO GROUND Cause: Short to ground or open circuit between the dump solenoid valve and the control unit (XCM), or the solenoid valve is faulty. Effects: The tractor transmission is disabled and the dashboard switches on the red stop warning light and emits a critical alarm. Possible fault modes: 1. Faulty connectors 2. Dump solenoid valve trouble 3. Wiring fault 4. Control unit (XCM) trouble 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 solenoid valve connector SOL--204, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3B). 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. Disconnect the dump solenoid valve connector SOL--204. Check the dump solenoid. A. Measure the resistance between the connector: SOL--204, pin 1 and pin 2 If the resistance indicated is not approximately 7.5 Ohm, remove and replace the dump solenoid valve. B. If the resistance is okay, continue to step 3. 3. Check the dump solenoid valve for short to ground. A. Check between the component side of connector: SOL--204 pin 1 and ground SOL--204 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. Check between: SOL--204 pin 1, wire 1.0 (LV) and ground SOL--204 pin 2, wire 1.0 (LR) 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. Disconnect the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3B). Check between: SOL--204 pin 1, wire 1.0 (LV) and MOD--1/3 (3B) pin 3, wire 1.0 (LV) SOL--204 pin 23, wire 1.0 (LR) and MOD--1/3 (1A) pin 6, wire 1.0 (LR) 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 (XCM).
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 WIRING DIAGRAMS 1 -- 2 -- 3
MPM1169A
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
149
WIRING DIAGRAMS 4 -- 5 -- 6
MPM1170A
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 WIRING DIAGRAMS 7 -- 8 -- 9 -- 10
MPM1171A
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151
WIRING DIAGRAMS 17 -- 18
MPM1174A
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152
Pin
Col.
Sect.
Pin
Col.
Sect.
1
V
1.5
26
--
--
2
H
1.5
27
--
--
3
AV
1.5
28
--
--
4
Z
1.0
29
--
--
5
R
1.0
30
LB
1.0
6
RG
1.0
31
--
--
7
RV
1.0
32
--
--
8
ZB
1.0
33
--
--
9
MN
0.5
34
--
--
10
NG
1.0
35
--
11
BL
1.0
36
12
RN
1.5
13
RN
1.5
41
31
21
11
1
42
32
22
12
2
43
33
23
13
3
--
44
34
24
14
4
--
--
45
35
25
15
5
37
--
--
46
36
26
16
6
47
37
27
17
7
38
--
--
48
38
28
18
8
49
39
29
19
9
50
40
30
20
10
14
AR
1.0
39
--
--
15
--
--
40
--
--
16
HN
0.5
41
--
--
17
N
0.5
42
--
--
18
VG
1.0
43
--
--
19
CA
1.0
44
--
--
20
M
1.0
45
--
--
21
AB
1.0
46
--
--
22
HR
1.0
47
--
--
23
G
1.0
48
N
1.5
24
BR
1.0
49
N
1.5
25
HV
1.0
50
N
1.5
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
87679925A1 - 02 - 2008
C--1
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Pin
Col.
Sect.
Pin
Col.
Sect.
1
C
1.0
14
R
1.0
2
C
1.0
15
G
0.75
3
--
--
16
V
0.75
4
AG
1.0
17
--
--
5
SB
1.0
18
--
--
6
LR
1.0
19
N
1.0
7
GR
1.0
20
RV
1.0
8
RN
0.5
21
--
--
9
MN
0.5
22
--
--
10
--
--
23
BR
1.0
11
LG
1.0
24
--
--
12
A
1.0
25
N
1.0
13
--
--
26
N
1.0
153
7
1
26
20
MOD--1/3 (1A)
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
18
VN
0.5
2
BL
0.5
19
RN
0.5
3
LR
0.5
20
MB
0.5
4
GR
0.5
21
BV
0.5
5
SN
0.5
22
HN
0.5
1
9
6
R
0.5
23
N
0.5
10
17
7
LG
0.5
24
B
0.5
18
25
26
34
SB
0.5
25
B
1.0
9
HV
1.0
26
--
--
10
GV
1.0
27
--
--
8
11
--
--
28
NB
0.5
12
H
0.5
29
RL
0.5
13
MB
0.5
30
RB
0.5
14
M
0.5
31
--
--
15
--
--
32
--
--
16
--
--
33
MV
0.5
17
S
0.5
34
HB
0.5
MOD--1/3 (1B)
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
154
Pin
Col.
Sect.
Pin
Col.
Sect.
1
ZB
0.5
14
--
--
2
--
--
15
--
--
3
MN
0.5
16
--
--
4
VB
0.5
17
--
--
5
MB
0.5
18
C
0.5
6
A
0.5
19
--
--
7
H
0.5
20
--
--
8
SB
0.5
21
--
--
9
--
--
22
--
--
10
L
0.5
23
--
--
11
CA
0.5
24
CB
0.5
12
H
0.5
25
--
--
13
MZ
0.5
26
MN
0.5
7
1
26
20
MOD--1/3 (3A)
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
Pin
Col.
Sect.
Pin
Col.
Sect.
1
AN
1.0
18
RG
1.0
2
LN
1.0
19
--
--
3
LV
1.0
20
--
--
4
GV
1.0
21
--
--
5
--
--
22
--
--
1
9
6
--
--
23
--
--
10
17
7
--
--
24
--
--
18
25
26
34
8
--
--
25
--
--
9
BG
0.5
26
--
--
10
--
--
27
--
--
11
--
--
28
--
--
12
--
--
29
--
--
13
--
--
30
RV
0.5
14
AV
1.0
31
RG
0.5
15
--
--
32
CL
0.5
16
--
--
33
--
--
17
BN
1.0
34
C
1.0
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
87679925A1 - 02 - 2008
MOD--1/3 (3B)
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Pin
Col.
Sect.
Pin
Col.
Sect.
1
BG
0.5
26
HB
0.5
2
BN
1.0
27
HN
0.5
3
AG
1.0
28
H
1.0
4
AN
1.0
29
MB
0.5
5
LG
1.0
30
MN
0.5
6
LN
1.0
31
VB
0.5
7
LR
1.0
32
NG
1.0
8
LV
1.0
33
BR
1.0
9
GR
1.0
34
ZB
1.0
10
GV
1.0
35
ZB
11
AV
1.0
36
12
RG
1.0
13
--
--
155
41
31
21
11
1
42
32
22
12
2
43
33
23
13
3
1.0
44
34
24
14
4
S
1.0
45
35
25
15
5
37
--
--
46
36
26
16
6
47
37
27
17
7
38
RV
1.0
48
38
28
18
8
49
39
29
19
9
50
40
30
20
10
14
L
1.0
39
RN
0.5
15
B
1.0
40
MV
0.5
16
GN
1.0
41
--
--
17
G
1.5
42
SB
1.0
18
R
1.0
43
AG
1.0
19
BV
0.5
44
A
1.0
20
NB
0.5
45
AR
1.0
21
--
--
46
S
0.5
22
--
--
47
B
1.0
23
--
--
48
BL
0.5
24
SN
1.0
49
GV
1.0
25
M
0.5
50
HV
1.0
C--2
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
Sect.
MN
0.5
2
L
0.5
4
SB
0.5
SW--13
For model without cab, version with Power Shuttle
2 3 4
For model with cab, version with Power Shuttle and Electronic Lift
1
Col.
3
2
Pin
0.5
3
Sect.
CA
4
Col.
1
1
Pin
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
156
Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
14
--
--
2
HN
0.5
15
GN
1.0
3
HV
1.0
16
RN
0.5
4
BR
1.0
17
--
--
5
RN
0.5
18
--
--
6
RG
0.5
19
--
--
7
BN
1.0
20
--
--
8
--
--
21
--
--
9
V
0.5
22
NG
1.0
10
--
--
23
N
1.0
11
M
1.0
24
LR
1.0
12
--
--
25
RV
1.0
13
G
1.0
26
R
1.0
MOD--27--1
For model with cab, version with Power Shuttle and Electronic Lift
Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
14
SN
1.0
2
--
--
15
HL
1.0
3
BN
0.5
16
CN
0.5
4
H
1.0
17
AV
1.0
5
CA
1.0
18
V
0.5
6
SB
1.0
19
BL
1.0
7
RB
1.0
20
AB
1.0
8
--
--
21
VN
1.0
9
BG
0.5
22
--
--
10
--
--
23
--
--
11
BV
0.5
24
--
--
12
VG
1.0
25
V
0.75
13
CB
0.5
26
G
0.75
For model with cab, version with Power Shuttle and Electronic Lift
87679925A1 - 02 - 2008
MOD--27--3
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Sect.
Pin
Col.
Sect.
B
0.5
3
RN
0.5
2
B
0.5
4
R
0.5
SW--35
1
Col.
1
1
Pin
157
4
4
3
3
2
2
For Power--Shuttle version
Pin
Col.
Sect.
Pin
Col.
Sect.
1
GR
0.5
5
R
0.5
2
SN
0.5
6
LG
0.5
3
--
--
7
BR
0.5
4
--
--
8
S
0.5
MOD--53
5
8
1
4
For model with cab, version with Power Shuttle and Electronic Lift
Pin
Col.
Sect.
Pin
Col.
Sect.
A
LR
0.5
E
MB
0.5
B
SB
0.5
F
RV
0.5
C
S
0.5
G
VN
0.5
D
BR
0.5
H
A
0.5
MOD--54
For model with cab, version with Power Shuttle and Electronic Lift
Sect.
1
VN
1.0
2
NG
1.0
Pin
Col.
Sect.
G
H
D
C
B
A
SW--59
1
Col.
F
2
Pin
E
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
2
H
0.5
9
--
--
3
MB
0.5
10
--
--
SW--79
--
--
11
--
--
5
R
0.5
12
--
--
6
RN
0.5
13
--
--
7
B
0.5
--
--
--
3
4
8
4
12 13
0.5
10 11
Sect.
N
9
Col.
8
7
Pin
0.5
2
Sect.
S
1
Col.
1
6
Pin
5
158
For model with cab, version with Power Shuttle and Electronic Lift For model without cab, version with Power Shuttle N
1.0
F
--
--
B
R
1.0
G
BL
1.0
C
G
0.75
H
--
--
D
V
0.75
J
--
--
E
--
--
--
--
--
Pin
Col.
Sect.
Pin
Col.
Sect.
1
BR
0.5
3
S
0.5
2
H
0.5
--
--
--
C--117
F
A
G
Sect.
H
Col.
E
Pin
A
Sect.
D
Col.
B
J
C
Pin
RES--156
For model with cab, version with Power Shuttle and Electronic Lift For model without cab, standard version
Pin
Col.
Sect.
1
LR
1.0
3
G
0.75
2
V
0.75
4
N
1.0
MOD--166
3
3
4
4
2 87679925A1 - 02 - 2008
1
1
Sect.
2
2
Col.
1
Pin
3
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Pin
Col.
Sect.
A
BR
1.0
B
M
1.0
Pin
Col.
Sect.
159
SEN--201
For model fitted with Power Shuttle and Electronic Lift
Col.
Sect.
A
AN
1.0
B
AG
1.0
Pin
Col.
Sect.
2
For model fitted with Power Shuttle and Electronic Lift
SOL--202
1
Pin
Col.
Sect.
A
LN
1.0
B
LG
1.0
Pin
Col.
Sect.
2
For model fitted with Power Shuttle and Electronic Lift
SOL--203
1
Pin
Sect.
A
LV
1.0
B
LR
1.0
Pin
Col.
Sect.
For model fitted with Power Shuttle and Electronic Lift
SOL--204
1
Col.
2
Pin
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Pin
Col.
Sect.
A
GV
1.0
B
GR
1.0
Pin
Col.
Sect.
2
For model fitted with Power Shuttle and Electronic Lift
SOL--205
1
160
Pin
Col.
Sect.
1
BV
1.0
2
ZB
1.0
Pin
Col.
Sect.
For model fitted with Power Shuttle and Electronic Lift
SEN--206
1
2
Pin
Col.
Sect.
1
NB
1.0
2
ZB
1.0
Pin
Col.
Sect.
For model fitted with Power Shuttle and Electronic Lift
SEN--207
1
2
Col.
Sect.
1
S
1.0
2
VB
1.0
Pin
Col.
Sect.
2
For model fitted with Power Shuttle and Electronic Lift
SW--209
1
Pin
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Col.
Sect.
1
S
1.0
2
MB
1.0
Pin
Col.
Sect.
2
For model fitted with Power Shuttle and Electronic Lift
SW--210
1
Pin
161
Col.
Sect.
1
S
1.0
2
MN
1.0
Pin
Col.
Sect.
2
For model fitted with Power Shuttle and Electronic Lift
SW--211
1
Pin
Pin
Col.
Sect.
1
HB
1.0
2
BR
1.0
Pin
Col.
Sect.
SEN--217
For model fitted with Power Shuttle and Electronic Lift
1
BR
1.0
3
S
1.0
2
BL
1.0
--
--
--
For model fitted with Power Shuttle and Electronic Lift
SEN--224
1
Sect.
2
Col.
3
Pin
1
Sect.
2
Col.
3
Pin
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
162
Pin
Col.
Sect.
Pin
Col.
Sect.
1
NG
1.0
3
--
--
2
HV
1.0
--
--
--
87679925A1 - 02 - 2008
SEN--315
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
163
DIAGNOSTICS CONNECTION AND CAN LINE CIRCUIT -- DIAGRAM 2
MPM0746
87679925A1 - 02 - 2008
164 ENGINE, SENSORS AND TRANSMITTERS CIRCUIT -- DIAGRAM 5
MPM0749
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
165
INSTRUMENT CIRCUIT -- DIAGRAM 8
MPM0752
87679925A1 - 02 - 2008
166 POWER SHUTTLE CIRCUIT -- DIAGRAM 17
MPM0760
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
167
ELECTRONIC LIFT CIRCUIT (EDC) -- DIAGRAM 18
MPM0761
87679925A1 - 02 - 2008
168
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
169
REAR PTO FAULT CODE LISTING FAULT CODE 5007
E.C.R. (*) NO
Description of Fault PTO clutch solenoid valve short to + 12 volts
5008
PTO clutch solenoid valve open circuit or short to ground
NO
5033
Rear PTO cab normally closed switch open circuit
NO
5034
Open circuit or short to ground to the PTO switches on the mudguards
NO
5035
Short to + 12V from the PTO switches on the mudguards
NO
5037
Cab rear PTO switch jammed on (normally off)
NO
5043
Switch on mudguards jammed on (**)
NO
(**) For the workflow for resolving these problems, see from page 249 onwards.
FOUR WHEEL DRIVE ERROR CODE LISTING FAULT CODE 6023
Description of Fault Four--wheel drive clutch solenoid valve open circuit or short to ground
E.C.R. (*) NO
DIFFERENTIAL LOCK ERROR CODE LISTING FAULT CODE 7017
Description of Fault Differential lock solenoid valve open circuit or short to ground
E.C.R. (*) NO
(*) Enter the HH programs of the control panel select the H3 program, enter the ECR, then select the options: E -- show only severe codes, F -- show all codes for 6 minutes of power then pass to “E”. With option E selected, the word: YES -- means that the code will not be shown on the display but only kept in memory, NO -- means the code will not be shown on the display. NOTE: For the location of the components, connectors and the wiring diagrams, please refer to the end of the troubleshooting section from page 178 to page 186.
87679925A2 - 02 - 2010
170
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 5007 -- PTO CLUTCH SOLENOID VALVE SHORT TO + 12 VOLTS Cause: Short circuit to + 12 Volt between the solenoid valve of the PTO clutch and the control unit (XCM), or the control unit (XCM) is faulty. Possible fault modes: 1. Faulty connector 2. PTO clutch solenoid valve faulty 3. Wiring fault 4. Control unit (XCM) trouble 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 clutch solenoid valve connector SOL--213, the transmission -- cab main connector C--2, and the connector of the control unit (XCM) MOD--1/3 (3B). 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 2. 2. Check the PTO clutch solenoid valve connector. A. Disconnect the connector SOL--213. Measure the resistance in the connector: SOL--213 between pins 1 and 2 If the resistance indicated is not approximately 8 Ohm, remove and replace the clutch solenoid valve. B. If the resistance is okay, continue to step 3. 3. Check for a short to +12 volts. A. Turn the ignition key switch ‘ON’. Measure the voltage between connector: SOL--213 pin 1, wire 1.0 (AV) and ground SOL--213 pin 2, wire 1.0 (RG) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connector MOD--1/3 (3B). Turn the ignition key switch ‘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 (XCM).
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
171
ERROR CODE 5008 -- PTO CLUTCH SOLENOID VALVE OPEN CIRCUIT OR SHORT TO GROUND Cause: Short to ground or open circuit between the PTO clutch solenoid valve and the control unit (XCM), or the solenoid valve is faulty. Possible fault modes: 1. Faulty connectors 2. PTO clutch solenoid valve faulty 3. Wiring fault 4. Control unit (XCM) trouble 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 clutch solenoid valve connector SOL--213, the transmission -- cab main connector C--02, and the connector of the control unit (XCM) MOD--1/3 (3B). 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 clutch solenoid valve connector. A. Disconnect the connector SOL--213. Measure the resistance in the connector: SOL--213 between pins 1 and 2 If the resistance indicated is not approximately 8 Ohm, remove and replace the clutch solenoid valve. B. If the resistance is okay, continue to step 3. 3. Check the PTO solenoid valve for a short to ground. A. Check between the component side of connector: SOL--213 pin 1 and ground SOL--213 pin 2 and ground If a short to ground is indicated, remove and replace the clutch 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 connector MOD--1/3 (3B). Check between: SOL--213 pin 1, wire 1.0 (AV) and ground SOL--213 pin 2, wire 1.0 (RG) 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--213 pin 1, wire 1.0 (AV) and MOD--1/3 (3B) pin 14, wire 1.0 (AV) SOL--213 pin 2, wire 1.0 (RG) and MOD--1/3 (3B) pin 8, wire 1.0 (RG) 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 (XCM).
87679925A1 - 02 - 2008
172
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 5033 -- PTO CAB NORMALLY CLOSED SWITCH OPEN CIRCUIT Effects: PTO disabled. Possible fault modes: 1. Faulty connectors 2. Faulty PTO switch 3. Wiring fault 4. Control unit (XCM) trouble 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 cab switch connector SW--80 and the connectors of the control unit (XCM) MOD--1/3 (3A). 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 cab switch. A. Disconnect the PTO cab switch connector SW--80. Operating the switch, check between: SW--80 pin 1 (HL) and SW--80 pin 3 The indication must be: a closed circuit when disengaged; an open circuit when engaged and an open circuit when only the yellow button is pressed. SW--80 pin 1 and C151 pin 2 The indication must be: an open circuit when disengaged; a closed circuit when engaged and an open circuit when only the yellow button is pressed. SW--80 pin 2 and C151 pin 3 An open circuit must be indicated when disengaged, engaged or when only the yellow button is pressed. If the switch operation is not as indicated, remove and replace the PTO switch. B. If the switch is okay, continue to step 3. 3. Check for a short to +12 volts. A. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: SW--80 pin 1, wire 0.5 (HL) and ground If the indicated voltage is not + 12 Volt, repair or replace the harness as required. B. If +12 Volts is indicated, continue to step 4. 4. Check for an open circuit. A. Turn ignition switch to OFF position. Disconnect the connector of the control unit (XCM) MOD--1/3 (3A). Check between the connector: SW--80 pin 3, wire 0.5 (MZ) and MOD--1/3 (3A) pin 13, wire 0.5 (MZ) 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. 5. Check for a short to ground. A. Check between the connector: MOD--1/3 (3A) pin 13, wire 0.5 (MZ) 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 (XCM).
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
173
FAULT CODE 5034 -- OPEN CIRCUIT OR SHORT TO GROUND TO THE PTO SWITCHES ON THE MUDGUARDS Effects: PTO disabled. With the key ON and pressing the push--button the transmission control unit (XCM) signals fault: Possible fault modes: 1. Faulty PTO switch 2. Wiring fault 3. Control unit (XCM) trouble 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 control unit (XCM) MOD--1/3 (3A) and the connector of the push--buttons on the mudguards SW--127 and SW--125. 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 switches are sound. A. Disconnect both buttons SW--127 and SW--125. Using a tester switched onto continuity tests, check whether between: SW--125 and SW--127 pin 1 and pin 2 there is continuity SW--125 and SW--127 pin 1 and pin 3 there is continuity only by pressing the button. B. If the push--buttons work properly, pass on to point 3, otherwise replace the push--button. 3. Check power supply. A. Using a tester, switched onto voltmeter, check that: with one rod to ground and the other on pin 1, wire 0.5 (HL) of the left--hand push--button connection SW--125 there is SW--125 on pin 1, wire 0.5 (RV) and ground there is a voltage of + 12Volt. Check that there is no continuity between: SW--125 on pin 2, wire 0.5 (RV) and SW--127 on pin 1, wire 0.5 (RV) B. If this condition is met pass on to point 4, otherwise repair the wiring or, if necessary, replace the fuse F2 (5A). 4. Disconnect the connector MOD--1/3 (3A), check short circuit to ground. A. Using a tester test the continuity with a rod on the connector: MOD--1/3 (3A) pin 3, wire 0.5 (MN) and ground MOD--1/3 (3A) pin 18, wire 0.5 (C) and ground If a short to ground is indicated, repair or replace the harness as required. 5. Check for an open circuit. A. Check between the connectors: MOD--1/3 (3A) pin 3, wire 0.5 (MN) and SW--127 pin 2, wire 0.5 (MN) MOD--1/3 (3A) pin 18, wire 0.5 (C) and SW--127 pin 3, wire 0.5 (C) MOD--1/3 (3A) pin 18, wire 0.5 (C) and SW--125 pin 3, wire 0.5 (C) 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 (XCM).
87679925A1 - 02 - 2008
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
FAULT CODE 5035 -- SHORT TO + 12V FROM THE PTO SWITCHES ON THE MUDGUARDS Effects: PTO disabled. With the key ON and pressing the push--button the transmission control unit (XCM) signals fault: Possible fault modes: 1. Faulty PTO switch 2. Wiring fault 3. Control unit (XCM) trouble Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. 1. Disconnect the connector of the control unit (XCM) MOD--1/3 (3A) and the connector of the push--buttons on the mudguards SW--127 and SW--125. 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 switches are sound. A. Disconnect both buttons SW--127 and SW--125. Using a tester switched onto continuity tests, check whether between: SW--125 and SW--127 pin 1 and pin 2 there is continuity SW--125 and SW--127 pin 1 and pin 3 there is continuity only by pressing the button. B. If the push--buttons work properly, pass on to point 3, otherwise replace the push--button. 3. Check for a short to +12 volts. A. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: SW--127 pin 2, wire 0.5 (MN) and ground SW--127pin 3, wire 0.5 (C) and ground If positive voltage is detected, turn the key OFF. Disconnect the connector MOD--1/3 (3A). Turn the key ON and try again If 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 (XCM).
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
175
ERROR CODE 5037 -- CAB PTO SWITCH JAMMED ON (NORMALLY OFF) Effects: PTO disabled. Possible fault modes: 1. Faulty PTO switch 2. Wiring fault 3. Control unit (XCM) trouble 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 cab switch. A. Disconnect the PTO cab switch connector SW--80. Operating the switch, check between: SW--80 pin 1 and SW--80 pin 3 The indication must be: a closed circuit when disengaged; an open circuit when engaged and an open circuit when only the yellow button is pressed. SW--80 pin 1 and SW--80 pin 2 The indication must be: an open circuit when disengaged; a closed circuit when engaged and an open circuit when only the yellow button is pressed. SW--80 pin 2 and SW--80 pin 3 An open circuit must be indicated when disengaged, engaged or when only the yellow button is pressed. If the switch operation is not as indicated, remove and replace the PTO switch. B. If the switch is okay, continue with step 2. 2. Check for a short circuit. A. Disconnect the connector of the control unit (XCM) MOD--1/3 (3A). Check between the connector: SW--80 pin 3, wire 0.5 (MZ) and SW--80 pin 2, wire 0.5 (H) If a short circuit is indicated, repair or replace the harness as required. B. If a short circuit is not indicated, continue to step 3. 3. Check there is a short to positive. A. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: SW--80 pin 2, wire 0.5 (H) and ground If 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 (XCM).
87679925A1 - 02 - 2008
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 6023 -- FOUR--WHEEL DRIVE CLUTCH SOLENOID VALVE OPEN CIRCUIT OR SHORT TO GROUND Cause: Short to ground or open circuit between the four--wheel drive clutch solenoid valve and the control unit (XCM), or the solenoid valve is faulty. Possible fault modes: 1. Faulty connectors 2. Four--wheel drive clutch solenoid valve faulty 3. Wiring fault 4. Control unit (XCM) trouble 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 clutch solenoid valve connector SOL--214, the transmission -- cab main connector C--2, and the connector of the control unit (XCM) MOD--1/3 (3B). 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 four wheel drive clutch solenoid. A. Disconnect the connector SOL--214. Measure the resistance in the connector: SOL--214 between pins 1 and 2 If the resistance indicated is not approximately 8 Ohm, remove and replace the four--wheel drive solenoid valve. B. If the resistance is okay, continue to step 3. 3. Check the four--wheel drive solenoid valve for short to ground. A. Check between the component side of connector: SOL--214 pin 1 and ground SOL--214 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. 4. Check for a short to ground. A. Disconnect the connector MOD--1/3 (3B). Check between: SOL--214 pin 1, wire 1.0 (BN) 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--214 pin 1, wire 1.0 (BN) and MOD--1/3 (3B) pin 17, wire 1.0 (BN) SOL--214 pin 2, wire 1.0 (N) and ground 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 (XCM).
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177
ERROR CODE 7017 -- DIFFERENTIAL LOCK SOLENOID VALVE OPEN CIRCUIT OR SHORT TO GROUND Cause: Short to ground or open circuit between the differential lock solenoid valve and the control unit (XCM), or the solenoid valve is faulty. Possible fault modes: 1. Faulty connectors 2. Differential lock solenoid valve faulty 3. Wiring fault 4. Control unit (XCM) trouble 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 differential lock solenoid valve connector SOL--215, the transmission -- cab main connector C--2, and the connector of the control unit (XCM) MOD--1/3 (3B). 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 solenoid valve of the differential lock. A. Disconnect the connector SOL--215. Measure the resistance in the connector: SOL--215 between pins 1 and 2 If the resistance indicated is not approximately 8 Ohm, remove and replace the solenoid valve. B. If the resistance is okay, continue to step 3. 3. Check the differential lock solenoid for a short to ground. A. Check between the component side of connector: SOL--215 pin 1 and ground SOL--215 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. 4. Check for a short to ground. A. Disconnect the connector MOD--1/3 (3B). Check between: SOL--215 pin 1, wire 1.0 (BG) 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--215 pin 1, wire 1.0 (BG) and MOD--1/3 (3B) pin 9, wire 0.5 (BG) SOL--215 pin 2, wire 1.0 (N) and ground 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 (XCM).
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 WIRING DIAGRAMS 4 -- 5 -- 6
MPM1170A
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WIRING DIAGRAMS 11 -- 12 -- 13
MPM1172A
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180
Pin
Col.
Sect.
Pin
Col.
Sect.
1
ZB
0.5
14
--
--
2
--
--
15
--
--
3
MN
0.5
16
--
--
4
VB
0.5
17
--
--
5
MB
0.5
18
C
0.5
6
A
0.5
19
--
--
7
H
0.5
20
--
--
8
SB
0.5
21
--
--
9
--
--
22
--
--
10
L
0.5
23
--
--
11
CA
0.5
24
CB
0.5
12
H
0.5
25
--
--
13
MZ
0.5
26
MN
0.5
7
1
26
20
MOD--1/3 (3A)
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
Pin
Col.
Sect.
Pin
Col.
Sect.
1
AN
1.0
18
RG
1.0
2
LN
1.0
19
--
--
3
LV
1.0
20
--
--
4
GV
1.0
21
--
--
5
--
--
22
--
--
1
9
6
--
--
23
--
--
10
17
7
--
--
24
--
--
18
25
26
34
8
--
--
25
--
--
9
BG
0.5
26
--
--
10
--
--
27
--
--
11
--
--
28
--
--
12
--
--
29
--
--
13
--
--
30
RV
0.5
14
AV
1.0
31
RG
0.5
15
--
--
32
CL
0.5
16
--
--
33
--
--
17
BN
1.0
34
C
1.0
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
87679925A1 - 02 - 2008
MOD--1/3 (3B)
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Pin
Col.
Sect.
Pin
Col.
Sect.
1
BG
0.5
26
HB
0.5
2
BN
1.0
27
HN
0.5
3
AG
1.0
28
H
1.0
4
AN
1.0
29
MB
0.5
5
LG
1.0
30
MN
0.5
6
LN
1.0
31
VB
0.5
7
LR
1.0
32
NG
1.0
8
LV
1.0
33
BR
1.0
9
GR
1.0
34
ZB
1.0
10
GV
1.0
35
ZB
11
AV
1.0
36
12
RG
1.0
13
--
--
181
41
31
21
11
1
42
32
22
12
2
43
33
23
13
3
1.0
44
34
24
14
4
S
1.0
45
35
25
15
5
37
--
--
46
36
26
16
6
47
37
27
17
7
38
RV
1.0
48
38
28
18
8
49
39
29
19
9
50
40
30
20
10
14
L
1.0
39
RN
0.5
15
B
1.0
40
MV
0.5
16
GN
1.0
41
--
--
17
G
1.5
42
SB
1.0
18
R
1.0
43
AG
1.0
19
BV
0.5
44
A
1.0
20
NB
0.5
45
AR
1.0
21
--
--
46
S
0.5
22
--
--
47
B
1.0
23
--
--
48
BL
0.5
24
SN
1.0
49
GV
1.0
25
M
0.5
50
HV
1.0
C--2
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
Pin
Col.
Sect.
Pin
Col.
Sect.
1
HL
0.5
3
MZ
0.5
2
H
0.5
--
--
--
SW--80
For model with cab, version with Power Shuttle and Electronic Lift 3
2
1
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182
Pin
Col.
Sect.
Pin
Col.
Sect.
1
HL
0.5
3
C
0.5
2
RV
0.5
--
--
--
SW--125
For model with cab, version with Power Shuttle and Electronic Lift 3
Pin
Col.
Sect.
Pin
Col.
Sect.
1
RV
0.5
3
C
0.5
2
MN
0.5
--
--
--
2
1
SW--127
For model with cab, version with Power Shuttle and Electronic Lift 3
Col.
Sect.
1
AV
1.0
2
RG
1.0
Pin
Col.
Sect.
SOL--213
2
For model fitted with Power Shuttle and Electronic Lift
1
1
Pin
2
Col.
Sect.
1
BN
1.0
2
N
1.0
Pin
Col.
Sect.
SOL--214
2
1
Pin
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Sect.
1
BG
1.0
2
N
1.0
Pin
Col.
Sect.
SOL--215
1
Col.
2
Pin
183
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184
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
185
BRAKES AND DIFFERENTIAL LOCK CIRCUIT -- DIAGRAM 4
MPM0748
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186 REAR PTO CIRCUIT -- DIAGRAM 12
MPM0755
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
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187
ANALOG--DIGITAL INSTRUMENT CLUSTER (ADIC) ERROR CODE LISTING
FAULT CODE 14001
Description of Fault Rear power take off (PTO) speed sensor open circuit or short to high voltage
E.C.R. (*) YES
14002
Rear power take off (PTO) speed sensor short to ground
YES
14011
Engine speed sensor open circuit or short to high voltage
YES
14012
Engine speed sensor short to ground
YES
14015
5V supply Voltage too high
NO
14016
5V supply Voltage too low
NO
14041
Engine coolant temperature sensor open circuit or short to high voltage
NO
14042
Engine coolant temperature sensor short to ground
NO
14051
Fuel tank level sender open circuit or short to high voltage
YES
14052
Fuel tank level sender short to ground
YES
14061
Pneumatic brake pressure sensor shorted to + 12V or sensor not connected
NO
14091
Wheel speed sensor open circuit or short to high voltage
NO
14092
Wheel speed sensor short to ground
NO
14093
Seat switch signal short to +12V or open circuit
NO
14094
Seat switch signal short to ground
NO
14100
Pneumatic brake pressure sensor detected but not configured
YES
14101
Contaminated fuel sender disconnected
NO
14200
YES
14900
Error with Electrically Erasable Programmable Read Only Memory (EEPROM) Control unit (XCM) disconnected
14905
Instrument cluster keypad disconnected
NO
14911
Enhanced cluster without keypad
NO
14912
Basic cluster with keypad
NO
NO
(*) Enter the HH programs of the control panel select the H3 program, enter the ECR, then select the options: E -- show only severe codes, F -- show all codes for 6 minutes of power then pass to â&#x20AC;&#x153;Eâ&#x20AC;?. With option E selected, the word: YES -- means that the code will not be shown on the display but only kept in memory, NO -- means the code will not be shown on the display. NOTE: For the location of the components, connectors and the wiring diagrams, please refer to the end of the troubleshooting section from page 210 to page 233.
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 14001 -- REAR POWER TAKE--OFF SPEED SENSOR OPEN CIRCUIT OR SHORT TO HIGH VOLTAGE Possible fault modes: 1. Faulty connector 2. PTO speed sensor faulty 3. Wiring fault 4. 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--218, instrument cluster (ADIC) connector MOD--27 (1) and the transmission -- cab main connector C--2. 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 2. 2. Check the PTO speed sensor. A. Disconnect the connector SEN--218. Measure the resistance in the connector: SEN--218 between pins 1 and 2 If the indicated resistance is not between 680 and 782 Ohm 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 an open circuit. A. Disconnect the connector MOD--27 (1). Check between: SEN--218 pin 1, wire 1.0 (HN) and MOD--27 (1) pin 2, wire 0.5 (HN) SEN--218 pin 2, wire 1.0 (NG) and MOD--27 (1) pin 22, wire 1.0 (NG) 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 there is a short to positive. A. Turn the ignition key switch â&#x20AC;&#x2DC;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: SEN--218 pin 1, wire 1.0 (HN) and ground If a short to positive is indicated, repair or replace the harness as required. B. If the harness is okay, continue to download the correct level of software. If the fault occurs again, remove and replace the control panel (ADIC).
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ERROR CODE 14002 -- REAR POWER TAKE--OFF SPEED SENSOR SHORT TO GROUND Possible fault modes: 1. Faulty connectors 2. PTO speed sensor faulty 3. Wiring fault 4. 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--218, instrument cluster (ADIC) connector MOD--27 (1) and the transmission -- cab main connector C--2. 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 the connector SEN--218. Measure the resistance in the connector: SEN--218 pin 1 and 2 If the indicated resistance is not between 680 and 782 Ohm 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 a short to ground. A. Disconnect the connector MOD--27 (1). Check for a short to ground between connector: MOD--27 (1) pin 2, wire 0.5 (HN) 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).
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 14011 -- ENGINE SPEED SENSOR OPEN CIRCUIT OR SHORT TO HIGH VOLTAGE Possible fault modes: 1. Faulty connectors 2. Faulty engine speed sensor 3. Wiring fault 4. 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--315, instrument cluster (ADIC) connector MOD--27 (1) and the transmission -- cab 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--315 between pins 1 and 2 If the indicated resistance is not between 850 and 950 Ohm at 20 degrees centigrade, 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--315 and MOD--27 (1). Check between: SEN--315 pin 1, wire 1.0 (NG) and MOD--27 (1) pin 22, wire 1.0 (NG) SEN--315 pin 2, wire 1.0 (HV) and MOD--27 (1) pin 3, wire 1.0 (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 there is a short to positive. A. Turn the key start ON. Measure the voltage between the connector: SEN--315 pin 2, wire 1.0 (HV) and ground If a short to positive 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).
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ERROR CODE 14012 -- ENGINE SPEED SENSOR SHORT TO GROUND Possible fault modes: 1. Faulty connectors 2. Faulty engine speed sensor 3. Wiring fault 4. 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--315, instrument cluster (ADIC) connector MOD--27 (1) and the transmission -- cab 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 the connector SEN--315. Check between: SEN--315 pin 1 and ground SEN--315 pin 2 and ground If 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 the connector MOD--27 (1). Check between connector SEN--315 pin 2, wire 1.0 (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 fault occurs again, remove and replace the control panel (ADIC).
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 14015 -- 5V SUPPLY VOLTAGE IS TOO HIGH Possible fault modes: 1. Faulty connectors 2. Short to +8 or +12 volt pin 19 of MOD--27 (1) 3. Wiring fault 4. 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 instrument cluster (ADIC) connector. A. Check in pin 19 of the instrument cluster (ADIC) connector MOD--27 (1), check that it is free and no wires are shorted on the pin. Repair as required. B. If the pin is okay, the code may be signalled for a control unit internal error, download the correct software release. If the fault occurs again, remove and replace the control panel (ADIC).
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ERROR CODE 14016 -- 5V SUPPLY VOLTAGE IS TOO LOW Possible fault modes: 1. Faulty connectors 2. Short to ground pin 19 of MOD--27 (1) 3. Wiring fault 4. 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 instrument cluster (ADIC) connector. A. Check in pin 19 of the instrument cluster (ADIC) connector MOD--27 (1), check that it is free and no wires are shorted on the pin. Repair as required. B. If the pin is okay, the code may be signalled for a control unit internal error, download the correct software release. If the fault occurs again, remove and replace the control panel (ADIC).
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 14041 -- ENGINE COOLANT TEMPERATURE SENSOR OPEN CIRCUIT OR SHORT TO HIGH VOLTAGE Possible fault modes: 1. Faulty connectors 2. Engine temperature sensor faulty 3. Wiring fault 4. 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 temperature sensor connector SEN--306, instrument cluster (ADIC) connectors MOD--27 (3) and MOD--27 (1) the transmission -- cab 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 the connector SEN--306. Measure the resistance in the connector: SEN--306 between pin A and C If the resistance indicated is not approximately 2.5 kOhm 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--27 (3) and MOD--27 (1). Check between: SEN--306 pin A, wire 1.0 (AB) and MOD--27 (3) pin 20, wire 1.0 (AB) SEN--306 pin C, wire 1.0 (NG) and MOD--27 (1) pin 3, wire 1.0 (NG) 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 there is a short to positive. A. Turn the ignition key switch ’ON’. Measure the voltage between connector: SEN--306 pin C, wire 1.0 (NG) and ground SEN--306 pin B, wire 1.0 (HR) and ground SEN--306 pin A, wire 1.0 (AB) and ground If a short to positive 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).
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ERROR CODE 14042 -- ENGINE COOLANT TEMPERATURE SENSOR SHORT TO GROUND Possible fault modes: 1. Faulty connectors 2. Engine temperature sensor faulty 3. Wiring fault 4. 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 temperature sensor connector SEN--306, instrument cluster (ADIC) connectors MOD--27 (3) and MOD--27 (1) the transmission -- cab 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 the connector SEN--306. Measure the resistance in the connector: SEN--306 between pin A and C If the resistance indicated is not approximately 2.5 kOhm 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. A. Disconnect the connector MOD--27 (3). Check between: SEN--306 pin B, wire 1.0 (HR) and ground SEN--306 pin A, wire 1.0 (AB) 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).
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 14051 -- FUEL TANK LEVEL SENDER OPEN CIRCUIT OR SHORT TO HIGH VOLTAGE Possible fault modes: 1. Faulty connectors 2. Fuel tank level sender faulty 3. Wiring fault 4. 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 25. 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 60 and 340, continue to step 2. B. If the values displayed are okay, while in H9 channel 25 wiggle the harness and connectors to check for a 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--212, instrument cluster (ADIC) connectors MOD--27 (3) and MOD--27 (1) the transmission -- cab main connector C--2. 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 the connector SEN--212. Check the connector: SEN--212 between pins 1 and 2 If the resistances indicated are not between 30 Ohms at full and 250 Ohms at empty, remove and replace the sender. B. If the resistances indicated are okay, continue to step 4. 4. Check for an open circuit. A. Disconnect the connectors of the instrument cluster (ADIC) MOD--27 (3) and MOD--27 (1). Check between: SEN--212 pin 2, wire 1.0 (SN) and MOD--27 (3) pin 14 wire 1.0 (SN). SEN--212 pin 1, wire 1.0 (NG) and MOD--27 (1) pin 22, wire 1.0 (NG) 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 there is a short to positive. A. Turn the key start ON. Check between the connector: SEN--212 pin 2, wire 1.0 (SN) and ground If a short to positive 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).
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197
ERROR CODE 14052 -- FUEL TANK LEVEL SENDER SHORT TO GROUND Possible fault modes: 1. Faulty connectors 2. Fuel tank level sender faulty 3. Wiring fault 4. 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 level sender potentiometer in H9, channel 25. 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 60 and 340, continue to step 2. B. If the values displayed are okay, while in H9 channel 25 wiggle the harness and connectors to check for a 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--212, instrument cluster (ADIC) connectors MOD--27 (3) and MOD--27 (1) the transmission -- cab main connector C--2. 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 the connector SEN--212. Check the connector: SEN--212 between pins 1 and 2 If the resistances indicated are not between 30 Ohms at full and 250 Ohms at empty, remove and replace the sender. B. If the resistances indicated are okay, continue to step 4. 4. Check for a short to ground. A. Disconnect the connectors SEN--212 and MOD--27 (3). Check between the connector: C67 pin 2, wire 1.0 (SN) 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).
87679925A1 - 02 - 2008
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
FAULT CODE 14061 -- PNEUMATIC BRAKE PRESSURE SENSOR SHORTED TO + 12V OR SENSOR NOT CONNECTED Possible fault modes: 1. Faulty connectors 2. Faulty air brake pressure sensor 3. Wiring fault 4. 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. Make sure that the sensor is connected, check the air brake pressure switch at H9, channel 24. A. Under normal conditions of operation, test the sensor at maximum pressure and at minimum pressure (discharge the pressure from the system). If the values displayed do not change continuously between 40 and 500, continue to step 2. B. If values displayed are okay, while in H9 channel 24 wiggle the harness and connectors to check for an intermittent circuit. Channel 24 values will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check the instrument cluster (ADIC) connectors MOD--27 (3) and MOD--27 (1) the trailer braking connector C--11 and the pressure switch SEN--340. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. B. If the connectors are okay, continue to step 3; otherwise, repair or replace as required. 3. Check short to + 12V. Disconnect the instrument cluster (ADIC) connectors MOD--27 (3) and MOD--27 (1), and the pressure switch SEN--340. A. After turning the key ON, check the connector: SEN--340 pin 1 wire 0.1 (NG) and ground SEN--340 pin 2 wire 1.0 (NG) and ground If a short to positive 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).
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
199
ERROR CODE 14091 -- WHEEL SPEED SENSOR OPEN CIRCUIT OR SHORT TO HIGH VOLTAGE Possible fault modes: 1. Faulty connectors 2. Wheel speed sensor faulty 3. Wiring fault 4. 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 speed sensor connector SEN--217, instrument cluster (ADIC) connector MOD--27 (1) and the transmission -- cab main connector C--2. 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 wheel speed sensor. A. Disconnect the connector SEN--217. Measure the resistance between the wheel speed sensor terminals. If the resistance indicated is not approximately 700 Ohm, remove and replace the speed sensor. B. If the wheel speed sensor is okay, continue to step 3. 3. Check for an open circuit. A. Disconnect the connector MOD--27 (1). Check between: SEN--217 pin 1, wire 1.0 (HB) and MOD--27 (1) pin 1 wire 0.5 (HB). SEN--217 pin 2, wire 1.0 (NG) and MOD--27 (1) pin 22, wire 1.0 (NG) 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 there is a short to positive. A. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: SEN--217 pin 1, wire 1.0 (HB) and ground If a short to positive 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).
87679925A1 - 02 - 2008
200
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 14092 -- WHEEL SPEED SENSOR SHORT TO GROUND Possible fault modes: 1. Faulty connectors 2. Wheel speed sensor faulty 3. Wiring fault 4. 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 speed sensor connector SEN--217, instrument cluster (ADIC) connector MOD--27 (1) and the transmission -- cab main connector C--2. 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 wheel speed sensor for a short circuit. A. Disconnect the connector SEN--217. Check the connector between: SEN--217 pins 1 and 2 If a short circuit is indicated, remove and replace the wheel speed sensor. B. If a short circuit is not indicated, continue to step 3. 3. Check the wheel speed sensor for a short to ground. A. Check between the component side of connector: SEN--217 pin 1 and ground SEN--217 pin 2 and ground If short to ground is indicated, remove and replace the wheel speed sensor. B. If the temperature sensor is okay, continue to step 4. 4. Check for a short to ground. A.Disconnect the connector MOD--27 (1). Check between the connector: SEN--217 pin 1, wire 1.0 (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).
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
201
ERROR CODE 14093 -- SEAT SWITCH SIGNAL SHORT TO + 12V OR OPEN CIRCUIT Possible fault modes: 1. Faulty connectors 2. Operator present sensor faulty 3. Wiring fault 4. 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 SW--59, in H9 channel 26. A. With the driver seated the display must show a value of between 292 ÷ 450, with the driver standing, the display will show a value of between 450 ÷ 585. If the values displayed are not okay, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 26 wiggle the harness and the connectors of the instrument cluster (ADIC) MOD--27 (1) and MOD--27 (3) and of the operator present switch SW--59 to check for an intermittent circuit. Channel 26 values will change if an intermittent circuit is indicated; Repair or replace as necessary. 2. Check the operator present switch. A. Disconnect the connector SW--59. Check the resistance between: SW--59 pin 1 and pin 2 With the driver seated the resistance must be approximately 500 ohms, with the driver standing it must be approximately 2000 ohms. If the resistances indicated are not okay, replace the operator present switch. B. If the switch is okay, continue to step 3. 3. Check for an open circuit. A. Disconnect the connectors MOD--27 (1) and MOD--27 (3) Check between: SW--59 pin 1, wire 1.0 (VN) and MOD--27 (3) pin 21 wire 1.0 (VN). SW--59 pin 2, wire 1.0 (NG) and MOD--27 (1) pin 22, wire 1.0 (NG) 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 there is a short to positive. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: SW--59 pin 1, wire 1.0 (VN) and ground If a short to positive 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).
87679925A1 - 02 - 2008
202
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 14094 -- SEAT SWITCH SIGNAL SHORT TO GROUND Possible fault modes: 1. Faulty connectors 2. Operator present sensor faulty 3. Wiring fault 4. 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 SW--59, in H9 channel 26. A. With the driver seated the display must show a value of between 292 รท 450, with the driver standing, the display will show a value of between 450 รท 585. If the values displayed are not okay, continue to step 2. B. If the values displayed are okay, while still in H9, ch. 26 wiggle the harness and the connectors of the instrument cluster (ADIC) MOD--27 (1) and MOD--27 (3) and of the operator present switch SW--59 to check for an intermittent circuit. Channel 26 values will change if an intermittent circuit is indicated; Repair or replace as necessary. 2. Check the operator present switch. A. Disconnect the connector SW--59. Check the resistance between: SW--59 pin 1 and pin 2 With the driver seated the resistance must be approximately 500 ohms, with the driver standing it must be approximately 2000 ohms. If the resistances indicated are not okay, replace the operator present switch. B. If the switch is okay, continue to step 3. 3. Check for a short to ground. A.Disconnect the connector MOD--27 (1). Check between: SW--59 pin 1, wire 1.0 (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).
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
203
FAULT CODE 14100 -- PNEUMATIC BRAKE PRESSURE SENSOR DETECTED BUT NOT CONFIGURED Possible causes include: 1. The air brake option has not been configured, the ADIC detects the pressure switch via the wire. 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 that the air brake option has been configured. A. Enter the HH MENU programs of the ADIC, in H3 configure the air brake.
NOTE: To enter the HH MENU programs, refer to Section 55 Chapter 10.
87679925A1 - 02 - 2008
204
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 14101 -- CONTAMINATED FUEL SENDER DISCONNECTED Possible fault modes: 1. Faulty connectors 2. Contaminated fuel sender faulty 3. Wiring fault 4. 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 contaminated fuel sender SEN--305, instrument cluster (ADIC) connector MOD--27 (1) and the transmission -- cab 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 for + 12 Volts. A. Disconnect the connector SEN--305. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: SEN--305 pin 3, wire 1.0 (ZB) and ground If the indicated voltage is not approximately + 12 Volt, repair or replace the harness as required. B. If approximately +12 Volts is indicated continue to step 3. 3. Check for an open circuit. A. Turn ignition switch to OFF position. Disconnect the connector MOD--27 (1). Check between: SEN--305 pin 2 wire 0.1 (N) and ground SEN--305 pin 1, wire 1.0 (G) and MOD--27 (1) pin 13, wire 1.0 (G) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the fuel contaminated sender. If the error code is still indicated, download the correct software release. If the fault occurs again, remove and replace the control panel (ADIC).
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
205
ERROR CODE 14200 -- ERROR WITH EEPROM (ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY) Effects: Analog--digital instrument cluster (ADIC) disabled. Possible fault modes: 1. 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 instrument cluster (ADIC). A. Delete the EEPROM of the instrument cluster (ADIC) with H8 and reconfigure the panel. If the error is still present, download the correct software release and reconfigure the instrument cluster (ADIC). If the fault occurs again, remove and replace the control panel (ADIC).
87679925A1 - 02 - 2008
206
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 14900 -- CONTROL UNIT (XCM) DISCONNECTED Possible fault modes: 1. Faulty connectors 2. Wiring fault 3. Control unit (XCM) trouble 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 instrument cluster (ADIC) MOD--27 (3) and the connectors of the control unit (XCM) MOD--1/3 (1A), MOD--1/3 (2) and MOD--1/3 (3B). 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 + 12 Volts. A. Disconnect the connectors MOD--1/3 (1A), MOD--1/3 (2) and MOD--1/3 (3B). Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between connector: MOD--1/3 (1A) pin 1, wire 1.0 (C) and ground MOD--1/3 (1A) pin 2, wire 1.0 (C) and ground MOD--1/3 (1A) pin 14, wire 1.0 (R) and ground MOD--1/3 (1A) pin 20, wire 1.0 (RV) and ground MOD--1/3 (3B) pin 34, wire 1.0 (C) and ground If the indicated voltage is not + 12 Volt, repair or replace the harness as required. B. If +12 Volts is indicated, continue to step 3. 3. Check for an open circuit. A. Turn ignition switch to OFF position. Check for an open circuit between connector: MOD--1/3 (1A) pin 19, wire 1.0 (N) and ground MOD--1/3 (1A) pin 25, wire 1.0 (N) and ground MOD--1/3 (1A) pin 26, wire 0.5 (N) and ground MOD--1/3 (2) pin 21, wire 0.5 (N) and ground MOD--1/3 (2) pin 26, wire 0.5 (N) and ground 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 an open circuit on the CAN BUS. A. Disconnect the connector MOD--27 (3). Check between: MOD--1/3 (1A) (CAN_H) pin 15, wire 0.75 (G) and MOD--27 (3) (CAN_H) pin 26, wire 0.75 (G) MOD--1/3 (1A) (CAN_L) pin 16, wire 0.75 (V) and MOD--27 (3) (CAN_L) pin 25, wire 0.75 (V) 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 (XCM).
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
207
ERROR CODE 14905 -- INSTRUMENT CLUSTER (ADIC) KEYPAD DISCONNECTED Possible fault modes: 1. Faulty connectors 2. Wiring fault 3. Faulty analog--digital instrument cluster (ADIC) keypad 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 instrument cluster (ADIC) connector MOD--27 (3) and the keypad connector MOD--166. 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 + 12 Volts. A. Disconnect the connector MOD--166. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: MOD--166 pin 1, wire 1.0 (LR) and ground If the indicated voltage is not + 12 Volt, repair or replace the harness as required. B. If +12 Volts is indicated, continue to step 3. 3. Check for an open circuit. A. Turn ignition switch to OFF position. Check for a short circuit between connector: MOD--166 pin 4, wire 1.0 (N) and ground 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 an open circuit on the CAN BUS. A. Disconnect the connector MOD--27 (3). Check between: MOD--166 (CAN_H) pin 3, wire 0.75 (G) and MOD--27 (3) (CAN_H) pin 26, wire 0.75 (G) MOD--166 (CAN_L) pin 2, wire 0.75 (V) and MOD--27 (3) (CAN_L) pin 25, wire 0.75 (V) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the instrument cluster (ADIC) keypad.
87679925A1 - 02 - 2008
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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 14911 -- ENHANCED CLUSTER WITHOUT KEYPAD Possible fault modes: 1. Faulty connectors 2. Wiring fault 3. Faulty analog--digital instrument cluster (ADIC) keypad Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. NOTE: This fault code can appear: A. After replacing the enhanced control panel. After first turning the key ”ON” the control unit performs auto-configuration, if it does not find the keypad it emits this code. B. After an H8 (Clear net configuration) on the enhanced control panel. After first turning the key ”ON” the control unit performs auto--configuration, if it does not find the keypad it emits this code. 1. Check the instrument cluster (ADIC) connector MOD--27 (3) and the keypad connector MOD--166. 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 other fault codes present. A. Delete the fault codes, afterwards turn the key back ON if there is the fault code 14905 (the keypad might be connected but there could be trouble with the connector wires). Resolve the fault code continuing to these tests. B. If the above code does not appear, remove and replace the keypad of the instrument cluster (ADIC).
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
209
ERROR CODE 14912 -- BASIC CLUSTER WITH KEYPAD Possible fault modes: 1. Fitting the basic cluster with keypad Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. NOTE: This fault code can appear: A. After replacing the basic control panel. After first turning the key ”ON” the control unit performs auto--configuration, if it finds the keypad it emits this code. B. After an H8 (Clear net configuration) on the basic instrument cluster. After first turning the key ”ON” the control unit performs auto--configuration, if it finds the keypad it emits this code. 1. Check the keypad connector MOD--166. A. Replace the keypad with the CAL--SEL button.
87679925A1 - 02 - 2008
210
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 WIRING DIAGRAMS 1 -- 2 -- 3
MPM1169A
1 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
211
WIRING DIAGRAMS 4 -- 5 -- 6
MPM1170A
2 87679925A1 - 02 - 2008
212
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 WIRING DIAGRAMS 7 -- 8 -- 9 -- 10
MPM1171A
3 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
213
WIRING DIAGRAMS 11 -- 12 -- 13
MPM1172A
4 87679925A1 - 02 - 2008
214
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 WIRING DIAGRAMS 14 -- 15 -- 16
MPM1173A
5 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
215
WIRING DIAGRAMS 17 -- 18
MPM1174A
6 87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
216
Pin
Col.
Sect.
Pin
Col.
Sect.
1
V
1.5
26
--
--
2
H
1.5
27
--
--
3
AV
1.5
28
--
--
4
Z
1.0
29
--
--
5
R
1.0
30
LB
1.0
6
RG
1.0
31
--
--
7
RV
1.0
32
--
--
8
ZB
1.0
33
--
--
9
MN
0.5
34
--
--
10
NG
1.0
35
--
11
BL
1.0
36
12
RN
1.5
13
RN
1.5
41
31
21
11
1
42
32
22
12
2
43
33
23
13
3
--
44
34
24
14
4
--
--
45
35
25
15
5
37
--
--
46
36
26
16
6
47
37
27
17
7
38
--
--
48
38
28
18
8
49
39
29
19
9
50
40
30
20
10
14
AR
1.0
39
--
--
15
--
--
40
--
--
16
HN
0.5
41
--
--
17
N
0.5
42
--
--
18
VG
1.0
43
--
--
19
CA
1.0
44
--
--
20
M
1.0
45
--
--
21
AB
1.0
46
--
--
22
HR
1.0
47
--
--
23
G
1.0
48
N
1.5
24
BR
1.0
49
N
1.5
25
HV
1.0
50
N
1.5
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
87679925A1 - 02 - 2008
C--1
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Pin
Col.
Sect.
Pin
Col.
Sect.
1
C
1.0
14
R
1.0
2
C
1.0
15
G
0.75
3
--
--
16
V
0.75
4
AG
1.0
17
--
--
5
SB
1.0
18
--
--
6
LR
1.0
19
N
1.0
7
GR
1.0
20
RV
1.0
8
RN
0.5
21
--
--
9
MN
0.5
22
--
--
10
--
--
23
BR
1.0
11
LG
1.0
24
--
--
12
A
1.0
25
N
1.0
13
--
--
26
N
1.0
217
7
1
26
20
MOD--1/3 (1A)
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
14
--
--
2
--
--
15
--
--
3
--
--
16
--
--
4
AG
1.0
17
--
--
5
AR
1.0
18
--
--
6
--
--
19
CL
0.5
7
--
--
20
--
--
8
--
--
21
N
0.5
9
--
--
22
--
--
10
--
--
23
--
--
11
S
0.5
24
SN
0.5
12
--
--
25
SB
0.5
13
--
--
26
N
0.5
7
1
26
20
MOD--1/3 (2)
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
218
Pin
Col.
Sect.
Pin
Col.
Sect.
1
AN
1.0
18
RG
1.0
2
LN
1.0
19
--
--
3
LV
1.0
20
--
--
4
GV
1.0
21
--
--
5
--
--
22
--
--
1
9
6
--
--
23
--
--
10
17
7
--
--
24
--
--
18
25
26
34
8
--
--
25
--
--
9
BG
0.5
26
--
--
10
--
--
27
--
--
11
--
--
28
--
--
12
--
--
29
--
--
13
--
--
30
RV
0.5
14
AV
1.0
31
RG
0.5
15
--
--
32
CL
0.5
16
--
--
33
--
--
17
BN
1.0
34
C
1.0
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
87679925A1 - 02 - 2008
MOD--1/3 (3B)
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Pin
Col.
Sect.
Pin
Col.
Sect.
1
BG
0.5
26
HB
0.5
2
BN
1.0
27
HN
0.5
3
AG
1.0
28
H
1.0
4
AN
1.0
29
MB
0.5
5
LG
1.0
30
MN
0.5
6
LN
1.0
31
VB
0.5
7
LR
1.0
32
NG
1.0
8
LV
1.0
33
BR
1.0
9
GR
1.0
34
ZB
1.0
10
GV
1.0
35
ZB
11
AV
1.0
36
12
RG
1.0
13
--
--
219
41
31
21
11
1
42
32
22
12
2
43
33
23
13
3
1.0
44
34
24
14
4
S
1.0
45
35
25
15
5
37
--
--
46
36
26
16
6
47
37
27
17
7
38
RV
1.0
48
38
28
18
8
49
39
29
19
9
50
40
30
20
10
14
L
1.0
39
RN
0.5
15
B
1.0
40
MV
0.5
16
GN
1.0
41
--
--
17
G
1.5
42
SB
1.0
18
R
1.0
43
AG
1.0
19
BV
0.5
44
A
1.0
20
NB
0.5
45
AR
1.0
21
--
--
46
S
0.5
22
--
--
47
B
1.0
23
--
--
48
BL
0.5
24
SN
1.0
49
GV
1.0
25
M
0.5
50
HV
1.0
C--2
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
220
Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
14
--
--
2
HN
0.5
15
GN
1.0
3
HV
1.0
16
RN
0.5
4
BR
1.0
17
--
--
5
RN
0.5
18
--
--
6
RG
0.5
19
--
--
7
BN
1.0
20
--
--
8
--
--
21
--
--
9
V
0.5
22
NG
1.0
10
--
--
23
N
1.0
11
M
1.0
24
LR
1.0
12
--
--
25
RV
1.0
13
G
1.0
26
R
1.0
MOD--27--1
For model with cab, version with Power Shuttle and Electronic Lift
Pin
Col.
Sect.
Pin
Col.
Sect.
1
--
--
14
SN
1.0
2
--
--
15
HL
1.0
3
BN
0.5
16
CN
0.5
4
H
1.0
17
AV
1.0
5
CA
1.0
18
V
0.5
6
SB
1.0
19
BL
1.0
7
RB
1.0
20
AB
1.0
8
--
--
21
VN
1.0
9
BG
0.5
22
--
--
10
--
--
23
--
--
11
BV
0.5
24
--
--
12
VG
1.0
25
V
0.75
13
CB
0.5
26
G
0.75
For model with cab, version with Power Shuttle and Electronic Lift
87679925A1 - 02 - 2008
MOD--27--3
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Col.
Sect.
1
VN
1.0
Pin
Col.
Sect.
2
NG
1.0
Pin
Col.
1
N
Sect.
Pin
Col.
Sect.
0.5
3
--
--
2
BN
1.0
4
--
--
SW--59
2
1
Pin
221
3
1
4
2
A
SW--122
Sect.
0.5
N
0.5
Pin
Col.
Sect.
Pin
Col.
Sect.
1
LR
1.0
3
G
0.75
2
V
0.75
4
N
1.0
9
B
10
1
MOD--166
1
GN
2
9 10
3
Col.
4
Pin
2
Sect.
3
Col.
4
Pin
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Col.
Sect.
1
NG
1.0
2
SN
1.0
Pin
Col.
Sect.
1
HB
1.0
2
BR
1.0
Pin
Col.
Sect.
Pin
Col.
Sect.
SEN--212
2
2
1
Pin
1
222
SEN--217
For model fitted with Power Shuttle and Electronic Lift
Sect.
HN
1.0
Pin
Col.
Sect.
2
NG
1.0
Pin
Col.
Sect.
Pin
Col.
Sect.
1
G
1.0
3
ZB
1.0
2
N
1.0
--
--
--
SEN--218
SEN--305
87679925A1 - 02 - 2008
2
2
3
3
1
Col.
1
1
Pin
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Pin
Col.
Sect.
Pin
Col.
Sect.
A
AB
1.0
C
NG
1.0
B
HR
1.0
--
--
--
223
SEN--306
C B
Pin
Col.
Sect.
Pin
Col.
Sect.
1
NG
1.0
3
--
--
2
HV
1.0
--
--
--
Pin
Col.
Sect.
Pin
Col.
Sect.
1
NG
1.0
2
HL
1.0
A
SEN--315
SEN--340
For model with pneumatic trailer brake
87679925A1 - 02 - 2008
224
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
225
ENGINE, SENSORS AND TRANSMITTERS CIRCUIT -- DIAGRAM 5 (STANDARD CAB)
MPM0733
87679925A1 - 02 - 2008
226 BATTERY CUT--OUT AND HANDBRAKE CIRCUIT -- DIAGRAM 1
MPM0745
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
227
DIAGNOSTICS CONNECTION AND CAN LINE CIRCUIT -- DIAGRAM 2
MPM0746
87679925A1 - 02 - 2008
228 ENGINE, SENSORS AND TRANSMITTERS CIRCUIT -- DIAGRAM 5
MPM0749
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
229
INSTRUMENT CIRCUIT -- DIAGRAM 8
MPM0752
87679925A1 - 02 - 2008
230 REAR PTO CIRCUIT -- DIAGRAM 12
MPM0755
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
231
POWER SOCKET AND TRAILER BRAKE CIRCUIT -- DIAGRAM 14
MPM0757
87679925A1 - 02 - 2008
232 POWER SHUTTLE CIRCUIT -- DIAGRAM 17
MPM0760
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
233
ELECTRONIC LIFT CIRCUIT (EDC) -- DIAGRAM 18
MPM0761
87679925A1 - 02 - 2008
234
87679925A1 - 02 - 2008
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
235
TRANSMISSION FAULT CODE LISTING FAULT CODE 2030
Description of Fault Critical code on transmission
E.C.R. (*) NO
2049
Voltage from the wheel speed sensor too high (20X20 version)
YES
2069
Wheel speed sensor voltage too low (20X20 version)
YES
2430
Creeper unit status switch voltage too low
YES
2431
Creeper unit status switch voltage too high
YES
2450
Configuration error
NO
NOTE: For the location of the components, connectors and the wiring diagrams, please refer to the end of the troubleshooting section from page 242 to page 248. (*) Enter the HH programs of the control panel select the H3 program, enter the ECR, then select the options: E -- show only severe codes, F -- show all codes for 6 minutes of power then pass to “E”. With option E selected, the word: YES -- means that the code will not be shown on the display but only kept in memory, NO -- means the code will not be shown on the display.
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
236
ERROR CODE 2030 -- CRITICAL CODE ON TRANSMISSION Cause: Fault codes for the gear or range lever position sensors and for the speed sensor, clutches engaged at maximum pressure and operator not present. Effects: The transmission is disabled and the red warning light on the dashboard blinks. Possible fault modes: 1. Faults on the gear or range lever position sensors:
2014
Voltage from the gear neutral position switch is high
2015
Voltage from the gear neutral position switch is low
2016
Voltage from the range position switch (R1) is high
2017
Voltage from the range position switch (R1) is low
2018
Voltage from the range position switch (R2) is high
2019
Voltage from the range position switch (R2) is low
2. Faults on the speed sensor:
2049
Wheel speed sensor voltage too high
2069
Wheel speed sensor voltage too low
3. The control unit does not see the operator present. 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 resolution of the faults generated with code 2030 (see note in the causes) the fault at issue must be resolved too.
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
237
ERROR CODE 2049 -- WHEEL SPEED SENSOR VOLTAGE TOO HIGH (20X20 VERSION) Cause: Short to a positive voltage or an open circuit between the advance speed sensor and the control unit (XCM), or the sensor is faulty. Effects: Shuttle shifting may not function correctly and a delay in upshifts may occur. Possible fault modes: 1. Faulty connector 2. Faulty speed sensor 3. Wiring fault 4. Control unit (XCM) trouble 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 speed sensor connector SEN--217B, the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3B) and the transmission -- cab main connector C--2. 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 2. 2. Check the speed sensor SEN--217B in H9, channel 11. A. If the values displayed are between 40 ÷ 55, continue to step 2. B. If the values displayed are okay, while still in H9, channel 11, wiggle the speed sensor SEN--217B, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (3A) and MOD--1/3 (1B) to check for an intermittent circuit. Channel 11 values will change if an intermittent circuit is detected. Repair or replace as required. 3. Check the wheel speed sensor. A. Disconnect the connector SEN--217B. Measure the resistance between the terminals: SEN--217B pin 1 and pin 2 If the resistance indicated is not between 646 Ohm and 714 Ohm, remove and replace the speed sensor. B. If the wheel speed sensor is okay, continue to step 3. 4. Check there is a short to positive. A. Disconnect the connector of the control unit MOD--1/3 (3B), turn the key ignition switch onto ’ON’. Measure the voltage between the connector: MOD--1/3 (3B) pin 22, cable 0.5 (BV) and ground If a short to positive is indicated, repair or replace the harness as required. B. If the harness is okay, continue to download the correct level of software. If the error is repeated, remove and replace the control unit (XCM).
87679925A2 - 02 - 2010
238
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 2069 -- WHEEL SPEED SENSOR VOLTAGE TOO LOW (20X20 VERSION) Cause: Short to ground between the advance speed sensor and the control unit (XCM), or the sensor is faulty. Effects: Shuttle shifting may not function correctly and a delay in upshifts may occur. Possible fault modes: 1. Faulty connector 2. Faulty speed sensor 3. Wiring fault 4. Control unit (XCM) trouble 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 speed sensor connector SEN--217B, the connectors of the control unit (XCM) MOD--1/3 (1A) and MOD--1/3 (3B) and the transmission -- cab main connector C--2. 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 2. 2. Check the speed sensor SEN--217B in H9, channel 11. A. If the values displayed are between 40 รท 55, continue to step 3. B. If the values displayed are okay, while still in H9, channel 11, wiggle the speed sensor SEN--217B, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (3A) and MOD--1/3 (1B) to check for an intermittent circuit. Channel 11 values will change if an intermittent circuit is detected. Repair or replace as required. 3. Check the wheel speed sensor. A. Disconnect the connector SEN--217B. Measure the resistance between the terminals: SEN--217B pin 1 and pin 2 If the resistance indicated is not between 646 Ohm and 714 Ohm, remove and replace the speed sensor. B. If the wheel speed sensor is okay, continue to step 4. 4. Validate sensor power supply. A. Measure the resistance between: SEN--217B pin 1 and ground If the indicated voltage is not approximately 12 Volt, remove and replace the fuse F18 )10A), if it has blown, or repair or replace as required. B. If the wheel speed sensor is okay, continue to step 5. 5. Check for a short to ground.. A. Disconnect the connector of the control unit MOD--1/3 (3B). Measure between: MOD--1/3 (3B) pin 22, cable 0.5 (BV) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, continue to download the correct level of software. If the error is repeated, remove and replace the control unit (XCM).
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
239
ERROR CODE 2430 -- CREEPER UNIT SWITCH VOLTAGE TOO LOW Cause: Short to ground or open circuit between the creeper unit switch and the control unit (XCM), or the switch is faulty. Effects: There could be sudden packing of the clutches on moving the shuttle lever. Possible fault modes: 1. Faulty connector 2. Creeper unit switch faulty 3. Wiring fault 4. Control unit (XCM) trouble 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 unit switch SW--296 in H9, channel 29. A. If the fast range is engaged, disengage it then operate the creeper unit lever. If the values displayed do not change to approximately 67 on engaging the reduction gear and 30 with the reduction gear disengaged, continue to step 2. B. If the values displayed are okay, while still in H9, channel 29, wiggle the harness, the creeper unit switch SW--296, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (3A) and MOD--1/3 (1B) to check for an intermittent circuit. Channel 29 values will change if an intermittent circuit is detected. Repair or replace as required. 2. Check the creeper unit switch SW--296, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (3A) and MOD--1/3 (1B). 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 2. 3. Check the creeper unit switch SW--296. A. Disconnect the connector SW--296. Measure the resistance between: SW--296 pin 1 and pin 2. With the lever of the creeper unit disengaged, it should indicate 560 Ohms. SW--296 pin 1 and pin 2. With the lever of the creeper unit engaged, it should indicate 2.76 kOhms. If the resistances indicated are not okay, remove and replace the range position switch. B. If the range position switch is okay, continue to step 3. 4. Check for an open circuit. A. Disconnect the connectors MOD--1/3 (3A) and MOD--1/3 (1B). Check between: SW--296 pin 1, wire 1.0 (S) and MOD--1/3 (1B) pin 17, wire 0.5 (S) SW--296 pin 2, wire 1.0 (MN) and MOD--1/3 (3A) pin 16, wire 0.5 (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. 5. Check for a short to ground.. A. Check between connector MOD--1/3 (3A) pin 16, wire 0.5 (ZB) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, continue to download the correct level of software. If the error is repeated, remove and replace the control unit (XCM).
87679925A2 - 02 - 2010
240
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 2431 -- CREEPER UNIT SWITCH VOLTAGE TOO HIGH Cause: Short to a voltage between the creeper unit switch and the control unit (XCM), or the switch is faulty. Effects: There could be sudden packing of the clutches on moving the shuttle lever. Possible fault modes: 1. Faulty connector 2. Creeper unit switch faulty 3. Wiring fault 4. Control unit (XCM) trouble 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 unit switch SW--296 in H9, channel 29. A. If the fast range is engaged, disengage it then operate the creeper unit lever. If the values displayed do not change to approximately 67 on engaging the reduction gear and 30 with the reduction gear disengaged, continue to step 2. B. If the values displayed are okay, while still in H9, channel 29, wiggle the harness, the creeper unit switch SW--296, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (3A) and MOD--1/3 (1B) to check for an intermittent circuit. Channel 29 values will change if an intermittent circuit is detected. Repair or replace as required. 2. Check the creeper unit switch SW--296, the transmission -- cab main connector C--2, and the connectors of the control unit (XCM) MOD--1/3 (3A) and MOD--1/3 (1B). 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 2. 3. Check the creeper unit switch SW--296. A. Disconnect the connector SW--296. Measure the resistance between: SW--296 pin 1 and pin 2. With the lever of the creeper unit disengaged, it should indicate 560 Ohms. SW--296 pin 1 and pin 2. With the lever of the creeper unit engaged, it should indicate 2.76 kOhms. If the resistances indicated are not okay, remove and replace the range position switch. B. If the range position switch is okay, continue to step 3. 4. Check there is a short to positive. A. Disconnect the connector of the control unit MOD--1/3 (3A). Turn the ignition key switch â&#x20AC;&#x2DC;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: MOD--1/3 (3A) pin 16, wire 0.5 (ZB) and ground If 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 Volts. A. With the keystart ON. Measure the voltage between the connector: SW--296 pin 1, wire 1.0 (S) and ground If the indicated voltage is not approximately + 5 Volt, repair or replace the harness as required. B. If the voltage is approximately +5 Volts, download the correct level of software. If the error is repeated, remove and replace the control unit (XCM).
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
241
ERROR CODE 2050 -- CONFIGURATION ERROR Cause: Incorrect configuration in the H3 program of the control unit (XCM) RJ. Effects: On 20X20 Power Shuttle machines with creeper unit incorrectly configured as: 12X12 Power Shuttle 24X24 Power Shuttle with Dual Command (2 Speed Power Shift) functions if the control unit (XCM) sees the switch of the creeper unit, in that moment it generates the code. On 24X24 Power Shuttle machines with Dual Command (2 Speed Power Shift) functions incorrectly configured as: 12X12 Power Shuttle 20X20 Power Shuttle with creeper unit if the control unit (XCM) sees the switch of the HI or LO, in that moment it generates the code. Possible fault modes: 1. Incorrect configuration 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 configuration in the H3 program of the control unit (XCM) RJ. A. Enter the diagnostics program HH powering the machine with button 380000843 engaged, select the control unit RJ with the buttons for setting minutes m and hours h, enter the control unit diagnostics program by pressing the brightness button. Select the H3 program, with the buttons for setting minutes m and hours h, enter by pressing the brightness button. Select channel ch6, with the buttons for setting minutes m and hours h, enter by pressing the brightness button, select the option, with the minutes m and hours h selection buttons, from between: PS12 -- Power Shuttle PS20 -- Power Shuttle with creeper unit PS24 -- Power Shuttle with Dual Command (2 Speed Power Shift) functions. pressing the minutes m and hours h selection buttons for one second will sound a beep and the change will be saved, press the brightness button to go back to the H3 program.
87679925A2 - 02 - 2010
87679925A2 - 02 - 2010
GND--159
C--2
RES--156
MOD--1/3
SW--35
SW--79
MOD--100
SOL--205
SEN--217B
SEN--225
GND--136
SW--167
SEN--224
SOL--222
SEN--217
SOL--204 SOL--203 SOL--202
SEN--207
SW--210
SW--211
SW--296
SEN--221
SW--164 MOD--54 MOD--55
LMP--162
MOD--53
SEN--227
SEN--201
SEN--206
SW--209
C--2
SW--13
GND--151
SOL--223
242 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 WIRING DIAGRAMS 17 -- 18
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Pin
Col.
Sect.
Pin
Col.
Sect.
1
C
1.0
14
R
1.0
2
C
1.0
15
G
0.75
3
--
--
16
V
0.75
4
AG
1.0
17
--
--
5
SB
1.0
18
--
--
6
LR
1.0
19
N
1.0
7
GR
1.0
20
RV
1.0
8
RN
0.5
21
--
--
9
MN
0.5
22
--
--
10
--
--
23
BR
1.0
11
LG
1.0
24
--
--
12
A
1.0
25
N
1.0
13
--
--
26
N
1.0
243
7
1
26
20
MOD--1/3 (1A)
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
Pin
Col.
Sect.
Pin
Col.
Sect.
1
ZB
0.5
14
--
--
2
--
--
15
--
--
3
MN
0.5
16
--
--
4
VB
0.5
17
--
--
5
MB
0.5
18
C
0.5
6
A
0.5
19
--
--
7
H
0.5
20
--
--
8
SB
0.5
21
--
--
9
--
--
22
--
--
10
L
0.5
23
--
--
11
CO
0.5
24
CB
0.5
12
H
0.5
25
--
--
13
MZ
0.5
26
MN
0.5
7
1
26
20
MOD--1/3 (3A)
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
244
Sect.
--
--
2
BN
1.0
27
HN
1.0
3
AG
1.0
28
H
1.0
4
AN
1.0
29
MB
1.0
5
LG
1.0
30
MN
1.0
6
LN
1.0
31
VB
1.0
7
LR
1.0
32
NG
1.0
8
LV
1.0
33
BR
1.0
9
GR
1.0
34
ZB
1.0
10
GV
1.0
35
ZB
1.0
11
AV
1.0
36
S
1.0
12
RG
1.0
37
Z
1.0
13
--
--
38
RV
1.0
14
L
1.0
39
RN
1.0
15
B
1.0
40
MV
1.0
16
GN
1.0
41
--
--
17
G
1.5
42
SB
1.0
18
R
1.0
43
AG
1.0
19
--
--
44
A
1.0
20
--
--
45
AR
1.0
21
BV
1.0
46
S
1.0
22
--
--
47
B
1.0
23
--
--
48
BL
1.0
24
SN
1.0
49
GV
1.0
25
M
1.0
50
HV
1.0
41 42 43 44 45 46 47 48 49 50
Col.
26
31 32 33 34 35 36 37 38 39 40
Pin
1.0
11 12 13 14 15 16 17 18 19 20
Sect.
BG
21 22 23 24 25 26 27 28 29 30
Col.
1
1 2 3 4 5 6 7 8 9 10
Pin
C--2
For model with cab and version with Power Shuttle 20X20 and Electronic Lift. TRANSMISSION CABLE SIDE Pin
Col.
Sect.
Pin
Col.
Sect.
1
ZB BV
1.0
3
BR
1.0
87679925A2 - 02 - 2010
2 3
1
2
For models fitted with Power Shuttle with creeper unit 20X20
1
1.0
3
2
SEN--217B
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 Sect.
S
1.0
2
Z
1.0
Pin
Col.
Sect.
SW--296
1
Col.
1
2
Pin
245
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
246
POWER SHUTTLE CIRCUIT (Diagram 17)
PS PS PS 12X12* 20X20** 24X24* MOD--1/3
YES
YES
YES
TCM transmission control unit
C--2
YES
YES
YES
Cab/transmission main connection
SW--13
YES
YES
YES
Gear lever switch
SW--35
YES
YES
YES
Clutch pedal switch
SW--79
YES
YES
YES
Shuttle lever switch
MOD--100
YES
YES
YES
Fuse box and main relay F--23 (+30 Key) -- Transmission control unit F--24 (+30 Key) -- Power Shuttle lever F--28 (+30 Key) -- Starter safety circuit
RES--156
YES
YES
YES
Clutch pedal potentiometer
GND--159
YES
YES
YES
Dashboard ground
SEN--201
YES
YES
YES
Transmission oil temperature sensor
SOL--202
YES
YES
YES
Clutch A solenoid valve
SOL--203
YES
YES
YES
Clutch B solenoid valve
SOL--204
YES
YES
YES
Clutch C solenoid valve (dump Vers. PS 12X12 and 20X20)
SOL--205
NO
NO
YES
Clutch D solenoid valve
SEN--206
NO
NO
YES
Safety pressure switch clutch A
SEN--207
NO
NO
YES
Safety pressure switch clutch B
SW--209
YES
YES
YES
G gear lever status switch
SW--210
YES
YES
YES
R1 range lever status switch
SW--211
YES
YES
YES
R2 range lever status switch
SEN--217
YES
NO
YES
Theoretical wheel speed sensor (Vers. PS 12X12 and 24X24)
SEN--217B
NO
YES
NO
Theoretical wheel speed sensor (Vers. PS 20X20)
SW--296
NO
YES
NO
Creeper unit lever status switch
*
On the Power Shuttle 12X12 and 24X24 version you fit the same cable as the transmission, it is identical.
** On the Power Shuttle 20X20 version you fit a specific transmission cable. Y
On the Power Shuttle version with Creeper Unit 20X20 there is no line 20F on node SA41.
YY
On the Power Shuttle version with Creeper Unit 20X20 line 261 is added to node SA93.
YYY
On the Power Shuttle version with Creeper Unit 20X20, in the diagram, there is line 4M, otherwise, for the other versions, there is line 4C.
YYYY
On all the versions when there is no EDC there are no calls to table 18.
YYYYY On the Power Shuttle version with Creeper Unit 20X20 connect the line of sensor SEN--217B, otherwise connect the line of sensor SEN--217. 87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
247
POWER SHUTTLE CIRCUIT -- DIAGRAM 17
MMP0356A
87679925A2 - 02 - 2010
248
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
249
REAR PTO FAULT CODE LISTING FAULT CODE 5043
Description of Fault Switch on mudguards jammed on
E.C.R. (*) NO
NOTE: For the location of the components, connectors and the wiring diagrams, please refer to the end of the troubleshooting section from page 251 to page 253. (*) Enter the HH programs of the control panel select the H3 program, enter the ECR, then select the options: E -- show only severe codes, F -- show all codes for 6 minutes of power then pass to “E”. With option E selected, the word: YES -- means that the code will not be shown on the display but only kept in memory, NO -- means the code will not be shown on the display.
87679925A2 - 02 - 2010
250
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
ERROR CODE 5043 -- SWITCH ON MUDGUARDS JAMMED ON Effects: PTO disabled. Possible fault modes: 1. Faulty PTO switch 2. Wiring fault 3. Control unit (XCM) trouble Remedies: NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. NOTE: If the error appears following an incorrect operation of starting the power take--off with the switches on the mudguards, proceeding as follows: -- Continue pressing the starter switch on the mudguards for longer than 12 sec (the control unit shuts down the PTO and makes the warning light blink). -- Try again, pressing the switch, for longer than 10 sec (the control unit disables the PTO and signals the relevant fault code). Simply switch off the machine and switch it back on again, proceeding as follows to start up the power take--off with the switches on the mudguards. Brief movement of the shaft to align the grooves. -- Briefly press the switch (for less than 5 sec) to make the shaft turn gradually and the movement will stop when the switch is released. Start up the PTO with the switches on the mudguards. -- Press the switch (for less than 12 sec but longer than 5 sec) to make the shaft turn, press the switch again to stop the shaft. On the contrary, proceed as follows. 1. Check the switches SW--127 and SW--125 in the HH programs on the control unit RJ in program H5. A. Press and release the switches on both mudguards, the display must show alternately codes d63 and d64, if there is no alternation continue to step 2. B. If the alternation is okay, while still in H5, wiggle the harness, the connectors of the switches SW--127 and SW--125 and the connectors of the control unit (XCM) MOD1/3 (3A) to check for an intermittent circuit. The values displayed will change if an intermittent circuit is detected. Repair or replace as required.. 2. Disconnect the connector of the control unit (XCM) MOD--1/3 (3A) and the connector of the push--buttons on the mudguards SW--127 and SW--125. 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 the switches are sound. A. Disconnect both buttons SW--127 and SW--125. Using a tester switched onto continuity tests, check whether between: SW--125 and SW--127 pin 1 and pin 2 there is continuity SW--125 and SW--127 pin 1 and pin 3 there is continuity only by pressing the button. B. If the push--buttons work properly, pass on to point 3, otherwise replace the push--button. 4. Check for a short to +12 volts. A. Turn the ignition key switch â&#x20AC;&#x2DC;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: SW--127 pin 2, wire 0.5 (MN) and ground SW--127 pin 3, wire 0.5 (C) and ground If positive voltage is detected, turn the key OFF. Disconnect the connector MOD--1/3 (3A). Turn the key ON and try again If 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 (XCM).
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
251
WIRING DIAGRAMS 11 -- 12 -- 13
MPM1172A
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
252
Pin
Col.
Sect.
Pin
Col.
Sect.
1
ZB
0.5
14
--
--
2
--
--
15
--
--
3
MN
0.5
16
--
--
4
VB
0.5
17
--
--
5
MB
0.5
18
C
0.5
6
A
0.5
19
--
--
7
H
0.5
20
--
--
8
SB
0.5
21
--
--
9
--
--
22
--
--
10
L
0.5
23
--
--
11
CO
0.5
24
CB
0.5
12
H
0.5
25
--
--
13
MZ
0.5
26
MN
0.5
7
1
26
20
MOD--1/3 (3A)
For model with cab, version with Power Shuttle and Electronic Lift MAIN CABLE SIDE
Pin
Col.
Sect.
Pin
Col.
Sect.
1
HL
0.5
3
C
0.5
2
RV
0.5
--
--
--
SW--125
For model with cab, version with Power Shuttle and Electronic Lift 3
Pin
Col.
Sect.
Pin
Col.
Sect.
1
RV
0.5
3
C
0.5
2
MN
0.5
--
--
--
For model with cab, version with Power Shuttle and Electronic Lift
87679925A2 - 02 - 2010
2
1
SW--127
3
2
1
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
253
REAR PTO CIRCUIT -- DIAGRAM 12
MPM0755
87679925A2 - 02 - 2010
254
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
1
SECTION 55 -- ELECTRICAL SYSTEM Chapter 10 -- HH MENU AND CALIBRATIONS
CONTENTS Description
Page
HH MENU access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 HH MENU of the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 HH MENU of the transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 HH MENU of the advanced keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
87679925A2 - 02 - 2010
2
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
HH MENU ACCESS 1. Turn the starter switch (1, fig. 2) to A (OFF) and connect the tool 380000843 (2) to the diagnostics socket (1).
1 2. Turn the starter switch (1) to B, the information monitor will show HH MENU.
MDB1669A
2 3. By using the clock adjustment buttons: minutes adjustment (1) and hours adjustment (2) it is possible to pass from one control unit to another. Therefore passing to the HO, or HP, or RJ, or JB control units; the monitor also shows two arrows showing the possibility of passing from one module to another, and the arrow at the bottom making it possible to access the menu of the single control unit. HP Standard control panel HO Advanced control panel. RJ Transmission, Differential Lock, Four--Wheel Drive, Power Take--Off and Electronic Lift. JB Advanced keypad.
87679925A2 - 02 - 2010
0 x100
1 3
2
3
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 4. Pressing the brightness control button (3, fig. 3) on the control panel confirms access to the relevant module.
3
HHMENU
HHMENU
HO
RJ
HHMENU
HHMENU
JB
HP
4 5. The menu of the selected control unit appears on the information monitor. If the control unit gives a negative response to the ADIC message for menu access the attention sign will appear, in this case you need to turn the switch (1, fig. 2) to A (OFF) and repeat the HH MENU access procedure after checking the supply and connection of the relevant control unit are correct. A. Correct access. B. Module responds incorrectly.
HH MENU
RJ HH MENU
A
B 5
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
4
HH MENU OF THE CONTROL PANEL (HO, HP) H3 -- OPTIONS H4 -- SOFTWARE REVISION LEVEL H5 -- CONTROL SWITCHES DIAGNOSTICS H8 -- DELETE DATA SAVED IN MEMORY H9 -- VOLTMETER FUNCTIONS HB -- SAVED FAULTS DISPLAY HC -- DELETION OF SAVED FAULTS HE -- FREQUENCY SIGNAL MONITORING HF -- HARDWARE VERSION
H3 MENU CONTROL PANEL Access the HH MENU HO/HP as described on page 2 and proceed as follows. -- Select the H3 MENU with buttons (1) and (2), press key (3) to access the above--mentioned H3 MENU. -- After making the modifications in the options of the various channels, press button (1) and (2), for 1 sec. an audible warning will be emitted for saving to memory and the program will go back to the H3 menu where it is possible to move through the various menus. -- After consulting the selected channel, without making any changes, press the button (3) to go back to the H3 menu where it is possible to move through the various menus. --
0 x100
1 3
2
6
Select the H3 MENU options with buttons (1, fig. 6) and (2, fig. 6), press button (3, fig. 6) to access modification of the chosen option.
HO H3
HO H3
HO H3
cab
7
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 --
--
By using the buttons (1, fig. 6) and (2, fig. 6) it is possible to vary the buzzer volume by selecting CAB (low volume) or NO CAB (high volume). To confirm the chosen option, keep the button (1, fig. 6) pressed until you hear the confirmation tone, you exit the option modification menu and go back to the H3 submenu.
5
HO H3
cab
HO H3 Cab No Cab
8 --
--
By using the buttons (1, fig. 6) and (2, fig. 6) it is possible to move the arrow between the two options for the air brakes, YES and NO. To confirm the chosen option, keep the button (1, fig. 6) pressed until you hear the confirmation tone, you exit the option modification menu and go back to the H3 submenu.
HO H3
HO H3 YES NO
9 --
--
By using the buttons (1, fig. 6) e (2, fig. 6) it is possible to move the arrow between the two transmission options, HI (40 Km/h) or LOW (30 Km/h). To confirm the chosen option, keep the button (1, fig. 6) pressed until you hear the confirmation tone, you exit the option modification menu and go back to the H3 submenu.
HO H3 C
HI LOW
HO H3 LOW HI
10 --
--
By using the buttons (1, fig. 6) and (2, fig. 6) it is possible to move the arrow between the two operator present switch options, OLD (switch without diagnostics) or NEW (switch with diagnostics). To confirm the chosen option, keep the button (1, fig. 6) pressed until you hear the confirmation tone, you exit the option modification menu and go back to the H3 submenu.
HO H3
HO H3
operator
NEW
SW
OLD
11 87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
6
NOTE: To know whether there is a switch with diagnostics or a conventional ON / OFF switch on the seat, proceed as follows: A Locate the two--pin connection of the operator present seat, disconnect it, then with a tester set as an ohmmeter measure the resistance between the two pins (switch side): with operator seated: Âľ 500 Ohm switch new with operator standing: Âľ 2000 Ohm switch new -- no value (open circuit) Switch old. B Set the old switch, if with operator seated the control unit gives error code 14094 (short circuit to ground); with operator standing 14093 (short circuit to 12 volts or open circuit) this means the switch is old. --
--
--
By using the buttons (1, fig. 6) and (2, fig. 6) it is possible to move the arrow between the two fault code management options. The central display will show: F, L, E: F = shows all the faults for the first six minutes after switching on then automatically passes on to mode E; L = shows all the faults; E = shows only the serious faults. To confirm the chosen option, keep the button (1 or 2 fig. 6) pressed until you hear the confirmation tone, you exit the option modification menu and go back to the H3 submenu.
F HO H3
L
ECR
E 12
H4 MENU CONTROL PANEL SOFTWARE REVISION LEVEL Access the HH MENU HO/HP as described on page 2 and proceed as follows. -- Select the H4 MENU with buttons (1) and (2), press key (3) to access the above--mentioned H4 MENU.
0 x100
1 3
2
13
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 --
--
The central display will show the identification numbers of the control unit software release in sequence: 1131 -- Software type. 01 -- Main release. 02 -- Secondary release. 00 -- Development project. 00 -- Development iteration. At the end of the procedure, auto kick out to H4, from here it is possible to move through all the menus.
7
1131 HO H4
0102 0000 14
H5 MENU CONTROL PANEL CONTROL SWITCHES DIAGNOSIS Access the HH MENU HO/HP as described on page 2 and proceed as follows. -- Select the H5 MENU with buttons (1) and (2), press key (3) to access the above--mentioned H5 MENU. -- The central display will show the code number of the switch that has been operated.
0 x100
1 3
2
15 --
Press the button (3, fig. 15) to go back to the H5 menu where it is possible to move through the various menus.
Code
Description
ECU pin(**) (*)
d10
Operator present
CN1--21
d65
Parking brake
CN3--7
d66
Main beam headlights
CN3--18
d67
Side lights
CN1--15
d68
Uncoupled service brake pedals
CN3--17
d70
Left direction indicator
CN1--5
d71
Right direction indicator
CN1--6
d72
Implement status
CN3--1
d135
Worklamps
CN3--10
HO H3
d 10
16
If in the H3 MENU you have selected the OLD operator present switch option, the diagnosis is done in H5 (switch transition test), if you have selected the NEW option the diagnosis can be done in H9 (switch signal analog reading). (**) Refer to chapter 55 section 6 page 252. (*)
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
8
H8 MENU CONTROL PANEL DELETE DATA SAVED IN MEMORY Access the HH MENU HO/HP as described on page 2 and proceed as follows. -- Select the H8 MENU with buttons (1, fig. 18) and (2, fig. 18), press key (3, fig. 18) to access the submenu. -- Once in the submenu, press button (3, fig. 18) to exit, without making any deletion, and access the H8 menu, from here it is possible to move through all the menus.
HO H8
HO H8
HO H8
Clear net config
Clear setting
17 --
Select the H8 MENU options with buttons (1) and (2), press button (3) to access the chosen option.
0 x100
1 3
2
18 ---
--
The central display will show EECL. To delete the memory configuration you need to keep the button (1, fig. 18) pressed down until the procedure is completed, that is when the display shows EE. The data to be deleted are: implement width, slip warning threshold, maintenance intervals, wheel calibration, slip calibration, clock configuration (12/24 hours), unit of measurement selection, key tone, error codes, worked surface area and values recorded in the odometer.
HO H8
4
Clear setting
3 2
EECL
1
5
EE 19
---
--
The central display will show EECL. To delete the memory configuration you need to keep the button (1, fig. 18) pressed down until the procedure is completed, that is when the display shows EE. The data to be deleted are: the machine configuration. When the control unit is next powered up it must configure itself and that is detect in what architecture it is located (if there is the Power shuttle control unit and the keypad).
HO H8 Clear net config
4 3 2
EECL
1
5
EE 20
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 --
9
Turn the switch (1) to A (OFF).
MDB1669A
21
H9 MENU CONTROL PANEL VOLTMETER FUNCTIONS Access the HH MENU HO/HP as described on page 2 and proceed as follows. -- Select the H9 MENU with buttons (1) and (2), press key (3) to access the above--mentioned H9 MENU.
0 x100
1 3
2
22
--
---
The central display will show the selected channel number followed by the relevant measurement. It is possible to select the various faults by pressing buttons (1, fig. 22) and (2, fig. 22). Press button (3, fig. 22) to go back to H9, from here it is possible to move through all the menus.
HC H9
ch04 578 23
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
10 ch
Description
ECU pin(**)
4
Supply voltage Vpp
CN1--26
5
Sensor supply voltage at 5 V
CN1--19
Standard value ∼ 600 ∼ 500
10 Supply voltage 12 VT
CN1--24
23 Engine coolant temperature
CN3--20
24 Brake air pressure
CN3--15
40 ÷ 500
25 Fuel level
CN3--14
60 full ÷ 340 empty
26 Operator present (*).
CN3--21
--
∼ 600 20 ÷ 950
If in the H3 MENU you have selected the OLD operator present switch option, the diagnosis is done in H5 (switch transition test), if you have selected the NEW option the diagnosis can be done in H9 (switch signal analog reading). (**) Refer to chapter 55 section 6 page 252. (*)
HB MENU CONTROL PANEL SAVED FAULT DISPLAY Access the HH MENU HO/HP as described on page 2 and proceed as follows. -- Select the HB MENU with buttons (1) and (2), press key (3) to access the above--mentioned HB MENU.
0 x100
1 3
2
24 ----
--
The central display will show the fault codes logged by the control unit. It is possible to select the various faults by pressing buttons (1, fig. 24) and (2, fig. 24). Besides the fault number, the display will show in sequence: the number of hours in which the fault first occurred; the number of hours in which the fault last occurred; the number of times the fault has occurred. Press button (3, fig. 24) to go back to HB, from here it is possible to move through all the menus.
87679925A2 - 02 - 2010
14061 HC HB
300 350 3 25
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
11
HC MENU CONTROL PANEL SAVED FAULT DELETION Access the HH MENU HO/HP as described on page 2 and proceed as follows. -- Select the HC MENU with buttons (1) and (2), press key (3) to access the above--mentioned HC MENU.
0 x100
1 3
2
26 ---
--
The central display will show FCL. To delete the memory you need to keep the button (1, fig. 26) pressed down until the procedure is completed, that is when the display shows EE. Press the button (3, fig. 26) to go back to the HC menu where it is possible to browse through the various menus.
4
HC HC
3 2 FCL
1
5
EE 27
HE MENU CONTROL PANEL FREQUENCY SIGNAL MONITORING Access the HH MENU HO/HP as described on page 2 and proceed as follows. -- Select the HE MENU with buttons (1) and (2), press key (3) to access the above--mentioned HE MENU.
0 x100
1 3
2
28
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
12 --
The central display will show the selected channel number followed by the relevant measurement. It is possible to select the various faults by pressing buttons (1, fig. 28) and (2, fig. 28). Press the button (3, fig. 28) to go back to the HE menu where it is possible to browse through the various menus.
---
ch18
HC HE
1500 29 Description
ch
ECU pin(**)
Standard value
18
Engine speed
CN1--3
0 รท 2700 rev/min
19
Theoretical speed (wheels)*
CN1--1
0 รท 40 km/h
96
Power Take Off Speed
CN1--2
0 รท 1200 rev/min
Only machines with manual transmission. (**) Refer to chapter 55 section 6 page 252. (*)
HF MENU CONTROL PANEL HARDWARE VERSION Access the HC/HE HH MENU as described on page 2 and proceed as follows. -- Select the HF MENU with buttons (1) and (2), press key (3) to access the above--mentioned HF MENU.
0 x100
1 3
2
30 --
--
The central display will show the identification numbers of the control unit hardware version in sequence: 0599 = type of hardware; 0300 -- 0000 = version number; 0647 -- 0013 = series number. At the end of the procedure, auto kick out to HF, from here it is possible to move through all the menus.
0599 HC HF
0300 0000 0647 0013 31
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
13
HH MENU OF THE TRANSMISSION (RJ) H1 -- CALIBRATIONS H2 -- DISPLAY OF THE CALIBRATION VALUES H3 -- OPTIONS H4 -- SOFTWARE REVISION LEVEL H5 -- CONTROL SWITCHES DIAGNOSTICS H6 -- VEHICLE INFORMATION VIEW H7 -- VEHICLE TEST H8 -- DELETE DATA SAVED IN MEMORY H9 -- VOLTMETER FUNCTIONS HB -- SAVED FAULTS DISPLAY HC -- DELETION OF SAVED FAULTS HE -- FREQUENCY SIGNAL MONITORING HF -- HARDWARE VERSION
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
14
MENU H1 CALIBRATIONS Calibrations Fault Codes If the Faults Detection Logic reads a fault condition, the code will flash on the information monitor. In this manner, the fault condition can be displayed whilst in HH mode. During calibration, certain faults may be masked.
1024
2024
ATTENTION Park the tractor on level ground in an unobstructed area (in case of sudden movement).
32
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 á 50 °C. Unless otherwise specified, the levers: - Shuttle control; - gear control; - range gear control; - creeper lever; are in the NEUTRAL position.
Access the HH MENU RJ as described on page 2 and proceed as follows. -- Select the H1 MENU with buttons (1) and (2), press key (3) to access the subsystem of the above--mentioned H1 MENU.
0 x100
1 3
2
33
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 --
Select the H1 MENU options with buttons (1, fig. 35) and (2, fig. 35) and with button (3, fig. 35) access the chosen option.
15
RJ H1
RJ H1
RJ H1
34
POWER SHUTTLE 12X12 AND 20X20 CLUTCH CALIBRATION TRANSMISSION Press button (3) to access the H1 MENU of the gearbox. -- To calibrate the clutches the operator must be seated in the driving seat.
0 x100
--
Press the clutch pedal, start up the engine and take it to a speed of 1250 ÷ 1350 rev/min.
--
Engage the 1st gear and III range, move the Power Shuttle control lever onto forward travel and release the clutch pedal.
1 3
2
35
NOTE: The clutches can also be calibrated without the tool 380000843, just keep the buttons (1 and 2, fig. 35) minutes adjustment or hours adjustment pressed simultaneously while starting the machine. --
If you have selected the H1 MENU you need to do the calibrations or turn the switch (1, fig. 40) to A (OFF).
--
The central display will show CAL then the transmission oil temperature 50 °C.
NOTE: Clutch calibration is possible with both high and low oil temperatures, even if the display signals two alarm conditions to the driver: CL -- in the case of cold oil (under 20 °C) CH -- in the case of hot oil (over 100 °C)
RJ
H1
CAL 50C 36
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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
16 --
--
--
Using button (2 or 1, fig. 35) select clutch A or B then keep the button (1, fig. 35) pressed to do the calibration. The display will show in sequence: A = clutch to calibrate; I = vertical bar that, blinking, moves from the left to the right: 280 = progressive calibration value: A / 295 = end calibration value that alternates with the clutch. Release the button (1, fig. 35).
RJ
A
H1
I 280 320
A 37
--
--
Using the button (2 or 1, fig. 35) select the clutch B and keep the button (1, fig. 35) pressed to calibrate the clutches. If a fault is found during calibration, the display will show the relevant error code U (see table on page 19).
RJ
b
H1
I 280 320
A 38
NOTE: After selecting the clutch to calibrate with the button (2 or 1, fig. 35) it is possible to start automatic calibration by pressing the hours adjustment button h (2, fig. 35) for a few seconds, then automatically, both clutches will calibrate and, at the end, the central display will show End.
RJ
H1
A b End 39
--
After calibrating all the clutches turn the switch (1) to A (OFF) to save the calibrations.
MDB1669A
40 87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
17
TRANSMISSION OF CALIBRATIONS OF POWER SHUTTLE CLUTCHES WITH DUAL COMMAND (2 SPEED POWER SHIFT) FUNCTIONS Press button (3) to access the H1 MENU of the gearbox. -- To calibrate the clutches the operator must be seated in the driving seat. -- Press the clutch pedal, start up the engine and take it to a speed of 1250 ÷ 1350 rev/min; -- Engage the 1st gear and III range, move the Power Shuttle control lever onto forward travel and release the clutch pedal.
0 x100
1 3
2
41
NOTE: The clutches can also be calibrated without the tool 380000843, just keep the buttons (2 and 3) of the HI and LO Dual Command (2 Speed Power Shift) pressed at the same time while starting up the machine. --
If you have selected the H1 MENU you need to do the calibrations or turn the switch (1, fig. 47) to A (OFF).
42
--
The central display will show CAL then the transmission oil temperature 50 °C.
NOTE: Clutch calibration is possible with both high and low oil temperatures, even if the display signals two alarm conditions to the driver: CL -- in the case of cold oil (under 20 °C) CH -- in the case of hot oil (over 100 °C)
RJ
H1
CAL 50C 43
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
18 --
--
--
Using button HI (2, fig. 42) select clutch A then keep the LO button (3, fig. 42) pressed to do the calibration. The display will show in sequence: A = clutch to calibrate; I = vertical bar that, blinking, moves from the left to the right: 280 = progressive calibration value: A / 295 = end calibration value that alternates with the clutch. Release the LO button (3, fig. 42).
RJ
A
H1
I 280 320
A 44
--
--
Using the HI button (2, fig. 42) select the clutches b, C and d and keep the LO button (3, fig. 42) pressed to calibrate the above--mentioned clutches. If a fault is found during calibration, the display will show the relevant error code U (see table on page 19).
b RJ
H1
C d 45
NOTE: After selecting the clutch to calibrate with the button LO (3, fig. 42) it is possible to start automatic calibration by pressing the hours adjustment button h (2, fig. 41) for a few seconds, then automatically, the other clutches will calibrate and, at the end, the central display will show End.
b RJ
H1
C d End 46
--
After calibrating all the clutches turn the switch (1) to A (OFF) to save the calibrations.
MDB1669A
47 87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
19
Calibration error code Code
Description
U19
Oil temperature <10 °C, calibration is not possible
U20
Wrong sequence, operate the Power Shuttle control lever and the clutch control pedal
U21
Engine speed too low
U22
Engine speed too high
U23
Power Shuttle control lever on neutral
U24
Wrong range selection (the III range is not engaged)
U25
Gear lever in neutral
U26
Clutch pedal pressed
U31
Tractor in motion
U33
Parking brake off
U34
Operator not seated in driving seat
U36
Calibration value too high
U37
Calibration value too low
CL
Low oil temperature <20 °C
CH
High oil temperature > 100 °C
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
20
CALIBRATION LIFT ----
--
Pre--Test Procedure. Apply a weight of approx. 200 kg to the lift arms. Lower lift arms and disconnect vertical rods supporting the automatic pick--up hitch (where fitted). Turn all the potentiometers for setting sensitivity, speed, arm height and slip clockwise.
48 --
Set the draft control ring (1) on 10 (during the calibrations the system must not read the draft).
49 Arm position control potentiometer calibration. Press button (3) to access the above--mentioned H1 MENU of the lift. 1. Press the clutch pedal, start up the engine and take it to a speed of 1200 รท 1400 rev/min;
0 x100
1 3
2
50 NOTE: The potentiometer can also be calibrated without the tool 380000843, simply keep the lift, lower, rapid ground entry button (1, fig. 51) pressed on lifting, start the machine and, when the lift status indicator light (1, fig. 52.) blinks, release the push--button.
51 87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
21
NOTE: There will be no message on the display, the only thing that will occur on entering calibration with the push--button (1, fig. 51) is the blinking of the warning light and...
52 NOTE: ...the performance monitor will show the fault code 1024 (run hydraulic lift auto--calibration). After potentiometer calibration, in this last case it is obviously necessary to calibrate the solenoid valves too.
1024
53 2. Capture the lift arms with the position lever, then move it fully back. When the lift arms stop rising (you will hear the pressure relief valve trip for a moment) the value of the potentiometer is taken as the top calibration limit. The arms will lower slightly by approximately 4% to protect the casing from mechanical damage. This position will be 96% of the travel, but it is considered to be 100%.
54 3. Move the position lever fully forwards, when the arms stop lowering the value of the arms control potentiometer is taken as the lower value.
55 87679925A2 - 02 - 2010
22
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
4. After calibrating turn the switch (1) to A (OFF) to save the calibrations.
MD1669A
56 Solenoid valve calibration. Press button (3) to access the above--mentioned H1 MENU of the lift. -- Press the clutch pedal, start up the engine and take it to a speed of 1200 รท 1400 rev/min;
0 x100
1 3
2
57 NOTE: The solenoid valves can also be calibrated without the tool 380000843, simply keep the lift, lower, rapid ground entry button (1, fig. 51) pressed fully down, and in this condition start the machine and, when the lift status indicator light (1, fig. 52.) blinks, release the push--button.
58 5. The central display will show CAL.
RJ
H1
CAL
59 87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 6. Capture the lift arms with the position lever, then move them fully back between 70% and 90% of the travel.
23
80
60 7. On the central display CAL will show 0 to indicate the start of calibration. During calibration the lift is automatically raised and lowered by a small amount 3 times, which takes 2--3 minutes. Each lifting and lowering is counted 0 -- 1 -- 2 on the central display. When the display shows End calibration is over.
CAL
0 1
2
End 61
8. After calibrating turn the switch (1) to A (OFF) to save the calibrations.
MDB1669A
62 NOTE: For the to calibrations of the lift it is advisable to calibrate the arms position control potentiometer and afterwards, without exiting calibration, calibrate the solenoid valves. Enter calibration either with program H1 of menu HH, or with button (1, fig. 63) pressed on rapid ground entry (fully down), then calibrate the lift by following the operations: -- 5, the one that appears on the central display, -- 1, 2, 3 and 4 to calibrate the arms lift potentiometer, -- 6, 7 and 8 to calibrate the solenoid valves.
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
24
MENU H2 DISPLAY OF THE CALIBRATION VALUES Access the HH MENU RJ as described on page 2 and proceed as follows. -- Select the H2 MENU with buttons (1) and (2), press key (3) to access the submenu.
0 x100
1 3
2
64 ---
Select the H2 MENU options with buttons (1) and (2), press button (3) to access the submenu. After consulting the selected submenu, press the button (3, fig. 64) to go back to the H2 menu where it is possible to move through the various menus.
RJ H2
RJ H2
RJ H2
65 Press the button (3, fig. 64) to access the submenu of the gearbox. -- The central display will show the current clutch calibration values. -- It is possible to select the various faults by pressing buttons (1, fig. 64) and (2, fig. 64). Channel
Description
Standard value
Ch1
Clutch A
220 รท 480 mA
Ch2
Clutch B
220 รท 480 mA
Ch3
Clutch C
160 รท 480 mA
Ch4
Clutch D
160 รท 480 mA
ch1 RJ H2
A 280 66
NOTE: The above values apply both to clutches A and B of the Power shuttle 12X12 version and the clutches A, B, C and D of the Power shuttle version with Dual Command (2 Speed Power Shift) functions. The predefined calibration values are: clutches A and B -- 275 mA clutches C and D -- 250 mA. The above--mentioned values are the standard values of the clutches that, after deleting the memory in H8, enable moving the machine.
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 Press the button (3, fig. 64) to access the submenu of the lift. -- The central display will show the current clutch calibration values. -- It is possible to select the various faults by pressing buttons (1, fig. 64) and (2, fig. 64). -- Press button (3, fig. 64) to go back to the higher level. Channel
Solenoid valve value
Standard value
Ch1
Lifting
20 รท 80 mA
Ch2
Lowering
20 รท 80 mA
25
ch1 RJ H2
R 54 ch2 L 56 67
NOTE: The predefined calibration values are: Lifting solenoid valve -- 50 mA Lowering solenoid valve -- 50 mA. After deleting the memory with program H8 the predefined values in mA of the solenoid valves permit lift movement.
H3 MENU OPTIONS Access the HH MENU RJ as described on page 2 and proceed as follows. -- Select the H3 MENU with buttons (1) and (2), press key (3) to access the above--mentioned H3 MENU.
0 x100
1 3
2
68 --
--
--
Select the H3 MENU options with buttons (1, fig. 68) and (2, fig. 68), press button (3) to access the submenus. After making the modifications in the options of the various channels, press button (1, fig. 68) and (2, fig. 68), for 1 sec. an audible warning will be emitted for saving to memory and the program will go back to the H3 menu where it is possible to move through the various menus. After consulting the selected channel, without making any changes, press the button (3, fig. 68) to go back to the H3 menu where it is possible to move through the various menus.
RJ H3 RJ H3
RJ H3
RJ H3
RJ H3
69
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
26 --
Select the gearbox (ch1), the central display will show the options: HI, LO and Mid (pick--up value with gear shift).
H3
RJ
Clutch engagement time change speed threshold
--
LO
5 kph
MID
6.5 kph
HI
13 kp/h (default)
Select the required option with the buttons (1, fig. 68) and (2, fig. 68).
ch1 HI
LO
Mid 70
---
It is possible to select the various faults by pressing buttons (1, fig. 68) and (2, fig. 68). After selecting the required channel you can change the filling time for each clutch (from 30 to 150 ms (milliseconds) with 10 ms increments.
H3
RJ
ch2
A4
ch3
b4
ch4
C6
ch5
d6 71
NOTE: The above values apply both to clutches A and B of the Power shuttle 12X12 and 20X20 versions and the clutches A, B, C and D of the Power shuttle version with Dual Command (2 Speed Power Shift) functions. The default filling times are: clutches A and B -- 60 ms clutches C and D -- 40 ms. --
--
Select the channel (ch6), the central display will show: PS12 (for machines with Power shuttle 12X12 transmission), PS20 (for machines with Power shuttle transmission and creeper unit) and PS24 (for machines with Power shuttle transmission with Dual Command (2 Speed Power Shift) functions). Select the required option with the buttons (1, fig. 68) and (2, fig. 68).
ch6 RJ
H3
PS12 PS20 PS24 72
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 --
--
Select the channel (ch7) to select the aggressiveness of clutch engagement during operations of gear changing and reversal. The central display will show: SOFT (for low aggressiveness), MID (for medium aggressiveness) and FAST (for high aggressiveness). Select the required option with the buttons (1, fig. 68) and (2, fig. 68).
27
ch7 RJ
H3
SOFT MID FAST 73
NOTE: This selection can also be made without entering the HH programs; do the following. -- Park the vehicle. -- Key--off the engine. -- With the shuttle lever on forward speed, the clutch pedal released and both pedals pressed, turn the starter switch onto power, without starting the engine. -- Then make the selection with the buttons (1, fig. 68) and (2, fig. 68). -- Press to save the button (1, fig. 68) and (2, fig. 68) for 1 sec, you will hear an acoustic signal.
--
--
Select the PTO channel (ch1), the central display will show: YES (for enabling PTO buttons on the mudguards) or NO (for disabling PTO buttons on the mudguards). Select the required option with the buttons (1, fig. 68) and (2, fig. 68).
ch1 RJ
H3
YES no 74
--
--
Select the 4WD channel (ch1), the central display will show: tr 2 (for two--wheel drive machines) and tr 4 (for four--wheel drive machines). Select the required option with the buttons (1, fig. 68) and (2, fig. 68).
ch1 RJ
H3
tr 2 tr 4 75
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
28 --
--
Select the lift channel (ch1), the central display will show: r 0, r 1 or r 2 to indicate the external cylinder size option. Select the required option with the buttons (1, fig. 68) and (2, fig. 68).
ch1 RJ
H3
r0 r1 r2 76
--
--
Select the channel (ch2), the central display will show: YES to indicate there is an electronic lift on the machine or NO if there is not. Select the required option with the buttons (1, fig. 68) and (2, fig. 68).
ch2 RJ
H3
YES no 77
--
--
Select the channel (ch2), the central display will show: YES to indicate there is an electronic lift with slip control on the machine or NO if there is not this control. Select the required option with the buttons (1, fig. 68) and (2, fig. 68).
ch3 RJ
H3
YES no 78
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
29
H4 MENU SOFTWARE REVISION LEVEL Access the HH MENU RJ as described on page 2 and proceed as follows. -- Select the H4 MENU with buttons (1) and (2), press key (3) to access the above--mentioned H4 MENU.
0 x100
1 3
2
79 --
--
The central display will show the identification numbers of the control unit software release in sequence: 1135 -- Software type. 01 -- Main release. 00 -- Secondary release. 00 -- Development project. 00 -- Development iteration. At the end of the procedure, auto kick out to H4, from here it is possible to move through all the menus.
1135 RJ H4
0100 0000 80
H5 MENU TRANSMISSION CONTROL SWITCHES DIAGNOSTICS Access the HH MENU RJ as described on page 2 and proceed as follows. -- Select the H5 MENU with buttons (1) and (2), press key (3) to access the above--mentioned H5 MENU.
0 x100
1 3
2
81 ---
The central display will show the number of the switch that has been operated. Press the button (3, fig. 81) to go back to the H5 menu where it is possible to move through the various menus.
RJ H5
d70
82 87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
30
PTO switches Code
Description
ECU pin(**)
d61
Engagement of power take--off (normally open)
CN3A--12
d62
Engagement of power take--off (normally closed)
CN3A--13
d63
Switch on mudguard (normally off)
CN3A--18
d64
Switch on mudguard (normally on)
CN3A--3
d65
Soft start switch
CN3B--22
Four--wheel drive and differential lock switches Code
Description
ECU pin(**)
d70
Four--wheel drive engagement
CN3A--24
d71
Differential lock on automatic
CN3B--30
d72
Differential lock permanently on
CN3B--31
d73
LH brake pedal
CN1B--22
d74
RH brake pedal
CN1B--23 Driveline switches
Code
Description
ECU pin(**)
d20
Clutch pedal potentiometer
CN3A--7
d21
Clutch pedal switch (12 VD) with Shuttle lever not in neutral.(*)
CN1A--8
d22
Forward switch (Power Shuttle lever)
CN1B--12
d23
Reverse switch (Power Shuttle lever)
CN1B--13
d24
LO gear control button
CN3A--11
d25
HI gear control button
CN3A--10
d26
Shuttle lever neutral/run switch
CN1B--24
d29
Oil temperature sensor
CN1B--14
d33
Gear lever switch (G)
CN3A--4
d34
Range lever switch (R1)
CN3A--5
d35
Theoretical speed sensor (12X12 and 24X24 version)
CN1B--34
d35
Theoretical speed sensor (20X20 version)
CN3B--22
d36
Seat switch
CAN
d39
Parking brake switch
CAN
d42
Clutch pressure switch A
CN1B--21
d43
Clutch pressure switch B
CN1B--28
d50
Range lever switch (R2)
CN3A--26
d55
Clutch cut--out switch on the Power Shuttle shift lever
CN3A--8
d56
Creeper unit status switch
CN3A--16
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
31
Lift switches Code
Description
ECU pin(**)
d1
EDC lowering switch on the mudguard
CN1B--30
d2
EDC raising switch on the mudguard
CN1B--29
d3
Lift--o--matic switch on lowering
CN1B--18
d4
Lift--o--matic switch on raising
CN1B--20
d5
Lift--o--matic switch on fast ground entry
CN3A--6
d7
Lift arms potentiometer
CN1B--2
d8
Position control potentiometer
CN1B--3
d9
Drop rate potentiometer
CN1B--4
d10
Height limit potentiometer
CN1B--5
d11
Sensitivity potentiometer
CN1B--6
d12
Draft control potentiometer
CN1B--8
d13
Right--hand draft sensing pin
CN1B--9
d14
Left--hand draft sensing pin
CN1B--10
d15
Radar sensing line
CN1B--19
d17
Slip limit potentiometer
CN1B--7
(*) Test the switch d21 with the shuttle lever in forward or reverse speed. If the operator moves the lever from neutral into the forward speed position, the codes displayed will be d26, d21 and d22; when it is moved from neutral into the reverse gear position, the codes displayed will be d26, d21 and d23. (**) Refer to chapter 55 section 6 page 249 and 251.
H6 MENU VEHICLE INFORMATION DISPLAY Access the HH MENU RJ as described on page 2 and proceed as follows. -- Select the H6 MENU with buttons (1) and (2), press key (3) to access the above--mentioned H6 MENU.
0 x100
1 3
2
83
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
32 --
--
Select the channel (ch1), with the buttons (1, fig. 83) and (2, fig. 83), the central display will show: PS 24 if there is a Power shuttle transmission with Dual Command (2 Speed Power Shift) functions or PS12 with Power shuttle 12X12 transmission. The central display will show the setting of the transmission: -- PS24 for PS with Dual Command (2 Speed Power Shift) functions -- PS12 for PS -- PS20 for PS with creeper unit press the button (3, fig. 83) to go back to the H3 menu where it is possible to move through the various menus.
ch1 RJ H6
PS24 PS12 PS20 84
H7 MENU TRANSMISSION VEHICLE TEST Access the HH MENU RJ as described on page 2 and proceed as follows. -- Select the H7 MENU with buttons (1) and (2), press key (3) to access the above--mentioned H7 MENU. -- It is possible to select the various channels by pressing buttons (1) and (2). -- Press the button (3) to go back to the H7 menu where it is possible to move through the various menus.
0 x100
1 3
2
85 Clutch pedal switch -- Select the channel (ch1), move the Power Shuttle lever onto forward travel. -- The display will show the percentage of the clutch pedal travel and the switch status (O for off, C for on). -- The status of the clutch pedal switch must change: > 5% of the travel on pressing the pedal; < 15% of the travel on releasing the pedal.
RJ H7
ch1 O6 C 14
Range switch R1 and R2 --
--
86
Select the channel (ch2), moving the range lever onto the various positions and the central display will show the corresponding range. Following the condition of the range lever status switches. Range
Switch R1
Switch R2
I
Closed
Closed
II
Closed
Open
III
Open
Closed
N
Open
Open
ch2 RJ H7
N r1 r2 r3 87
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 Manual calibration of clutches with Power Shuttle transmission with Dual Command (2 Speed Power Shift) functions 24X24. -- To calibrate the clutches the operator must be seated in the driving seat. -- Engage the 1st gear and III range, and switch on the machine. -- Select the channel (ch3), with the shuttle in neutral and the clutch pedal raised, the central display will show the oil temperature. -- Move the Power Shuttle lever forwards to select clutch A or backwards to select clutch B.
33
ch3 50C
RJ H7
A280
b290
C275
C275
d285
d285 88
--
Press the clutch pedal and, using buttons (1, fig. 89) and (2, fig. 89), select clutches A, C and D or B, C and D.
0 x100
1 3
2
89 --
Release the clutch pedal and press the HI (2) or LO (3) buttons to increase or decrease the calibration of each clutch.
NOTE: When optimizing the calibration values, driveline oil temperature should be warm to hot; preferably no lower than 40 °C. NOTE: It is possible to test the modified calibration values by carrying out one of the following procedures. --
--
As soon as the calibration value has been modified, engage the gear and range levers (do not leave them in neutral), release the clutch pedal above 95% of the travel, put the shuttle lever into neutral and then put it into forward drive (for clutch A, C and D) and into reverse drive (for clutch B, C and D), you will hear the relevant clutch engage. Switch off the machine.
90 Clutch to test
Clutches applied P.S. lever forward
P.S. lever reverse
A
A+C
B
B+C
C
A+C
B+C
D
A+D
B+C
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
34
Manual calibration of clutches with Power Shuttle 12X12 and 20X20 transmission. ----
--
To calibrate the clutches the operator must be seated in the driving seat. Engage the 1st gear and III range, and switch on the machine. Select the channel (ch3), with the shuttle in neutral and the clutch pedal raised, the central display will show the oil temperature. Move the Power Shuttle lever forwards to select clutch A or backwards to select clutch B.
ch3 RJ H7
50C A280
b290 91
--
Release the clutch pedal and press the buttons (1, fig. 92) and (2, fig. 92) to increase or decrease the calibration of each clutch.
0 x100
1 3
2
92 NOTE: When optimizing the calibration values, driveline oil temperature should be warm to hot; preferably no lower than 40 °C.
Clutch to test
Clutch applied
Solenoid valve powered
NOTE: It is possible to test the modified calibration values by carrying out one of the following procedures.
A
A
Drain
B
B
Drain
--
--
As soon as the calibration value has been modified, engage the gear and range levers (do not leave them in neutral), release the clutch pedal above 95% of the travel, put the shuttle lever into neutral and then put it into forward drive (for clutch A) and into reverse drive (for clutch B), you will hear the relevant clutch engage. Switch off the machine.
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 Modify filling time of clutches with Power Shuttle transmission with Dual Command (2 Speed Power Shift) functions 24X24 -- To make the modification the operator must be seated in the driving seat. -- Engage the 1st gear and III range, and switch on the machine. -- Select the channel (ch4), with the shuttle in neutral and the clutch pedal raised, the central display will show the oil temperature. -- Move the Power Shuttle lever forwards to select clutch A or backwards to select clutch B.
35
ch4 50C
RJ H7
A4
b4
C6
C6
d6
d6 93
--
Press the clutch pedal and, using buttons (1) and (2) select clutches A, C and D or B, C and D.
0 x100
1 3
2
94 --
Release the clutch pedal and press the HI (2) or LO (3) buttons to increase or decrease the modification value of the filling times.
NOTE: When optimizing the calibration values, driveline oil temperature should be warm to hot; preferably no lower than 40 °C. NOTE: It is possible to test the modified filling values by carrying out one of the following procedures. --
--
As soon as the calibration value has been modified, engage the gear and range levers (do not leave them in neutral), release the clutch pedal above 95% of the travel, put the shuttle lever into neutral and then put it into forward drive (for clutch A, C and D) and into reverse drive (for clutch B, C and D), you will hear the relevant clutch engage. Switch off the machine.
95 Clutch to test
Clutches applied P.S. lever forward
P.S. lever reverse
A
A+C
B
B+C
C
A+C
B+C
D
A+D
B+C
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
36
Modify filling time of clutches with Power Shuttle 12X12 and 20X20 transmission ----
--
To make the modification the operator must be seated in the driving seat. Engage the 1st gear and III range, and switch on the machine. Select the channel (ch4), with the shuttle in neutral and the clutch pedal raised, the central display will show the oil temperature. Move the Power Shuttle lever forwards to select clutch A or backwards to select clutch B.
ch3 RJ H7
50C 48
52 96
--
Release the clutch pedal and press buttons (1) and (2) to increase or decrease the filling time of each clutch.
0 x100
1 3
2
97 NOTE: When optimizing the calibration values, driveline oil temperature should be warm to hot; preferably no lower than 40 °C.
Clutch to test
Clutch applied
Solenoid valve powered
NOTE: It is possible to test the modified filling values by carrying out one of the following procedures. -- As soon as the calibration value has been modified, engage the gear and range levers (do not leave them in neutral), release the clutch pedal above 95% of the travel, put the shuttle lever into neutral and then put it into forward drive (for clutch A) and into reverse drive (for clutch B), you will hear the relevant clutch engage. Switch off the machine.
A
A
Drain
B
B
Drain
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
37
H8 MENU TRANSMISSION DELETION OF DATA SAVED IN MEMORY Access the HH MENU RJ as described on page 2 and proceed as follows. -- Select the H8 MENU with buttons (1, fig. 97) and (2, fig. 97), press key (3, fig. 97) to access. NOTE: On entering H8 you can delete the control unit memory on two levels: -- from the highest one, on entering H8 you delete everything concerning the control unit irrespective of the submenus, -- from the lowest one, on entering the subsystems, you can delete the values of the subsystem, -- The values to delete are: calibration currents, filling times and gear shift pick/up values (the values must be taken to the default ones, for the calibration currents the control unit will create fault codes 1024 and 2024), fault codes. -- Once you have decided with to delete everything or only a portion, enter the subsystems using the buttons (1, fig. 97 and (2, fig. 97) and press button (3, fig. 97) to confirm, and delete as follows. -- The central display will show EECL. -- To delete the memory configuration you need to keep the button (1, fig.) pressed down until the procedure is completed, that is when the display shows EE. NOTE: In the example of fig. 99 the transmission, four--wheel drive, differential lock, lift, transmission and power take--off memory will be deleted.
RJ H8
RJ H8
RJ H8
RJ RJ H8
98
RJ H8
4 3 2
EECL
1
5
EE 99
--
Turn the switch (1) to A (OFF).
MDB1669A
100
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
38
H9 MENU TRANSMISSION VOLTMETER Access the HH MENU RJ as described on page 2 and proceed as follows. -- Select the H9 MENU with buttons (1) and (2), press key (3) to access the above--mentioned H9 MENU.
0 x100
1 3
2
101 --
It is possible to select the various faults by pressing buttons (1, fig. 101) and (2, fig. 101). The central display will show the selected channel followed by the relevant measurement. Press button (3, fig. 101) to go back to the HH MENU.
---
RJ H9
ch 1 70 102
Description
ch
ECU pin(*)
Module
Standard value
1
Clutch pedal potentiometer
CN3A--7
Transmiss.
∼ 12 (pressed) ∼ 79 (released)
2
Transmission oil temperature
CN1B--14
Transmiss.
∼ 47 (at 25 °C)
4
12VH
CN1A--20
EDC
45
5
12VT
CN3B--34
BD
42
7
Clutch A
CN3B--1
Transmiss.
∼ 3 (clutch disengaged) ∼ 70 (clutch engaged)
8
Clutch B
CN3B--2
Transmiss.
∼ 3 (clutch disengaged) ∼ 70 (clutch engaged)
9
Forward switch
CN1B--12
Transmiss.
∼ 60 (Shuttle lever on forward) ∼ 30 (Shuttle lever in neutral)
10
REV-- Switch
CN1B--13
Transmiss.
∼ 60 (Shuttle lever in reverse) ∼ 30 (Shuttle lever in neutral)
11
Wheel speed sensor (12X12 and 24X24 version)
CN1B--34
Transmiss.
∼ 40 ÷ 55
12
Clutch C and dump solenoid valve
CN3B--3
Transmiss.
∼ 3 (clutch disengaged) ∼ 70 (clutch engaged)
13
Clutch D
CN3B--4
Transmiss.
∼ 3 (clutch disengaged) ∼ 70 (clutch engaged)
14
Engine speed
CAN
Transmiss.
Engine RPM received from CAN network
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
39
16
Gear lever switch (G)
CN3A--4
Transmiss.
∼ 30 (gear engaged) ∼ 67 (gearbox in neutral)
17
Range lever switch (R1)
CN3A--5
Transmiss.
∼ 30 (range gear in neutral and I) ∼ 67 (range II and III engaged)
18
Range lever switch (R2)
CN3A--26
Transmiss.
∼ 30 (range gear in neutral and II) ∼ 67 (range I and III engaged)
19
12 VF
CN1A--1 CN1A--2
Transmiss.
∼ 48 (engine running)
20
12 VD
CN1A--8
Transmiss.
∼ 48 (engine running, clutch pedal released and Shuttle lever engaged) ∼ 0 (engine running, clutch pedal lowered and Shuttle lever in neutral)
21
5 Volts sensor supply
CN1B--17
Transmiss.
∼ 49
22
8 Volts sensor supply
CN1B--25
Transmiss.
∼ 79
23
Wheel speed sensor (20x20 version)
CN3B--22
Transmiss.
∼ 40 ÷ 55 99 open circuit
25
Power take--off solenoid valve
CN3B--18
PTO
∼ 100
26
Dump solenoid valve
CN3B--3
Transmiss.
∼ 100
27
Power supply fuse of pressure switch for clutches A and B (F18 -- 10A)
CN3A--1
Transmiss.
30
Lifting solenoid valve
CN2--4
EDC
∼ 0 (solenoid valve de--energized) ∼ 66 (solenoid valve energized)
31
Lowering solenoid valve
CN2--5
EDC
∼ 0 (solenoid valve de--energized) ∼ 66 (solenoid valve energized)
32
Lift arm position Pot
CN1B--2
EDC
∼ 6 (arms down) ∼ 79 (arms up)
33
Work control potentiometer in position
CN1B--3
EDC
∼ 25 (arms down) ∼ 74 (arms up)
34
Drop rate potentiometer
CN1B--4
EDC
∼ 14 (minimum speed) ∼ 84 (maximum speed)
35
Height limit potentiometer
CN1B--5
EDC
∼ 14 (maximum lift limit) ∼ 84 (minimum lift limit)
36
Sensitivity potentiometer
CN1B--6
EDC
∼ 14 (minimum sensitivity) ∼ 84 (maximum sensitivity)
37
Slip limit potentiometer
CN1B--7
EDC
∼ 14 (minimum slip limit) ∼ 84 (maximum slip limit)
38
Right--hand draft sensing pin
CN1B--9
EDC
∼ 42
39
Left--hand draft sensing pin
CN1B--10
EDC
∼ 42
40
Draft setting potentiometer
CN1B--8
EDC
∼ 14 (draft mode) ∼ 89 (position mode)
∼ 100
(*) Refer to chapter 55 section 6 page 249 and 251.
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
40
HB MENU TRANSMISSION SAVED FAULTS DISPLAY Access the HH MENU RJ as described on page 2 and proceed as follows. -- Select the HB MENU with buttons (1) and (2), press button (3) to access the submenu.
0 x100
1 3
2
103 --
Select the subsystem module with the buttons (1, fig. 103) and (2, fig. 103), press the button (3, fig. 103) to access the submenu.
RJ HB RJ HB RJ HB
RJ HB RJ HB
RJ HB
104 ----
--
The central display will show the fault codes logged in the control unit module. It is possible to select the various faults by pressing buttons (1, fig. 103) and (2, fig. 103). Besides the fault number, the display will show in sequence: the number of hours in which the fault first occurred; the number of hours in which the fault last occurred; the number of times the fault has occurred. Press the button (3, fig. 103) to go back to the H8 menu where it is possible to access the various menus.
87679925A2 - 02 - 2010
F PA
HB
14061 300 350 3 105
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
41
HC MENU TRANSMISSION DELETION OF SAVED FAULTS Access the HH MENU RJ as described on page 2 and proceed as follows. -- Select the HC MENU with buttons (1) and (2), press key (3) to access the above--mentioned HC MENU.
0 x100
1 3
2
106 ---
--
The central display will show FCL. To delete the memory you need to keep the button (1, fig. 106) pressed down until the procedure is completed, that is when the display shows EE. Press the button (3, fig. 106) to go back to the HC menu where it is possible to browse through the various menus.
4
RJ HC
3 2 FCL
1
5
EE 107
HE MENU TRANSMISSION FREQUENCY SIGNAL MONITORING Access the HH MENU RJ as described on page 2 and proceed as follows. -- Select the HE MENU with buttons (1) and (2), press key (3) to access the above--mentioned HE MENU.
0 x100
1 3
2
108
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
42 --
The central display will show the selected channel number followed by the relevant measurement. It is possible to select the various faults by pressing buttons (1, fig. 108) and (2, fig. 108). Press the button (3, fig. 108) to go back to the HE menu where it is possible to browse through the various menus.
---
Description
ch
RJ HE
ECU pin(*)
1
Wheel speed sensor (Hz) (12X12 and 24X24 version)
CN1B--34
1
Wheel speed sensor (Hz) (20x20 version)
CN3B--22
2
Wheel speed (km/h) (12X12 and 24X24 version)
CN1B--34
2
Wheel speed (km/h) (20x20 version)
CN3B--22
3
Engine rpm (rpm)
4
Radar
CAN CN1B--33
ch1
151
ch2
5.3
ch3
750 109
(*) Refer to chapter 55 section 6 page 249 and 251.
HF MENU TRANSMISSION HARDWARE VERSION Access the HH MENU RJ as described on page 2 and proceed as follows. -- Select the HF MENU with buttons (1) and (2), press key (3) to access the above--mentioned HF MENU.
0 x100
1 3
2
110 --
The central display will show the identification numbers of the control unit hardware version in sequence: 604 = type of hardware with EDC; 603 = type of hardware without EDC; 0100 -- 0000 = version number; 0000 -- 2000 = serial number. It will automatically go back to HF where it is possible to browse among the various menus.
604 RJ HF
0100 0000 0000 2000 111
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
43
HH MENU OF THE ADVANCED KEYPAD (JB) H4 -- SOFTWARE REVISION LEVEL HF -- HARDWARE VERSION
H4 MENU ADVANCED KEYPAD SOFTWARE REVISION LEVEL Access the JB HH MENU as described on page. 2 and proceed as follows. -- Select the H4 MENU with buttons (1) and (2), press key (3) to access the above--mentioned H4 MENU.
0 x100
1 3
2
112 --
The central display will show the identification numbers of the control unit software release and then automatically go back to the H4 menu where it is possible to browse through the various menus.
1024 JB H4
0100 0000 113
HF MENU ADVANCED KEYPAD HARDWARE VERSION Access the JB HH MENU as described on page 2 and proceed as follows. -- Select the HF MENU with buttons (1) and (2), press key (3) to access the above--mentioned HF MENU.
0 x100
1 3
2
114
87679925A2 - 02 - 2010
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
44 --
The central display will show the identification numbers of the control unit hardware version in sequence: 0531 = type of hardware; 0100 -- 0000 = version number; 9949 -- It295 = serial number. It will automatically go back to the H4 menu where it is possible to browse through the various menus.
0531 JB HF
0100 0000 9949 It295 115
87679925A2 - 02 - 2010
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
1
SECTION 90 -- BODYWORK AND DRIVING POSITION Chapter 1 -- Removing components
CONTENT Description
Page
Bonnet R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Platform. R.I.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Driverâ&#x20AC;&#x2122;s seat R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Cab. R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cab right-- or left--hand door. R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Cab windscreen. Repl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Cab RH or LH bottom front window. Repl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Cab rear window. Repl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Left--hand upright strip. Repl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Right--hand upright strip. Repl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Fixed padding on right--hand wall. Repl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Fixed padding on left--hand wall. Repl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Hydraulic control lever guard. Repl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Cab ceiling fitting. Repl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
87679925A - 12 - 2007
2
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
BONNET R.I.
ATTENTION 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. Lift the bonnet (1) and disconnect the battery negative cable.
1 2. Disconnect the connection of the front lights cable (1).
3. Insert the lifting sling (1).
2
3
87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
3
4. Remove the retaining clips and disconnect the two gas cylinders (1) for raising the bonnet.
5. Remove the four bolts (1) fastening the rear support for hinging the bonnet (2).
4
5 6. Remove the bonnet assembly (1).
7. To refit, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Insert the lifting sling on the bonnet.
--
Reconnect the rear support hinging the bonnet and tighten the four fixing screws.
--
Reconnect the two gas cylinders for raising the bonnet and refit the retaining clips.
--
Reconnect the front lights cable connection and the battery negative cable.
--
Close the bonnet.
6
87679925A - 12 - 2007
4
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
PLATFORM R.I.
ATTENTION
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 remove the cab, proceed as follows:
1. Remove the exhaust pipe extension (1), lift the bonnet (2) and disconnect the battery negative cable. 2. Remove the bonnet (2) as described in operation page 2. 3. Take out the three exhaust silencer rear retaining bolts (1).
7
8 4. Remove the clamp (1), the air filter dust ejector pipe (2) and the four nuts (3) securing the silencer to the exhaust manifold and the two bonnet support retaining bolts, then remove the silencer.
9
87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
5
5. Remove the four rear retaining bolts (1) of the bonnet support (2).
6. Remove the three front retaining bolts (1) of the bonnet support (2).
10
11 7. Disconnect the electrical connections (1) and (2) between the engine and platform cable and the transmission.
8. Disconnect all the electrical connections (1) located on the platform main cable and connect on the engine users. In the same way, disconnect all the connections of the platform main cable connected on users that remain on the transmission.
12
13 87679925A - 12 - 2007
6
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
9. Disconnect the two flexible hoses (1) from the power steering control cylinder and the delivery pipe between the pump and power steering.
10. Remove the electrical connections (2) from the brake fluid reservoir (1).
14
15 11. Remove the electrical connections (2) installed on the brake pumps (1). 12. Detach the control lines on the brake pump, removing the pressure gauges.
13. Remove the retaining clips (1) and detach the flexible cables governing the hand throttle (5) and pedal throttle (4). 14. Remove the retaining clip (3) and detach the throttle control tie--rod (2) connected to the injection pump.
16
17 87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1 15. Remove the four knobs (1) and take off the two right-- and left--hand dashboard panels (2).
1
7
2
MDD2562A
16. Take out the retaining nut and remove the clutch control tie--rod (1), take off the rubber guard and take the tie--rod out of its hole.
18
1
25393
19 17. Remove the return pipe from the power steering.
18. Remove the retaining clips and detach the two draft and position control rods (1).
20
1
24923
21 87679925A - 12 - 2007
8
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
19. Detach the auxiliary control valve rods (1).
20. Detach the retaining clips (2) on the PTO synchronised with gearbox control lever. 21. Disconnect the Creeper engagement lever (1).
22
1
2 MDF1799A
23 22. Remove the tie--rod (1) governing power take--off speed selection.
1
24928
23. Slide the dust hood down, unscrew the retaining bolt and detach the Shuttle control lever (1) (in the case of the standard machine).
24
1
24929
25 87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1 24. Lower the dust hood, disconnect the electrical connection on the power shuttle, loosen the retaining bolt and detach the gear selection lever (1). 25. Lower the dust hood, loosen the retaining bolt and remove the range selection lever (2).
1
9
2
25416
26. Remove the snap ring (1), extract the pin and disconnect the parking brake control cable.
26
1
24932
27 27. If a rear mechanical lock is fitted, remove the front and rear split pins and pivot pins from the drive lever and remove.
24934
28. Remove the Lift--O--Matic control cable (1) from the lever on the lift body and extract it from the bracket (2). 29. Disconnect the PTO clutch cable located under the gearbox on the fuel tank side.
28
1
2
24936
29 87679925A - 12 - 2007
10
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
30. Take out the retaining bolts (2) and disconnect the ground cable (3) and the breather pipe (1) of the rear transmission.
30
31. Remove the clamps (1) and the breather pipe (2) connecting the front and rear of the fuel tank.
31 32. Unscrew the bolts (1) securing the platform to the final drive (carry out on both sides).
1
24948
32
33. Hitch the platform to a hoist using 2 nylon slings and take up the slack.
24949
33 87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1 34. Unscrew the front bolt (1) securing the platform to the relative support (carry out on both sides). 35. Slightly raise the platform, making sure that there are no obstructions or connected parts, then remove and position on the flooring on a suitable support.
11
1
24951
34 36. To refit the platform, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Pick up the platform from the wooden base, transfer and lower it slowly onto the tractor body, carefully checking there are no cables or pipes that get in the way of the engine or transmission to prevent them getting damaged.
--
Reconnect the parking brake cable, refit the pin and the retaining circlip.
--
Fit the range selection lever, tighten the retaining bolts and lower the external guard.
--
Fit the retaining bolts on the front right-- and left--hand side of the platform.
--
--
Working from the rear of the tractor, fit the retaining bolts on the right-- and left--hand sides of the platform.
Fit the gear lever, tighten the retaining bolt and, if applicable, reconnect the electrical connection of the power shuttle, then lower the external guard.
--
Fit the reverser lever (in the case of the standard machine), tighten the retaining bolt and lower the external guard.
--
Refit the PTO speed selection tie--rod.
--
Reconnect the Creeper engagement lever.
--
Refit the retaining clips on the PTO synchronised with gearbox control lever.
--
Refit the auxiliary control valve rods.
--
Remove the two nylon ropes from the platform and disconnect them from the hoist.
--
Fit the breather pipe connecting the front and rear of the fuel tank and the associated clamps.
--
Reconnect the ground cable and the breather pipe of the rear transmission, tightening the associated retaining bolts.
--
Reconnect the PTO clutch cable located under the gearbox on the fuel tank side.
--
Fit the two draft and position control rods and their retaining clips.
--
Reconnect the Lift--O--Matic control cable to the lever on the lift body and insert it on the associated bracket.
--
Fit the return pipe from the power steering.
--
Fit the clutch tie--rod, rubber guard and associated retaining nut.
--
Fit the right-- and left--hand dashboard panels and the relevant four knobs.
--
If a rear mechanical lock is fitted, fit the drive lever, then the front and rear pins and the retaining split pins.
87679925A - 12 - 2007
12
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
--
Refit the throttle control tie--rod connected to the injection pump and the associated retaining clip.
--
Reconnect the transmission and engine main cables to the platform main cable.
--
Install the flexible cables governing the hand and pedal throttle and the associated retaining clips.
--
Fit the three front retaining bolts of the engine bonnet.
--
Reconnect the brake pump control lines with the pressure gauges.
--
Fit the four rear retaining bolts of the bonnet support.
--
Connect the electrical connections installed on the brake pumps.
--
--
Connect the brake fluid reservoir electrical connections.
Mount the silencer assembly, connect the air filter dust ejector pipe, mount the clamp and the four silencer retaining bolts to the exhaust manifold and the two retaining bolts to the bonnet support.
--
Fit and tighten the three rear exhaust silencer retaining bolts.
--
Install the bonnet as described in the operation page 2.
--
Reconnect the battery negative cable and lower the bonnet and reconnect the exhaust extension.
--
--
Connect the two oil delivery and return hoses to the power steering cylinders and the delivery pipe between the pump and power steering. Reconnect the other electrical connections located between the platform main cable and engine users and platform cable and transmission users.
87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
13
DRIVERâ&#x20AC;&#x2122;S SEAT R.I.
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. Unscrew the bolts (1) securing the seat to the bodywork and remove the seat.
1
24838
2. To assemble, proceed as follows:
35
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Fit the seat on the platform of the bodywork and lock the retaining bolts (1).
87679925A - 12 - 2007
14
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
CAB R.I.
ATTENTION
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 remove the cab, proceed as follows:
1. Lift the bonnet (1) and disconnect the battery negative cable. 2. Remove the bonnet (1) as described in operation page 2. 3. Take out the three exhaust silencer rear retaining bolts (1).
36
37 4. Remove the clamp (1), the air filter dust ejector pipe (2) and the four nuts (3) securing the silencer to the exhaust manifold.
38
87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
15
5. Remove the silencer (2) together with the exhaust pipe (1).
6. Remove the four rear retaining bolts (1) of the bonnet support (2).
39
40 7. Remove the three front retaining bolts (1) of the bonnet support (2).
8. Disconnect the electrical connections (1) and (2) between the cab and engine and transmission.
41
42 87679925A - 12 - 2007
16
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
9. Disconnect all the electrical connections (1) located on the cab main cable and connect on the engine users. In the same way, disconnect all the connections of the cab main cable connected on users that remain on the transmission.
10. Disconnect the two oil delivery and return hoses (1) to the power steering cylinders and the delivery pipe between the pump and power steering.
43
44 11. Remove the electrical connections (2) from the brake fluid reservoir (1).
12. Remove the electrical connections (2) installed on the brake pumps (1). 13. Detach the control lines on the brake pump, removing the pressure gauges.
45
46 87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
17
14. Remove the retaining clips (1) and detach the flexible cables governing the hand throttle (5) and pedal throttle (4). 15. Remove the retaining clip (3) and detach the throttle control tie--rod (2) connected to the injection pump.
47
16. Remove the four knobs (1) and take off the two right-- and left--hand dashboard panels (2).
1
2
MDD2562A
48 17. Take out the retaining nut and remove the clutch control tie--rod (1), take off the rubber guard and take the tie--rod out of its hole.
1
25393
18. Remove the three retaining bolts (1) and the guard (2) on the right--hand side of the fan.
49
50 87679925A - 12 - 2007
18
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
19. Detach the fitting (3) of the return pipe (2) for the coolant from the cab heater radiator connected to the underside of the coolant pump (1) and drain off the engine coolant.
20. Detach the clamp (1) and the cab heater delivery pipe (2).
51
52 21. Unhook the top pin (1) retaining the condenser.
22. Turn the steering wheel fully to the left, remove the radiator of the condenser (1) from the same side of the tractor.
53
54 87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1 23. Remove the two retaining bolts (2) and detach the support (3) together with the dryer filter (1) and pipes.
1
3 24. Remove the compressor (1) as described in section 50 without detaching pipes (2) and (3) so as not to then have to recover, evacuate and charge the gas in the air conditioning system.
19
2 55
56 25. Remove the condenser radiator (1). the dryer filter (2) with its support and the compressor (3), resting them alongside the right--hand rear wheel with the associated piping.
26. Remove the return pipe from the power steering.
57
58 87679925A - 12 - 2007
20
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
27. Remove the retaining clips and detach the two draft and position control rods (1).
1
24923
59
28. Detach the auxiliary control valve rods (1).
60 29. Detach the retaining clips (2) on the PTO synchronised with gearbox control lever. 30. Disconnect the Creeper engagement lever (1).
1
2 MDF1799A
31. Remove the tie--rod (1) governing power take--off speed selection.
61
1
24928
62 87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1 32. Slide the dust hood down, unscrew the retaining bolt and detach the Shuttle control lever (1) (in the case of the standard machine).
21
1
24929
63
33. Lower the dust hood, disconnect the electrical connection on the power shuttle, loosen the retaining bolt and detach the gear selection lever (1). 34. Lower the dust hood, loosen the retaining bolt and remove the range selection lever (2).
1
2
25416
64 35. Remove the snap ring (1), extract the pin and disconnect the parking brake control cable.
1
24932
65
36. If a rear mechanical lock is fitted, remove the front and rear split pins and pivot pins from the drive lever and remove.
24934
66 87679925A - 12 - 2007
22
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
37. Remove the Lift--O--Matic control cable (1) from the lever on the lift body and extract it from the bracket (2). 38. Disconnect the PTO clutch cable located under the gearbox on the fuel tank side.
1
2
24936
39. Remove the rear window washer liquid reservoir (1).
67
68 40. Take out the retaining bolts (2) and disconnect the ground cable (3) and the breather pipe (1) of the rear transmission.
41. Remove the clamps (1) and the breather pipe (2) connecting the front and rear of the fuel tank.
69
70 87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
23
42. Working from the rear of the tractor, take out the two retaining bolts (1) on the right-- and left--hand sides of the cab.
71
43. Take out the retaining bolts (1) on the front right-and left--hand sides of the cab, removing the nuts and washers.
72 44. Position tool 380000294 (1) inside the cab, hitch to a hoist using two nylon slings and take up the slack.
1
25552
45. Insert the condenser radiator (2) inside the cab. the dryer filter (1) with its support and the compressor (3), resting them on the deck together with the piping.
73
74 87679925A - 12 - 2007
24
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
46. Slowly raise the cab, checking there are no parts still connected or interfering with the engine or with the transmission, remove the cab (1) and put it down on a wooden base.
75
47. To re--fit the cab, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
--
--
Pick up the cab from the wooden base, transfer and lower it slowly onto the tractor body, carefully checking there are no cables or pipes that get in the way of the engine or transmission to prevent them getting damaged.
--
Reconnect the Lift--O--Matic control cable to the lever on the lift body and insert it on the associated bracket.
--
If a rear mechanical lock is fitted, fit the drive lever, then the front and rear pins and the retaining split pins.
--
Reconnect the parking brake cable, refit the pin and the retaining circlip.
--
Fit the range selection lever, tighten the retaining bolts and lower the external guard.
--
Fit the gear lever, tighten the retaining bolt and, if applicable, reconnect the electrical connection of the power shuttle, then lower the external guard.
--
Fit the reverser lever (in the case of the standard machine), tighten the retaining bolt and lower the external guard.
--
Refit the PTO speed selection tie--rod.
--
Reconnect the Creeper engagement lever.
--
Refit the retaining clips on the PTO synchronised with gearbox control lever.
Fit the retaining bolts on the front right-- and left--hand side of the cab. Working from the rear of the tractor, fit the two retaining bolts on the right-- and left--hand sides of the cab.
--
From inside the cab, extract the condenser radiator, the dryer filter with its support and the compressor of the air conditioner with all the associated piping, resting them alongside the right--hand rear wheel.
--
Remove the cab lifting tool 380000294, working from inside the cab and detach it from the hoist.
--
Fit the breather pipe connecting the front and rear of the fuel tank and the associated clamps.
--
Reconnect the ground cable and the breather pipe of the rear transmission, tightening the associated retaining bolts.
--
Install the rear window washer liquid reservoir.
--
Refit the auxiliary control valve rods.
--
Reconnect the PTO clutch cable located under the gearbox on the fuel tank side.
--
Fit the two draft and position control rods and their retaining clips.
87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
25
--
Fit the return pipe from the power steering.
--
Connect the electrical connections installed on the brake pumps.
--
Install the compressor as described in section 50 together with the pipes.
--
Connect the brake fluid reservoir electrical connections.
--
Refit the dryer filter together with its support and piping and tighten the retaining bolts.
--
--
Working on the left--hand side of the tractor, insert the condenser radiator and tighten it with the top pin.
Connect the two oil delivery and return hoses to the power steering cylinders and the delivery pipe between the pump and power steering.
--
Reconnect the other electrical connections located between the cab main cable and engine users and cab cable and transmission users.
--
Reconnect the transmission and engine main cables to the cab main cable.
--
Refit the cab heater return pipe and its clamp.
--
Refit the cab heater delivery pipe and its clamp.
--
Refill the radiator with engine coolant.
--
Fit the three front retaining bolts of the engine bonnet.
--
Fit the guard on the right--hand side of the fan and tighten the three retaining bolts.
--
Fit the four rear retaining bolts of the bonnet support.
--
Fit the clutch tie--rod, rubber guard and associated retaining nut.
--
Fit the silencer and exhaust pipe.
--
Fit the right-- and left--hand dashboard panels and the relevant four knobs.
--
Connect the air filter dust ejector pipe, fit the clamp and the four nuts securing the silencer to the exhaust manifold.
--
Refit the throttle control tie--rod connected to the injection pump and the associated retaining clip.
--
Fit and tighten the three rear exhaust silencer retaining bolts.
--
Install the flexible cables governing the hand and pedal throttle and the associated retaining clips.
--
Install the bonnet as described in the operation page 2.
--
Reconnect the brake pump control lines with the pressure gauges.
--
Reconnect the battery negative cable and lower the bonnet.
87679925A - 12 - 2007
26
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
CAB RIGHT-- OR LEFT--HAND DOOR 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. To assemble, proceed as follows: 1. Carry out the disassembly sequences described in this section for the LH or RH upright strips. 2. Detach the door--closing gas springs.
MDEO332A
76 3. Working from the inside of the cab, unscrew the two upper screws (1) holding the door hinge in position.
1
4. Working from the inside of the cab, unscrew the two lower nuts (1) securing the hinge and remove the door.
24900
5. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Fit the left-- or right--hand door back on and tighten the retaining nuts.
--
Fit the door--closing gas springs back on.
--
Carry out the assembly sequences described in this section for the LH or RH upright strips.
87679925A - 12 - 2007
77
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
27
GLUED CAB WINDSCREENS Repl. 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.
MDEO340A
78
1. Working from the inside of the cab, push the cutting wire (1, fig. 78) through the adhesive (2) between the window and its surround, using the needle on the tool. 2. Thread the cutting wire (1, fig. 79) into the tool and lock in position. 3. Secure the wire (1) to the handgrip (2). 4. Lock the tool on the adhesive (see fig. A). Keep the wire close to the window and pull on the handgrip (2, fig. 80). 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.
MDEO341A
79
6. Using suction cups, remove the window and place on a flat surface to avoid damage. 7. Using a spatula, remove all the adhesive (1, fig. 81) from the tubular elements holding the glass, taking care not to damage them. 8. Remove the adhesive from the window as described in the previous operation.
MDEO342A
80
NOTE: When replacing a broken window: remove any fragments still attached to the cab support frame, following only the necessary aforementioned operations. 9. Clean the windscreen surround and windscreen using a suitable solvent.
MDEO343A
81 87679925A - 12 - 2007
28
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
Fitting the window
Proceed as follows. 10. Make sure that the contact area between the windscreen and its surround is perfectly clean. 11. 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. 82) and thoroughly dry with a dry cloth. 12. 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 (minimum: 30 seconds).
MDEO344A
82 60
65
13. Apply the metal plate primer Betaprime 5402 GURIT ESSEX on the window surround (contact area with the adhesive) using the applicator supplied and leave to dry thoroughly. 14. Cut the spout on the adhesive dispenser as shown in fig. 83 to obtain a triangular cross--section bead. 15. Apply a bead of polyurethane based Betamate 7120 Sprint ESSEX on the window (the cross--section of the bead must be triangular, with a 10 mm base and 12 รท 15 mm height). NOTE: Make sure that there are no areas where adhesive is missing, otherwise water may penetrate. 16. Using suction cups, position the windscreen and its surround, inserting support shims under the windscreen. 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. Definitive glue hardening will require a total of 48 hours. The cab must, however, remain stationary during this period, to ensure correct windscreen installment.
87679925A - 12 - 2007
7.0 3.0
MDEO345A
83
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
29
CAB REAR WINDSCREEN Renew 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. 1. Working from the outside of the cab, remove the windscreen wiper blade (1).
1
24848
84 2. Unscrew the small nut (1) securing the windscreen wiper motor unit to the screen.
1
24849
85
3. Unscrew the large nut (1) and extract the windscreen wiper motor unit from the screen, leaving the wiring connected.
1
24850
86
87679925A - 12 - 2007
30
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
4. Working from inside the cab, open the rear windscreen, remove the rotation locking pin (1) on the handle (2).
1 2
24853
87
5. Remove the circular cap (1) on the end of the handle.
1
24854
88 6. Using a pipe wrench unscrew the internal nut securing the handle (1) to the glass.
1
24855
89
7. Remove the handle (2), seals and threaded pin (1).
1 2
24856
90 87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
31
8. Disconnect the two gas spring terminals (1).
1
2
24851
91
9. Unscrew the hinge (1) retaining bolts, remove the cab rear window together with the frame (2, fig. 91). 10. With the cab rear windscreen removed, unscrew the retaining bolts and the frame (2, fig. 91).
1
24852
92 11. Remove the rubber seal (1) on the rear window.
1 12. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. ------
Take the new rear window and refit or replace the seal on the outer edge of the screen. Refit the hinge and frame on the inside of the window. Refit the handle assembly. Reassemble the rear window wiper motor unit on the glass with the two retaining screws and refit the blades. Refit the rear window on the cab.
24857
93
87679925A - 12 - 2007
32
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
SEAL ON LH UPRIGHT Renew 1. Open the rear left--hand window with the handle (3), extract the pins (2) from the left--hand upright seal (1).
MDEO332A
94
2. Disconnect the electrical connections (1) on the cab light and cigar lighter, remove the left--hand upright seal (2).
1
2
MDEO333A
95 3. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
Connect the electrical connections on the cab light and cigar lighter, on the left--hand upright seal.
--
Fit the strip on the left--hand upright, insert the anchoring plugs and close the left--hand rear window with the handle.
87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1 STRIP ON RH UPRIGHT Renew
33
1
Remove the right--hand side upright strip, as described in the following operations:
3
2
1. Open the right--hand rear window (2) with the handle (1). 2. Take out the plugs (3), caps and the two screws anchoring the strip to the right--hand side upright. 3. Move the strip (1) away from the right--hand upright.
MDF1827A
96
MDF1828A
97
4. Disconnect the electrical connections from the terminal block (1).
1
24829
98 5. Disconnect the plug connections (1).
1
MDF1829A
99 87679925A - 12 - 2007
34
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
6. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
Reconnect the electrical connections previously disconnected.
--
Fit the strip on the right--hand side upright.
--
Fit the plugs, caps and the two screws anchoring the strip to the right--hand upright.
--
Close the right--hand rear window with the handle.
87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1 FIXED PADDING ON RH WALL Renew
35
1
Remove the right--hand side upright padding, as described in the following operations:
3
2
1. Open the right--hand rear window (2) with the handle (1). 2. Take out the plugs (3), caps and the two screws anchoring the strip to the right--hand side upright. 3. Pull out the right--hand upright trim (1).
MDF1827A
100
MDF1828A
101
4. Disconnect the electrical connections from the terminal block (1).
1
24829
102 5. Disconnect the plug connections (1).
1
MDF1829A
103 87679925A - 12 - 2007
36
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
6. Extract the pin on the hand throttle lever (1) and remove the lever.
1
24835
104
7. Unscrew the three screws securing the cover (1) on the LIFT--O--MATIC unit and remove the cover.
1
24836
105 8. Remove the plastic caps and the screws (1) on the right--hand side panel.
9. Carry out the disassembly sequences described in this section, as described on page 40 of this section, on the HYDRAULIC CONTROL
1
24837
LEVER GUARD.
106
10. Unscrew the bolts (1) securing the right--hand side padding.
1
24843
107 87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
37
11. Remove the right--hand side panel (1).
1
12. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Fit the complete right--hand padding in place.
--
Fit the screws retaining the padding on the right--hand wall and the plastic plugs.
--
Carry out the assembly sequences described in this section, as described on page 40 of this section, on the HYDRAULIC CONTROL
24844
108
LEVER GUARD.
--
Fit the LIFT--O--MATIC (or PTO) control cover with the retaining bolts.
--
Fit the throttle lever on by hand, on the pin, and insert the retaining pin.
--
Reconnect the electrical connections previously disconnected.
--
Fit the trim on the right--hand upright.
--
Fit the plugs and the two screws anchoring the strip to the right--hand side upright together with the caps.
--
Close the right--hand rear window with the handle.
87679925A - 12 - 2007
38
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
FIXED PADDING ON LH WALL Renew 1. Open the rear left--hand window with the handle (3), extract the pins (2) from the left--hand upright seal (1).
MDEO332A
109
2. Remove the caps (1) covering the left hand panel retaining screws.
1
MDEO334A
110 3. Remove the two screws (1) securing the left hand panel.
1
MDEO335A
111
4. Remove the left--hand panel (1).
1
MDEO336A
112 87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
39
5. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
--
Fit the left--hand padding in place.
--
Fit in the two screws securing the left--hand padding.
--
Fit the caps on the screws securing the left--hand padding.
--
Insert the plugs retaining the left--hand upright strip.
--
Close the left--hand rear window with the handle.
87679925A - 12 - 2007
40
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
HYDRAULIC CONTROL LEVER GUARD Renew 1. Unscrew the bolts (1) securing the seat to the tractor bodywork, remove the seat and the covering underneath.
1
24838
113
2. Take out the bolts securing the knobs (1) to the control levers: lift, auxiliary control valves, creeper unit and synchronized PTO.
1
24839
114 3. Remove the knob (1) on the PTO speed selection lever.
1 24840
115
4. Unscrew the bolts (1) securing the guard covering the levers.
1 24841
116 87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
41
5. Disconnect the electrical connection on the two--pole plug and remove the guard (1).
1
24842
6. To assemble, proceed as follows:
117
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Connect the electrical connection to the two--pin plug fitted on the guard.
--
Fit and secure the lever cover guard with the retaining screws.
--
Fit on the knob of the PTO speed selection lever.
--
Mount the knobs on the control levers: lift, auxiliary control valves, creeper unit and synchronized PTO and tighten the retaining bolts.
--
Fit the seat on the platform of the bodywork and tighten the retaining bolts (1).
87679925A - 12 - 2007
42
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
CAB CEILING FITTING Renew
1
1. Working from the inside of the cab, unscrew the bolts (1) on the roof hatch locking catch.
24793
2. Unscrew the two compartment cover.
screws
on
the
118
radio
1
24794
119 3. Unscrew the retaining bolts and remove the sun shade.
1
24795
120
4. Remove the plastic pins (1) securing the cab ceiling trim.
1
24796
121 87679925A - 12 - 2007
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
43
5. Detach the cab ceiling lining (1) from the roof and disconnect the electrical connection on the front windscreen wiper motor.
1
24797
6. To assemble, proceed as follows:
122
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --
Reconnect the electrical connection on the front windscreen wiper motor.
--
Fit the ceiling trim and secure it to the cab with the plastic plugs.
--
Fit the sun blind and secure by means of the relative bolts.
--
Fit the radio compartment cover and secure it with the bolts.
--
Fit the roof hatch locking catch and secure it with the bolts.
87679925A - 12 - 2007
44
SECTION 90 -- BODYWORK AND DRIVING POSITION -- CHAPTER 1
87679925A - 12 - 2007