TTV-7210-7230-7250.pdf

7210 TTV Agrotron ->WSXW830400LD50010 7230 TTV Agrotron ->WSXAD00400LD50010 7250 TTV Agrotron ->WSXAD30400LD50010

Workshop manual

CONTENTS 0 - Introduction 0.1 - Introduction 0.1.1 - Safety notes 0.1.2 - General safety rules 0.1.3 - Safety precautions for removal and refitting operations 0.1.4 - Lifting instructions 0.1.5 - Tightening torques 0.1.6 - Threadlockers, adhesives, sealants and lubricants 0.1.7 - Conversion factors 0.2 - Tightening torques for nuts and bolts of electrical connections 0.2.1 - Standard tightening torques 0.2.2 - Battery terminal tightening torques 0.2.3 - Starter motor tightening torques 0.2.4 - Alternator tightening torques 0.3 - Wheel rim to hub screws and nuts tightening torques 0.4 - Introduction 0.4.1 - Safety notes 0.4.2 - General safety rules 0.4.3 - Safety precautions for removal and refitting operations 0.4.4 - Lifting instructions 0.4.5 - Tightening torques 0.4.6 - Threadlockers, adhesives, sealants and lubricants 0.4.7 - Conversion factors

0-2 0-2 0-2 0-3 0-4 0-5 0-8 0-10 0-12 0-12 0-12 0-13 0-13 0-14 0-15 0-15 0-15 0-16 0-17 0-18 0-21 0-23

10 - Technical characteristics 10.1 - Engine 10.1.1 - Motor description - construction type 10.1.2 - Engine description - Images of engine 10.1.3 - Engine description - Lubricant oil diagram 10.1.4 - Engine description - Fuel circuit diagram 10.1.5 - Engine description - Coolant diagram 10.1.6 - Engine description - Exhaust gas recovery 10.1.7 - Engine description - Exhaust gas after-treatment 10.1.8 - Engine description - Electrical/electronic system 10.1.9 - Use - Environmental conditions 10.1.10 - Use - First start-up 10.1.11 - Usage - Starting procedure 10.1.12 - Usage - Controlling engine operation 10.1.13 - Use - exhaust gas after-treatment systems 10.1.14 - Usage - Active regeneration 10.1.15 - Usage - Passive regeneration 10.1.16 - Use - Stop procedure 10.1.17 - Operating materials - lubricant oil 10.1.18 - Operating materials - Fuel 10.1.19 - Operating materials - Coolant 10.1.20 - Fluids - SCR reduction agent 10.1.21 - Maintenance - Maintenance schedule

10-2 10-2 10-9 10-19 10-21 10-22 10-23 10-24 10-27 10-29 10-30 10-35 10-37 10-43 10-45 10-47 10-50 10-51 10-53 10-54 10-56 10-58 III

CONTENTS 10.1.22 - Care and maintenance work - Lubricant oil system 10-60 10.1.23 - Care and maintenance work - Fuel distribution system 10-68 10.1.24 - Care and maintenance - SCR 10-76 10.1.25 - Care and maintenance work - Cooling system 10-77 10.1.26 - Care and maintenance work - Engine cleaning 10-80 10.1.27 - Care and maintenance work - Intake system 10-80 10.1.28 - Care and maintenance work - Belt transmissions 10-84 10.1.29 - Care and maintenance - Adjustments and settings 10-88 10.1.30 - Care and maintenance work - Electrical system 10-90 10.1.31 - Malfunctions - Malfunction table 10-92 10.1.32 - Faults - Engine management 10-94 10.1.33 - Transport and storage - Transport 10-98 10.1.34 - Transport and storage - Transport and storage 10-99 10.1.35 - Technical data - Engine data and adjustment data 10-102 10.1.36 - Technical data - Tools 10-104 10.2 - Engine accessories 10-112 10.2.1 - Pressure transducer (L3) 10-112 10.2.2 - Pressure sensor (L3) 10-113 10.2.3 - Temperature sender (L3) 10-114 10.2.4 - Temperature sender (L3) 10-115 10.2.5 - Temperature sender (L3) 10-118 10.2.6 - Temperature sender (L3) 10-119 10.2.7 - Speed indicator (L3) 10-121 10.2.8 - NOx sensor (L3) 10-123 10.2.9 - NOx sensor (L3) 10-123 10.2.10 - Removing and fitting fuel lines (fuel delivery pump - fuel control block) (L3) 10-124 10.2.11 - Fitting and removing the temperature sender (exhaust gas) (L3) 10-128 10.2.12 - Temperature sender (L3) 10-130 10.2.13 - Removing and fitting NOx sensor (L3) 10-130 10.2.14 - Temperature sender (exhaust gas) (L3) 10-133 10.3 - Transmission 10-134 10.3.1 - Transmission (7210 TTV Agrotron ->WSXW830400LD50010) 10-134 10.3.2 - Transmission (50 Km/h) (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 10-139 10.3.3 - Transmission (60 Km/h) (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 10-145 10.3.4 - System diagram (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 10-152 10.3.5 - Description of function (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 10-155 10.3.6 - Transmission control (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 10-159 10.4 - Front axle 10-162 10.4.1 - Front axle - Version with disc brakes 10-162 10.5 - Bodywork - Cab - Platform 10-164 10.5.1 - Air conditioning system 10-164 10.5.2 - Supplementary heating - Webasto - General description 10-166 IV

CONTENTS 10.5.3 - Supplementary heating - Webasto - Description of operation 10.5.4 - Supplementary heating - Webasto - Faults 10.5.5 - Supplementary heating - Webasto - Technical specifications 10.5.6 - Supplementary heater - Webasto - Wiring diagrams 10.6 - Hydraulic system 10.6.1 - Hydraulic system 10.6.2 - 45 cc variable displacement pump 10.6.3 - 63 cc variable displacement pump 10.6.4 - Hydraulic pump 10.6.5 - Load sensing valve, pressure cut-off valve 10.6.6 - Priority valve 10.6.7 - Power steering 10.6.8 - Hydraulic front axle suspension 10.6.9 - Servo-brake valve for front axle 10.6.10 - Hydraulic trailer braking system - Italy version 10.6.11 - Hydraulic trailer braking system - Export version 10.6.12 - Steering gear pump - Version without compressor 10.6.13 - Steering gear pump - Version with compressor 10.6.14 - Braking system 10.6.15 - Master cylinder 10.6.16 - Remote control valve - 8-way version 10.6.17 - Ancillary utility distributor - 10-way version 10.6.18 - Remote control valve - 12-way version 10.6.19 - Remote control valve - 14-way version 10.6.20 - Air trailer braking system - Italy version 10.6.21 - Air trailer braking system - DE Export version 10.6.22 - Air trailer braking system - CH Export version 10.6.23 - Compressor 10.6.24 - Pressure cut-off valve 10.6.25 - Quick pressure release valve 10.6.26 - Pressure limiting valve 10.6.27 - Trailer air braking valve (2-way) 10.6.28 - Pneumatic trailer braking valve with unbraked front axle (2-way) 10.6.29 - Trailer air braking valve (1-way) 10.6.30 - Trailer air brake boost solenoid valve 10.6.31 - Trailer parking brake control solenoid valve

10-170 10-172 10-173 10-174 10-178 10-178 10-181 10-183 10-185 10-189 10-195 10-196 10-197 10-199 10-200 10-202 10-204 10-205 10-206 10-207 10-208 10-209 10-210 10-211 10-212 10-214 10-216 10-218 10-219 10-220 10-221 10-222 10-223 10-224 10-225 10-226

20 - Calibrations and electronic diagnosis 20.1 - ECU interrogation 20.1.1 - Diagnostics 20.1.2 - How diagnostics works 20.1.3 - ECUs interrogated by the All Round Tester (ART®) and SDF Analyser 20.1.4 - How to select the ECU interrogated 20.1.5 - Menus available for each ECU 20.2 - Diagnostic sockets and connections 20.2.1 - Positioning of the diagnostic sockets 20.2.2 - Serdia 2010 connection 20.2.3 - SDF Analyser/PC Tester connection

20-2 20-2 20-2 20-2 20-2 20-3 20-5 20-5 20-6 20-6 V

CONTENTS 20.2.4 - SDF Analyser/CVT Diag connection 20.2.5 - ART connection 20.3 - Diagnostic tools 20.3.1 - All Round Tester (ART® SAME) 20.3.2 - SDF Analyser 20.3.3 - Serdia 2010 20.4 - Commissioning and calibrating the tractor 20.4.1 - Putting in service - Introduction (Software HLHP versione SC134AE) 20.4.2 - Putting in service - Basic procedure for startup 20.4.3 - Putting in service - End of line settings 20.4.4 - Putting in service - Transmission 20.4.5 - Putting in service - PTO 20.4.6 - Putting in service - ASM 20.4.7 - Putting in service - Lift 20.4.8 - Putting in service - Suspension 20.4.9 - Putting in service - System 20.4.10 - Putting in service - Distributors 20.4.11 - Putting in service - Engine 20.4.12 - Putting in service - Air conditioner 20.4.13 - Putting in service - Park brake 20.4.14 - Putting in service - Agrosky 20.4.15 - Putting in service - MR-D Cabin 20.4.16 - Putting in service - Delete alarms 20.5 - ECU alarms 20.5.1 - Engine alarms 20.5.2 - Transmission alarms 20.5.3 - Armrest alarms 20.5.4 - Electrohydraulic control valve alarms 20.5.5 - HLHP alarms 20.5.6 - AC system alarms 20.5.7 - EPB Alarms 20.5.8 - Electronic battery master switch alarms

20-6 20-6 20-7 20-7 20-11 20-14 20-108 20-108 20-108 20-112 20-113 20-122 20-123 20-125 20-129 20-131 20-139 20-147 20-151 20-154 20-155 20-155 20-158 20-160 20-160 20-229 20-459 20-462 20-462 20-484 20-488 20-497

30 - Method of intervention 30.1 - Index Repair instructions (7210 TTV Agrotron ->WSXW830400LD50010) 30.1.1 - Repair level III 30.2 - Index Repair instructions (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30.2.1 - Repair level III 30.3 - Installation of solenoid valves and cartridge valves 30.3.1 - Installation 30.3.2 - Solenoid valve tightening torques 30.3.3 - Cartridge valve tightening torques 30.4 - B0 - Engine 30.4.1 - Removal and refitting of the crankcase breather 30.4.2 - Removal and refitting of the crankcase breather 30.4.3 - Renewal of the crankshaft oil seal VI

30-2 30-2 30-4 30-4 30-6 30-6 30-6 30-7 30-8 30-8 30-11 30-14

CONTENTS 30.4.4 - Changing the crankshaft ring gasket (flywheel side) 30.4.5 - Installation and removal of the crankshaft sleeve 30.4.6 - Removal and refitting of the front cover (fixing elements) 30.4.7 - Removal and refitting of the oil sump pan 30.4.8 - Removal and refitting of the oil filler pipe 30.4.9 - Removal and refitting of the V-belt pulley 30.4.10 - Removal and refitting of the torsional vibration damper 30.4.11 - Removal and refitting of the flywheel (fixing elements) 30.4.12 - Compression test 30.4.13 - Removal and refitting of the cylinder head cover 30.4.14 - Check and adjust valve clearances 30.4.15 - Removal and refitting of oil cooler (auxiliary services) 30.4.16 - Removal and refitting of the lube oil cooler housing 30.4.17 - Removal and refitting of the pilot block 30.4.18 - Removal and refitting of the high-pressure pump, Installation position A 30.4.19 - Installation and removal of the high pressure pump, Assembly position B 30.4.20 - Removal and refitting of the injector 30.4.21 - Removal and refitting of the common rail 30.4.22 - Removal and refitting of the charge air duct 30.4.23 - Removal and refitting of the charge air manifold 30.4.24 - Removal and refitting of the air intake pipe 30.4.25 - Removal and refitting of the water pump 30.4.26 - Removing and installing the belt tensioner (Level 1). 30.4.27 - Removing and installing the support plate (Level 1) 30.4.28 - Removing and installing the support console (Level 1) 30.4.29 - Removal and installation of the exhaust pipe (auxiliaries) 30.4.30 - Removal and refitting of the exhaust gas turbocharger 30.4.31 - Removal and refitting of the lubricating oil pipe (exhaust gas turbocharger) 30.4.32 - Removal and refitting of the lubricating oil return pipe (exhaust gas turbocharger) 30.4.33 - Removing and installing the belt tensioner (Level 2) 30.4.34 - Removing and installing the vee-groove pulley (#1) 30.4.35 - Removing and installing the vee-groove pulley (#2) 30.4.36 - Removing and installing the support console (Level 2) 30.4.37 - Removing and installing the console (Level 1) 30.4.38 - Removing and installing the support console (Level 2) 30.4.39 - Assembly and disassembly of the piston cooling nozzles (L3) 30.4.40 - Assembly and disassembly of the piston cooling nozzles (L3) 30.4.41 - Replacing the starter ring gear on the flywheel (L3) 30.4.42 - Replacing the starter ring gear on the flywheel (L3) 30.4.43 - Fitting and removing counterweight drive system, checking (L3) 30.4.44 - Assembly and disassembly of the crankshaft (L3) 30.4.45 - Crankshaft check (L3) 30.4.46 - Check the endfloat of the crankshaft (L3) 30.4.47 - Fitting and removing crankshaft bearings (L3) 30.4.48 - Check the crankshaft bearings (L3) 30.4.49 - Assembly and disassembly of the connecting rod drum (L3) 30.4.50 - Connecting rod drum check (L3) 30.4.51 - Replace the crankshaft O-ring (flywheel end) (L3)

30-18 30-20 30-23 30-25 30-28 30-30 30-31 30-33 30-35 30-37 30-40 30-43 30-45 30-47 30-50 30-54 30-58 30-66 30-74 30-75 30-77 30-79 30-81 30-82 30-85 30-87 30-89 30-92 30-94 30-97 30-98 30-101 30-103 30-104 30-105 30-107 30-108 30-109 30-110 30-112 30-120 30-122 30-125 30-128 30-131 30-132 30-140 30-147 VII

CONTENTS 30.4.52 - Disassembly and assembly of the gear box (L3) 30-151 30.4.53 - Disassembly and assembly of the gear box (L3) 30-154 30.4.54 - Disassembly and assembly of the gear box (L3) 30-157 30.4.55 - Assembly and disassembly of the camshaft (L3) 30-159 30.4.56 - Check the camshaft (L3) 30-160 30.4.57 - Assembly and disassembly of the distribution valve (L3) 30-161 30.4.58 - Removing and refitting the valve timing system (L3) 30-164 30.4.59 - Assembly and disassembly of the control elements (L3) 30-166 30.4.60 - Assembly and disassembly of the oil intake pipe (L3) 30-168 30.4.61 - Assembly and disassembly of the oil intake pipe (L3) 30-170 30.4.62 - Disassembly and completion of the pilot unit (L3) 30-171 30.4.63 - Disassembly and completion of the pilot unit (L3) 30-175 30.4.64 - A/C drive belt alignment and tension adjustment 30-179 30.5 - C0 - Engine accessories 30-185 30.5.1 - Removal and installation of the fuel filter console 30-185 30.5.2 - Removal and installation of the fuel lift pump 30-187 30.5.3 - Removal and refitting of fuel lines (fuel lift pump - pilot block) 30-189 30.5.4 - Removal and refitting of fuel lines (pilot block - high pressure pump) 30-193 30.5.5 - Removal and refitting of fuel lines (pilot block - fuel lift pump) 30-195 30.5.6 - Removal and refitting of fuel lines (rail, cylinder head, pilot block - fuel filter) 30-198 30.5.7 - Removal and refitting of the heater 30-202 30.5.8 - Removal and refitting of the heater (details) 30-204 30.5.9 - Installing and removing the thermostat 30-207 30.5.10 - Thermostat check (with thermostat disassembled) 30-210 30.5.11 - Removal and installation of the thermostat housing 30-211 30.5.12 - Removal and refitting of the fan support 30-214 30.5.13 - Removal and assembly of the fan support 30-215 30.5.14 - Installing and removing the temperature transmitter (Exhaust gas) 30-220 30.5.15 - Removal and refitting of the starter motor 30-221 30.5.16 - Removal and refitting of the alternator (ribbed V-belt, level 2) 30-223 30.5.17 - Removal and refitting of the alternator (ribbed V-belt, level 1) 30-224 30.5.18 - Removal and refitting of the crankshaft speed sensor 30-226 30.5.19 - Removal and refitting of the camshaft speed sensor 30-227 30.5.20 - Installation and removal of the rotation device 30-229 30.5.21 - Installation and removal of the rotation device (torsional vibration damper) 30-231 30.5.22 - Removal and installation of the air conditioning compressor 30-232 30.6 - D0 - Transmission 30-235 30.6.1 - Separation of Rear Axle from Transmission (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-235 30.6.2 - Removal of cartridge (7210 TTV Agrotron ->WSXW830400LD50010) 30-236 30.6.3 - Removal of Cartridge (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-238 30.6.4 - Disassembly of shifting drum (7210 TTV Agrotron ->WSXW830400LD50010) 30-241 30.6.5 - Disassembly of Shifting Drum (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-241 30.6.6 - Disassembly of P1 ring gear carrier 30-242 30.6.7 - Disassembly of P1/P2 Planetary drive 30-245 30.6.8 - Disassembly of P5/P6 Planetary drive 30-247 VIII

CONTENTS 30.6.9 - Disassembly of KV clutch 30-249 30.6.10 - Disassembly of K1 clutch 30-250 30.6.11 - Disassembly of K3/K4 clutch and P3/P4 planetary drive 30-251 30.6.12 - Disassembly of K3/K4 clutch 30-252 30.6.13 - Disassembly of P3/P4 planetary drive 30-253 30.6.14 - Disassembly of KR clutch 30-254 30.6.15 - Disassembly of K2 clutch (7210 TTV Agrotron ->WSXW830400LD50010) 30-254 30.6.16 - Disassembly of K2 Clutch (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-256 30.6.17 - Disassembly of hydrostatic unit (7210 TTV Agrotron ->WSXW830400LD50010) 30-258 30.6.18 - Disassembly of Hydrostatic Unit (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-260 30.6.19 - Disassembly of control (TCU) (7210 TTV Agrotron ->WSXW830400LD50010) 30-262 30.6.20 - Disassembly of Control (TCU) (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-262 30.6.21 - Disassembly of pump (7210 TTV Agrotron ->WSXW830400LD50010) 30-263 30.6.22 - Disassembly of Pump (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-265 30.6.23 - Disassembly of Suction filter (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-267 30.6.24 - Disassembly of suction filter (7210 TTV Agrotron ->WSXW830400LD50010) 30-267 30.6.25 - Disassembly of filter head (7210 TTV Agrotron ->WSXW830400LD50010) 30-268 30.6.26 - Disassembly of pressure relief valves (7210 TTV Agrotron ->WSXW830400LD50010) 30-268 30.6.27 - Disassembly of control unit (7210 TTV Agrotron ->WSXW830400LD50010) 30-269 30.6.28 - Disassembly of valves, pressure sensor, inductive sensors (7210 TTV Agrotron ->WSXW830400LD50010) 30-269 30.6.29 - Disassembly of wiring harness, valve block and plate (7210 TTV Agrotron ->WSXW830400LD50010) 30-271 30.6.30 - Disassembly of valve block (filter head, pressure relief valves, thermocouple) (7210 TTV Agrotron ->WSXW830400LD50010) 30-274 30.6.31 - Disassembly of Valve Block (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-276 30.6.32 - Disassembly of valve block (all-wheel-drive / park lock) (7210 TTV Agrotron ->WSXW830400LD50010) 30-278 30.6.33 - Disassembly of Valve Block (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-279 30.6.34 - Disassembly of valve block (hydraulic control) (7210 TTV Agrotron ->WSXW830400LD50010) 30-281 30.6.35 - Disassembly of Valve Block (P.R.V. - Pressure Relief Valve) (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-282 30.6.36 - Disassembly of valve block (pressure reducing valve) (7210 TTV Agrotron ->WSXW830400LD50010) 30-283 30.6.37 - Disassembly of wiring harnesses and control unit (7210 TTV Agrotron ->WSXW830400LD50010) 30-283 30.6.38 - Disassembly of wiring harnesses and control unit 30-285 30.6.39 - Disassembly of W.H. and E.C.U. (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-287 30.6.40 - Disassembly of inductive sensors (7210 TTV Agrotron ->WSXW830400LD50010) 30-289 IX

CONTENTS 30.6.41 - Disassembly of Inductive Sensors (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-289 30.6.42 - Disassembly of plug-in module (7210 TTV Agrotron ->WSXW830400LD50010) 30-290 30.6.43 - Disassembly of Plug-In Module (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-291 30.6.44 - Disassembly of clutch (all-wheel-drive) (7210 TTV Agrotron ->WSXW830400LD50010) 30-298 30.6.45 - Disassembly of spur gear (7210 TTV Agrotron ->WSXW830400LD50010) 30-302 30.6.46 - Disassembly of pinion (7210 TTV Agrotron ->WSXW830400LD50010) 30-302 30.6.47 - Disassembly of park lock (7210 TTV Agrotron ->WSXW830400LD50010) 30-304 30.6.48 - Disassembly of output shaft (7210 TTV Agrotron ->WSXW830400LD50010) 30-306 30.6.49 - Disassembly of Output Shaft (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-307 30.6.50 - Disassembly of intermediate housing (7210 TTV Agrotron ->WSXW830400LD50010) 30-308 30.6.51 - Disassembly of Intermediate Housing (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-309 30.6.52 - Disassembly of drive shaft (7210 TTV Agrotron ->WSXW830400LD50010) 30-310 30.6.53 - Disassembly of Drive Shaft (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-312 30.6.54 - Reassembly of Transmission Housing (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-313 30.6.55 - Reassembly of Drive Shaft (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-314 30.6.56 - Reassembly of Intermediate Housing (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-317 30.6.57 - Reassembly of Plug-In Module (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-319 30.6.58 - Reassembly of Output Shaft (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-331 30.6.59 - Preassembly of Housing Lid (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-333 30.6.60 - Reassembly of Inductive Sensors (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-334 30.6.61 - Reassembly of W.H. and E.C.U. (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-334 30.6.62 - Reassembly of Valve Block (P.R.V. - Pressure Relief Valve) (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-336 30.6.63 - Reassembly of Valve Block (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-337 30.6.64 - Reassembly of Valve Block (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-339 30.6.65 - Reassembly of Pump (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-343 30.6.66 - Reassembly of Control (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-345 30.6.67 - Reassembly of Hydrostatic Unit (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-346 30.6.68 - Reassembly of Suction filter (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-349 X

CONTENTS 30.6.69 - Preassembly of transmission housing (7210 TTV Agrotron ->WSXW830400LD50010) 30-349 30.6.70 - Reassembly of drive shaft (7210 TTV Agrotron ->WSXW830400LD50010) 30-350 30.6.71 - Reassembly of intermediate housing (7210 TTV Agrotron ->WSXW830400LD50010) 30-353 30.6.72 - Reassembly of pinion (7210 TTV Agrotron ->WSXW830400LD50010) 30-355 30.6.73 - Reassembly of park lock (7210 TTV Agrotron ->WSXW830400LD50010) 30-359 30.6.74 - Reassembly of clutch (all-wheel-drIve) (7210 TTV Agrotron ->WSXW830400LD50010) 30-363 30.6.75 - Reassembly of spur gear (7210 TTV Agrotron ->WSXW830400LD50010) 30-372 30.6.76 - Reinstallation of plug-in module (7210 TTV Agrotron ->WSXW830400LD50010) 30-373 30.6.77 - Reassembly of output shaft (7210 TTV Agrotron ->WSXW830400LD50010) 30-374 30.6.78 - Preassembly of housing lid (7210 TTV Agrotron ->WSXW830400LD50010) 30-376 30.6.79 - Reassembly of plate (7210 TTV Agrotron ->WSXW830400LD50010) 30-377 30.6.80 - Reassembly of valve block (7210 TTV Agrotron ->WSXW830400LD50010) 30-380 30.6.81 - Reassembly of wiring harnesses (7210 TTV Agrotron ->WSXW830400LD50010) 30-381 30.6.82 - Reassembly of inductive sensors, pressure sensors, valves (7210 TTV Agrotron ->WSXW830400LD50010) 30-383 30.6.83 - Reassembly of control unit (hydrostatic unit) (7210 TTV Agrotron ->WSXW830400LD50010) 30-386 30.6.84 - Reassembly of pressure relief valves (PRV) (7210 TTV Agrotron ->WSXW830400LD50010) 30-386 30.6.85 - Reassembly of filter head (7210 TTV Agrotron ->WSXW830400LD50010) 30-387 30.6.86 - Reassembly of wiring harnesses and control unit (7210 TTV Agrotron ->WSXW830400LD50010) 30-388 30.6.87 - Reassembly of valve block (pressure reducing valve) (7210 TTV Agrotron ->WSXW830400LD50010) 30-390 30.6.88 - Reassembly of valve block (hydraulic control) (7210 TTV Agrotron ->WSXW830400LD50010) 30-391 30.6.89 - Reassembly of valve block (all wheel-drive / park lock) (7210 TTV Agrotron ->WSXW830400LD50010) 30-393 30.6.90 - Reassembly of valve block (filter head, pressure relief valves, thermocouple) (7210 TTV Agrotron ->WSXW830400LD50010) 30-394 30.6.91 - Reassembly of pump (7210 TTV Agrotron ->WSXW830400LD50010) 30-397 30.6.92 - Reassembly of control (7210 TTV Agrotron ->WSXW830400LD50010) 30-399 30.6.93 - Reassembly of hydrostatic unit (7210 TTV Agrotron ->WSXW830400LD50010) 30-400 30.6.94 - Reassembly of suction filter (7210 TTV Agrotron ->WSXW830400LD50010) 30-403 30.6.95 - Reassembly of K2 Clutch 30-403 30.6.96 - Reassembly of KR clutch 30-406 30.6.97 - Reassembly of P3/P4 planetary drive 30-408 30.6.98 - Reassembly of K3/K4 clutch (7210 TTV Agrotron ->WSXW830400LD50010) 30-409 30.6.99 - Reassembly of K3/K4 Clutch (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-414 30.6.100 - Reassembly of K1 Clutch 30-419 30.6.101 - Reassembly of KV Clutch 30-419 30.6.102 - Reassembly of P5/P6 planetary drive 30-422 30.6.103 - Reassembly of P1/P2 planetary drive 30-426 30.6.104 - Reassembly of P1 Ring gear carrier 30-431 30.6.105 - Reinstallation of cartridge (7210 TTV Agrotron ->WSXW830400LD50010) 30-437 30.6.106 - Reinstallation of Cartridge (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-440 XI

CONTENTS 30.6.107 - Fitting of rear axle to the transmission (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-444 30.6.108 - Pipes and closing components (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-445 30.7 - E0 - Rear axle 30-446 30.7.1 - Removing the axle housing (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-446 30.7.2 - Removing brakes (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-449 30.7.3 - Removing the differential (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-451 30.7.4 - Removing the PTO (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-454 30.7.5 - Removing the oil feed (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-466 30.7.6 - Removing the lifter (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-467 30.7.7 - Fitting lifter, oil feed and blanking elements (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-468 30.7.8 - Fitting the lifter (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-468 30.7.9 - Fitting the oil feed (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-471 30.7.10 - Fitting blanking elements (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-473 30.7.11 - Fitting the PTO (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-473 30.7.12 - Fitting the differential (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-500 30.7.13 - Fitting brakes (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-504 30.7.14 - Fitting the axle housing (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30-507 30.7.15 - Separating rear axle from transmission (7210 TTV Agrotron ->WSXW830400LD50010) 30-513 30.7.16 - Axle Stub - Disassembly (7210 TTV Agrotron ->WSXW830400LD50010) 30-514 30.7.17 - Brake Disassembly (7210 TTV Agrotron ->WSXW830400LD50010) 30-517 30.7.18 - Differential - Disassembly (7210 TTV Agrotron ->WSXW830400LD50010) 30-519 30.7.19 - PTO Transmission - Disassembly (7210 TTV Agrotron ->WSXW830400LD50010) 30-522 30.7.20 - Oil Supply - Disassembly (7210 TTV Agrotron ->WSXW830400LD50010) 30-528 30.7.21 - Lifting Unit - Disassembly (7210 TTV Agrotron ->WSXW830400LD50010) 30-529 30.7.22 - Rear Axle Housing - Preassembly (7210 TTV Agrotron ->WSXW830400LD50010) 30-530 30.7.23 - Lifting Unit - Assembly (7210 TTV Agrotron ->WSXW830400LD50010) 30-530 30.7.24 - Oil Supply - Assembly (7210 TTV Agrotron ->WSXW830400LD50010) 30-533 30.7.25 - Fitting the PTO transmission (7210 TTV Agrotron ->WSXW830400LD50010) 30-536 30.7.26 - Fitting the differential (7210 TTV Agrotron ->WSXW830400LD50010) 30-550 30.7.27 - Brake Assembly (7210 TTV Agrotron ->WSXW830400LD50010) 30-555 30.7.28 - Axle Stub - Assembly (7210 TTV Agrotron ->WSXW830400LD50010) 30-558 30.7.29 - Attaching rear axle to gearbox (7210 TTV Agrotron ->WSXW830400LD50010) 30-564 XII

CONTENTS 30.7.30 - Procedure for checking EPB travel (7210 TTV Agrotron ->WSXW830400LD50010) 30.7.31 - Procedure to check EPB stroke (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30.8 - F0 - Front axle 30.8.1 - Toe-in/steering angle/assembly tests 30.8.2 - Steering cylinders assembly 30.8.3 - Axle shaft assembly 30.8.4 - Flange assembly 30.8.5 - Differential assembly - carrier 30.8.6 - Checking the bevel gear pair 30.8.7 - Differential disassembly 30.8.8 - Axle pivot bearings assembly 30.8.9 - Bevel pinion assembly 30.8.10 - Planetary reduction gear assembly 30.8.11 - Wheel hub assembly 30.8.12 - Brake assembly 30.9 - G0 - Bodywork - Cab - Platform 30.9.1 - Handbrake adjustment 30.9.2 - Supplementary heater - Webasto - Troubleshooting 30.9.3 - Supplementary heating - Webasto - Functional tests 30.9.4 - Supplementary heating - Webasto - Maintenance 30.9.5 - Supplementary heater - Webasto - Disassembly and reassembly 30.10 - H0 - Hydraulic system 30.10.1 - Tightening the hydraulic power steering unit fastener screws 30.11 - L0 - Electrical system 30.11.1 - Fitting BDS cables 30.11.2 - Steering position sensor assembly 30.12 - R0 - Rear lift 30.12.1 - 939272 - Pulling force sensor (23/11/2010) 30.13 - S0 - Wheels 30.13.1 - 939267 - Tyre fitting (23/11/2010)

30-565 30-578 30-590 30-590 30-593 30-598 30-601 30-604 30-612 30-613 30-622 30-628 30-635 30-638 30-649 30-657 30-657 30-659 30-663 30-664 30-674 30-684 30-684 30-686 30-686 30-687 30-695 30-695 30-696 30-696

40 - Wiring diagrams 40.1 - Introduction 40.1.1 - Introduction 40.1.2 - Basic electronics for mechanics (1/2) 40.1.3 - Basic electronics for mechanics (2/2) 40.1.4 - Electrical and electronic components (1/2) 40.1.5 - Electrical and electronic components (2/2) 40.2 - Components 40.2.1 - 2.8519.134.0/50 - HLHP control unit 40.2.2 - 2.8519.133.0/20 - Transmission control unit 40.2.3 - Engine control unit 40.2.4 - Main power relay switch (TGC/RME-SA1) 40.2.5 - A - Starting and charging 40.2.6 - B - Fuses 40.2.7 - C - Grounds

40-2 40-2 40-4 40-7 40-13 40-21 40-26 40-26 40-28 40-30 40-35 40-42 40-42 40-52 XIII

CONTENTS 40.2.8 - D - Intermediate connections 40.2.9 - E - On-board instruments and visual and audible indicators 40.2.10 - F - External lights 40.2.11 - G - Interior lights 40.2.12 - H - Electrical and manual controls 40.2.13 - I - Circuit breakers 40.2.14 - J - Relays 40.2.15 - K - Sensors and transmitters 40.2.16 - L - Electromagnets and solenoid valves 40.2.17 - M - Electrical/electronic devices, flasher units and timers 40.2.18 - N - Electric motors and actuators 40.2.19 - O - Resistors, rheostats, diodes and diode boards 40.2.20 - P - Various services 40.2.21 - R - Diagnostics 40.2.22 - T - Power supply points (+15 o +30) 40.3 - Systems 40.3.1 - S001 - Electrical engine governor 40.3.2 - S002 - Starter 40.3.3 - S003 - Preheating 40.3.4 - S004 - AdBlue 40.3.5 - S005 - Transmission 40.3.6 - S005A - Transmission - Version with performance steering 40.3.7 - S006 - Front axle suspension 40.3.8 - S007 - Instrument panel 40.3.9 - S008 - Lights – Version without front hitch 40.3.10 - S009 - Lights – Version with front hitch 40.3.11 - S010 - Turn indicators 40.3.12 - S011 - Work lights 40.3.13 - S012 - Semi-active cab suspension 40.3.14 - S013 - Manual air conditioner 40.3.15 - S014 - Automatic air conditioning 40.3.16 - S015 - +15 Positives 40.3.17 - S016 - +30 Positives 40.3.18 - S017 - CAN BUS Line - Standard version 40.3.19 - S017A - Standard CAN BUS line - Version with automatic A/C system 40.3.20 - S017B - Visual guidance Can Bus line - Version without ISO11783 40.3.21 - S018 - CAN BUS Line - Version with ISO 11783 40.3.22 - S018A - ISO11783 Can Bus line - Version with visual guidance 40.3.23 - S018B - ISO11783 Can Bus line - Version with assisted steering 40.3.24 - S018C - ISO11783 Can Bus line - Version with performance steering 40.3.25 - S019 - CAN BUS line - Version without I-Monitor 40.3.26 - S020 - PTO 40.3.27 - S021 - Front and rear hitches 40.3.28 - S022 - Brakes 40.3.29 - S023 - Hydraulic trailer braking 40.3.30 - S024 - Hydraulic distributors 40.3.31 - S025 - Windscreen wipers 40.3.32 - S026 - Radio XIV

40-55 40-78 40-79 40-82 40-82 40-83 40-88 40-90 40-95 40-96 40-99 40-100 40-102 40-104 40-104 40-106 40-106 40-112 40-117 40-120 40-125 40-134 40-141 40-144 40-148 40-157 40-169 40-178 40-194 40-196 40-201 40-207 40-211 40-217 40-231 40-245 40-250 40-269 40-278 40-287 40-297 40-309 40-315 40-321 40-332 40-337 40-342 40-346

CONTENTS 40.3.33 - S027 - Accessories 40.3.34 - S028 - Diagnostics 40.3.35 - S029 - Monitor 40.3.36 - S030 - Agrosky - Version with visual guidance, without ISO11783 40.3.37 - S031 - ISO 11783 40.3.38 - S031A - ISO11783 Can Bus line - Version with visual guidance 40.3.39 - S031B - ISO11783 Can Bus line - Version with assisted steering 40.3.40 - S031C - ISO11783 Can Bus line - Version with performance steering 40.3.41 - S032 - Webasto 40.3.42 - S033 - Lights - Version without front hitch (U.S.A.) 40.3.43 - S034 - Lights - Version with front hitch (U.S.A.) 40.3.44 - S035 - Turn indicators (U.S.A.) 40.3.45 - S036 - Work lights (U.S.A.) 40.3.46 - S037 - +15 Positives (U.S.A.) 40.3.47 - S038 - +30 Positives (U.S.A.) 40.3.48 - S039 - PTO (USA) 40.3.49 - S040 - Braking (U.S.A.) 40.3.50 - S041 - ISO 11783 (U.S.A.) 40.4 - Wiring harnesses 40.4.1 - 0.012.2018.4/20 - License plate light 40.4.2 - 0.014.0007.4/20 - Lights selector switch 40.4.3 - 0.014.5144.4/10 - Battery negative 40.4.4 - 0.015.3974.4/10 - Front axle suspension 40.4.5 - 0.015.4257.4/10 - PTO sensor (USA) 40.4.6 - 0.015.5429.4/20 - Front lift control 40.4.7 - 0.016.0642.4/20 - Rear LH lower work light on cab - Xenon version 40.4.8 - 0.016.0642.4/20 - Rear RH lower work light on cab - Xenon version 40.4.9 - 0.016.0650.4/10 - LH front supplementary work light on arm - Xenon version 40.4.10 - 0.016.0650.4/10 - RH front supplementary work light on arm - Xenon version 40.4.11 - 0.017.0496.4/10 - Supplementary RH front work light on arm 40.4.12 - 0.017.0496.4/10 - Supplementary RH front work light on arm 40.4.13 - 0.017.0497.4/10 - Rear RH lower work light on cab 40.4.14 - 0.017.0497.4/10 - Rear LH lower work light on cab 40.4.15 - 0.017.8425.4/10 - Rear trailer socket 40.4.16 - 0.017.8426.4 - Rear trailer socket (U.S.A.) 40.4.17 - 0.017.8887.4/10 - ISO 11783 - Front line 40.4.18 - 0.018.8803.4 - Battery positive terminal 40.4.19 - 0.018.9843.4/20 - ISO 11783 - Rear line 40.4.20 - 0.018.9845.4/10 - Fuses and relays 40.4.21 - 0.018.9990.4/10 - Distributors 40.4.22 - 0.018.9992.4/10 - AdBlue 40.4.23 - 0.019.2378.4/40 - LH mudguard 40.4.24 - 0.019.2378.4/40 - RH mudguard 40.4.25 - 0.019.2379.4/20 - Front LH lower work lights on cab 40.4.26 - 0.019.2379.4/20 - Front RH lower work lights on cab 40.4.27 - 0.019.2380.4/30 - Hazard warning lights switch (USA) 40.4.28 - 0.019.2383.4/20 - Engine cowl 40.4.29 - 0.019.2474.4/10 - Rear PTO

40-350 40-366 40-371 40-374 40-380 40-388 40-398 40-408 40-419 40-423 40-431 40-442 40-450 40-466 40-469 40-475 40-481 40-487 40-496 40-496 40-497 40-498 40-499 40-500 40-500 40-501 40-502 40-502 40-503 40-504 40-505 40-506 40-507 40-508 40-509 40-511 40-512 40-513 40-515 40-517 40-518 40-521 40-523 40-525 40-527 40-528 40-530 40-532 XV

CONTENTS 40.4.30 - 0.019.2539.4/10 - Hydraulic braking 40.4.31 - 0.019.2571.4/10 - ISO 11786 40.4.32 - 0.019.2617.4/70 - ISO 11783 - Cab line 40.4.33 - 0.019.3658.4/20 - Agrosky solenoid valve 40.4.34 - 0.019.3659.4/10 - On-board monitor - Armrest 40.4.35 - 0.019.4559.4/10 - Rear service work light 40.4.36 - 0.019.4688.4/10 - Front top work lights on cab 40.4.37 - 0.019.4689.4/20 - RH rear work lights on cab roof 40.4.38 - 0.019.4689.4/20 - LH rear work lights on cab roof 40.4.39 - 0.019.4711.4/10 - Semi-active cab 40.4.40 - 0.019.4913.4/10 - Front top work lights on cab - LED version 40.4.41 - 0.019.4914.4/20 - LH rear work lights on cab roof - LED version 40.4.42 - 0.019.4914.4/20 - RH rear work lights on cab roof - LED version 40.4.43 - 0.019.5311.4/10 - Automatic A/C system interface 40.4.44 - 0.019.9825.4/10 - Agrosky antenna (Assisted Steering) 40.4.45 - 0.019.9826.4/30 - Agrosky - I-Monitor 40.4.46 - 0.019.9827.4/10 - Front work lights on cab roof - LED version with Agrosky 40.4.47 - 0.019.9828.4/10 - Front work lights on cab roof - Version with Agrosky 40.4.48 - 0.019.9829.4/20 - Agrosky antenna (Visual guidance) 40.4.49 - 0.020.1009.4 - Front LH lower work lights on cab (USA) 40.4.50 - 0.020.1009.4 - Front RH lower work lights on cab (USA) 40.4.51 - 0.020.1026.4/10 - LH front supplementary work light on arm (U.S.A.) 40.4.52 - 0.020.1026.4/10 - RH front supplementary work light on arm (U.S.A.) 40.4.53 - 0.020.5056.4 - Brake hydraulic system pressure sensor - 60 km/h 40.4.54 - 0.020.8658.4 - Side instrument panel 40.4.55 - 0.020.8664.4 - RH transmission 40.4.56 - 0.020.8854.4 - Windscreen washer pumps 40.4.57 - 0.020.8862.4 - Roof 40.4.58 - 0.021.0396.4 - LH transmission 40.4.59 - 0.021.0489.4 - Auxiliary heating - Webasto 40.4.60 - 0.021.0490.4 - Trailer socket with ABS brakes 40.4.61 - 0.900.0816.0 - Front PTO 40.4.62 - 04217216 - Preheating relay power supply 40.4.63 - 04217217 - Preheating 40.4.64 - 04218107 - Engine 40.4.65 - 04436707 - Left hand rotating beacon 40.4.66 - 04436707 - RH rotating beacon 40.4.67 - 04502029 - Fuel injectors

XVI

40-533 40-535 40-538 40-541 40-543 40-544 40-545 40-546 40-548 40-549 40-551 40-553 40-554 40-556 40-558 40-560 40-562 40-564 40-565 40-566 40-567 40-568 40-569 40-570 40-571 40-577 40-579 40-581 40-583 40-585 40-586 40-588 40-589 40-589 40-590 40-591 40-592 40-593

0 - Introduction

0-1

Introduction 0.1 - Introduction

The purpose of this workshop manual is to provide instruction for repair technicians and a practical guide to improving the quality of repairs. This manual enables repair technicians to acquire a thorough knowledge of the machine, indicating the correct methods for fault diagnosis, for working in safety and for accurate dimensional checks and visual inspections. The instructions also indicate the products to use, the tightening torques and the adjustment data. The technical material contained in this manual is reserved to Authorised Dealers and Service Centres who will be duly informed of any technical changes to the machines in question through the issue of documents regarding modifications, updates and supplements for optional equipment. All technicians and their colleagues are expressly forbidden from reproducing any part of this manual in any form or from communicating the contents to third parties without the express written permission of the Manufacturer, who remains the sole owner of this document with all rights reserved in accordance with applicable laws.

0.1.1 - Safety notes

To ensure that machines entrusted to Authorised Service Centres for repair or overhaul continue to function correctly, it is very important that all repair work is carried out in the prescribed manner. The procedures for checks and repairs indicated in this manual are safe and effective. Some of the operations described require the use of special tools and equipment; these tools have been specifally designed for the intended purpose and may be ordered directly from the Manufacturers. DO NOT USE MAKESHIFT TOOLS; not only is there a risk of personal injury, but such tools are rarely suited to the purpose for which they are used. In potentially hazardous situations, always give priority to personal safety and take the necessary actions to eliminate the danger

0.1.2 - General safety rules l

l

l

l

l

l

l

l

l

l l

l l l

l

l

0-2

Even if you have a thorough knowledge of the machine as regards its components, operation and controls, always take special care when carrying out the following operations; Remember that the machine you are working on is in need of repair or overhaul and consequently may not always behave as expected. Before starting work, clean the tractor thoroughly to remove all mud, dust and road dirt. Also clean the cab to remove all traces of oil, snow and ice from the access steps and grab rails. When climbing up to or down from the cab, always ensure you maintain three points of contact at a time (foot or handholds) in order to keep your balance and prevent accidental falls. Always take special care when carrying out fault diagnosis operations; these operations often require two persons, who must never stand in front of the wheels when the engine is running. When carrying out checks and repairs, wear close-fitting clothing, safety goggles and protective gloves that are suitable for the task (cleaning, draining fluids, repairs). When working near moving parts, long hair should be gathered up and tied back safely under a cap to prevent the risk of entanglement and severe injury. Do not allow anyone who is not directly involved in the work to come near the tractor; ensure that they remain at a safe distance. Keep well clear of moving parts; when the engine is running, some moving parts are not easily visible and therefore present a risk of entanglement, even if protected by safety guards. Ensure that the area is well ventilated before starting the engine in order to avoid the formation of dangerous concentrations of toxic gases; always connect suitable fume extraction equipment to the exhaust pipe. Do not start the engine with the safety guards removed under any circumstances; all repair and adjustment operations must be carried out with the engine stopped. Do not top up fuel, oil or coolant levels when the engine is running. Never smoke and ensure there are no naked flames nearby when topping up fuel or oil. Always remove the battery from the machine before recharging. Before checking or removing the battery, stop the engine and remove the key from the starter switch. Remove the battery and recharge in a well-ventilated area where the temperature exceeds 0°C. When checking or recharging the battery, do not smoke or allow naked flames in the vicinity as the hydrogen gas given off by the battery is highly explosive. The liquid (electrolyte) contained in the battery is very harmful if it comes into contact with the skin and the eyes; for this reason, always wear gloves and safety goggles with side shields when checking or topping up the battery. Should any electrolyte accidentally come into contact with your skin, wash the affected areas immediately with plenty of fresh water; if electrolyte comes into contact with your clothing, this should be removed as soon as possible. In case of accidental ingestion of electrolyte, drink copious amounts of water, milk or vegetable oil and take antacids such as magnesium, bicarbonate, etc. and seek medical attention immediately. Before working on the electrical systems, always disconnect the battery terminals.

Introduction DANGER Always disconnect the negative lead (--) before the positive lead (+); when re-connecting the battery on completion of the work, first connect the positive terminal (+) and then the negative (--). l

l l

l

l l l

l

l

l

l l

l

l

l

l

l

Before carrying out any arc welding (permitted only on implements attached to the machine) always disconnect the battery terminals and unplug all the connectors of the electronic control units and the alternator. When topping up lubricants, always wear suitable protective gloves. Do not wear clothing contaminated by engine or hydraulic oil; prolonged contact with the skin can be harmful and may cause allergic reactions. Used engine oil and hydraulic oil must be disposed of properly; recover used lubricants and dispose of them in accordance with the applicable regulations. Before carrying out any work on the hydraulic or pneumatic systems, discharge all residual pressure from the circuits. Before carrying out any work on the hydraulic system or engine, allow the oil and engine coolant to cool down. When removing and refitting certain assemblies, it will be necessary to support the tractor; use stands, jacks or blocks capable of supporting the weight and arrange them in a triangular pattern to prevent the machine from overturning. To lift heavy components, use a hoist or crane. Check that wire ropes, chains or fibre slings are not worn and that hooks are not damaged. Always use lifting equipment of suitable capacity for the weight of the components to be removed. Ensure lifting equipment is attached correctly. When lifting or supporting an assembly or component, manoeuvre the parts slowly and carefully to avoid swinging movements or collision with other components. Never work on components suspended from a hoist or crane. When removing the retaining bolts of a component that could fall, always leave two opposing bolts in place for safety; before removing these last two bolts, attach the component to suitable lifting equipment or position support blocks. Any oil or fuel spilled during removal or dismantling operations should be cleaned up as soon as possible to prevent the risk of slipping and fire. When refitting electrical wiring looms and wires, ensure that they are properly secured with their original retaining straps or brackets to prevent the possibility of damage caused by vibration. Never insert your fingers or hands to check the alignment between fixing holes in components; always use a suitable dowel of soft material. When refitting assemblies or components, always use the specified tightening torques; the tightening torques indicated in the paragraphs regarding assembly/refitting operations have been determined through experimentation and must be scrupulously adhered to. When refitting parts that are subject to vibration or that rotate at high speed, take particular care when carrying out final installation checks.

0.1.3 - Safety precautions for removal and refitting operations When removing or refitting parts, always take the following safety precautions.

Precautions for removal operations l l l l l

l l l l l

l

Unless otherwise indicated, lower the lifting equipment until it the component or assembly rests on the ground. After disconnecting hydraulic and fuel system pipes, always fit plugs to the open ends of the pipes to prevent ingress of dirt. Before removing a cylinder, fully retract the piston and secure it in this position using a retaining strap. Use containers of sufficient capacity when draining oil, coolant or fuel. Before removing a part from the machine, check for alignment markings indicating the correct assembly position. If necessary, make new markings to ensure correct assembly. When unplugging electrical connectors, always grip the connectors firmly to avoid pulling on the wires. Where necessary, label wires and pipes before removal to avoid confusion when reconnecting. Check the number and thickness of any shims removed and keep them together in a safe place. To lift the tractor or any of its main components, use lifting equipment of suitable capacity. When using eyebolts for lifting components, first check that they are not deformed or damaged; screw them fully home and then turn the bolt so that the eye is aligned with the lifting hook. Before removing a part, clean the surrounding area and, after removing the part, cover it to protect it from dirt and dust.

0-3

Introduction Precautions for refitting operations l l l

l l

l

l l l

l

Tighten nuts and screws to the specified tightening torques. When refitting flexible pipes and cables, take care not to twist or tangle them. Always fit new seals, O-rings, split pins and safety stop rings; make sure that the ends of the cotter pins are separated and bent back so that the pin cannot be withdrawn from the hole. Ensure that circlips are correctly installed in their seatings. When applying threadlocking compound, first clean the part to remove all oil and grease, then cover the thread evenly applying a few drops of the compound. When applying sealant, first clean the surface removing all traces of oil and grease and check for dirt or indentations, then apply the sealant evenly making sure that it forms a continuous film around any fixing holes. Clean all parts, removing dirt, oxidisation, carbon deposits, burrs and indentations. Coat all moving parts with a thin film of engine oil. When reconnecting electrical wiring connectors, first remove all traces of oil, dust and water from the inside of the connector and then push the two halves together firmly; connectors with locking tabs should be pushed together until the tab engages the keeper. Bolt down flanged fittings evenly, tightening the screws gradually in a crosswise pattern.

Precautions to be taken on completion of removal/refitting operations l

l

l

l

If coolant has been drained from the engine, refit the drain plug and pour in new coolant to the correct level. Start the engine to circulate the coolant and then check the level again and top up. After removing hydraulic components, top up the hydraulic oil to the specified level. Start the engine to circulate the oil in the hydraulic circuits and then recheck the level and top up as necessary. After having removed a variable displacement pump, connect the drain pipe and fill the pump casing with oil through the filler hole provided. Grease stub axle housings, cylinder pivot mountings and drive shafts thoroughly after assembly.

0.1.4 - Lifting instructions DANGER Components weighing over 25 kg or of significant size must be supported and removed using suitable lifting equipment with wire rope or polyester slings.

Wire ropes - slings l

Use wire ropes or polyester slings of suitable capacity for the parts to be lifted, referring to the following tables:

Table 1 WIRE ROPES (standard twisted “S” or “Z” type) Ø rope mm Capacity (kg)

POLYESTER SLINGS (eye-and-eye - simple loop) Width (mm) Capacity (kg)

8 10 12 14 16 18

25 50 62 75 100 150

650 1000 1450 2000 2600 3300

620 1740 2500 3460 4500 5710

500 1420 2050 2820 3670 4660

500 1000 1250 1400 2000 2500

400 800 1000 1120 1600 2000

860 1730 2160 2420 3460 4330

700 1410 1760 1980 2820 3530

Lifting capacities are calculated with a safety coefficient.

l

l

0-4

The lifting hook should be attached to the central part of the rope or sling; if the hook is attached near the ends of the rope/ sling, this could cause the load to slip during lifting. Never lift a heavy load using a single rope; always use two or more symmetrically arranged ropes.

Introduction DANGER Suspension of a load from a single rope could cause the load to start rotating and consequently cause the rope strands to untwist or the load to slip; this could lead to serious injury. l

Never lift a heavy load when the two legs of the ropes form a wide angle. the permitted load (kg) decreases in inverse proportion to the angle of suspension; the table below indicates how the permitted load varies according to the angle of suspension for two Ø 10 mm ropes each with a load capacity of 1000 kg.

Fig. 1

0.1.5 - Tightening torques Bolts and nuts

DANGER The tightening torques for certain specific components and special tightening methods are indicated in the relative assembly paragraphs. The tightening torques indicated below refer to screws and nuts assembled without lubrication and, where applicable, with anaerobic threadlocking compound. the values apply to tightening on steel or cast iron components; for soft materials such as aluminium, copper, plastic, sheet metal or panels, the indicated tightening torques must be reduced by 50%.

Table 2 BOLT SIZE M6x1 M8x1.25 M10x1.5 M12x1.75 M14x2 M16x2 M18x2.5 M20x2.5 M22x2.5 M24x3 M27x3

BOLT CLASS 8.8 Nm 8.0 – 8.8 19.4 – 21.4 38.4 – 42.4 66.5 – 73.5 106 – 117 164 – 182 228 – 252 321 – 355 441 – 487 553 – 611 816 – 902

lb.ft. 5.9 – 6.5 14.3 – 15.8 28.3 – 31.2 49.0 – 54.2 78.1 – 86.2 120.9 – 134.1 168.0 – 185.7 236.6 – 261.6 325.0 – 358.9 407.6 – 450.3 601.4 – 664.8

10.9 Nm 11.8 – 13.0 28.5 – 31.5 56.4 – 62.4 96.9 – 107 156 – 172 241 – 267 334 – 370 472 – 522 647 – 715 812 – 898 1198 – 1324

lb.ft. 8.7 – 9.6 21.0 – 23.2 41.6 – 46.0 71.4 – 78.9 115.0 – 126.8 117.6 – 196.8 246.2 – 272.7 347.9 – 384.7 476.8 – 527.0 598.4 – 661.8 882.9 – 975.8

12.9 Nm 13.8 – 15.2 33.3 – 36.9 67.4 – 74.4 115 – 128 184 – 204 282 – 312 391 – 432 553 – 611 751 – 830 950 – 1050 1419 – 1569

lb.ft. 10.2 – 11.2 24.5 – 27.2 49.7 – 54.8 84.8 – 94.3 135.6 – 150.3 207.8 – 229.9 288.2 – 318.4 407.6 – 450.3 553.5 – 611.7 700.2 – 773.9 1045.8 – 1156.4

0-5

Introduction FINE

M8x1 M10x1.25 M12x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x2

20.8 – 23.0 40.6 – 44.8 72.2 – 79.8 69.4 – 76.7 114 – 126 175 – 194 256 – 282 355 – 393 482 – 532 602 – 666

15.3 – 17.0 29.9 – 33.0 53.2 – 58.8 51.1 – 56.5 84.0 – 92.9 129 – 143 188.7 – 207.8 261.6 – 289.6 355.2 – 392.1 443.7 – 490.8

30.6 – 33.8 59.7 – 65.9 106 – 118 102 – 112 168 – 186 257 – 285 375 – 415 523 – 578 708 – 782 884 – 978

22.6 – 24.9 44.0 – 48.6 78.1 – 87.0 75.2 – 82.5 123.8 – 137.1 189.4 – 210.0 276.4 – 305.9 385.5 – 426.0 521.8 – 576.3 651.5 – 720.8

35.8 – 39.6 71.2 – 78.6 126 – 140 121 – 134 199 – 220 301 – 333 439 – 485 611 – 676 821 – 908 1035 – 1143

26.4 – 29.2 52.5 – 57.9 92.9 – 103.2 89.2 – 98.8 146.7 – 162.1 221.8 – 245.4 323.5 – 357.4 450.3 – 498.2 605.1 – 669.2 762.8 – 842.4

Fittings The tightening torques indicated below refer to fittings assembled on any material.

Table 3 METRIC

Straight end fittings

Thread size Wrench M10x1.25 M12x1.25 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M26x1.5 M27x2 M33x2 M42x2 M48x2 G 1/8” G 1/4” G 3/8” G 1/2” G 3/4” G 1” G 1 1/4” G 1 1/2”

17 19 19 19 22 24 27 30 36 36 41 50 60 17 19 19 22 24 27 30 36 41 46 50 60

T” end fittings

Torque Nm Wrench ±10% 14 14 14 17 30 17 40 19 48 22 58 24 65 27 73 30 95 36 100 36 160 41 250 50 305 60 13 14 13 37 19 37 53 24 73 27 73 100 36 160 41 160 250 50 305 60

L” end fittings

90° end fittings

Torque Nm Wrench ±10% 14 14 14 17 30 17 40 19 48 22 58 24 65 27 73 30 95 36 100 36 160 41 250 50 305 60 13 14

Torque Nm Wrench ±10% 14 14 14 30 17 40 19 48 22 58 24 65 27 73 30 95 36 100 36 160 41 250 50 305 60 13 14

Torque Nm ±10% 14 30 40 48 58 65 73 95 100 160 250 305 13

37

19

37

19

37

53 73

24 27

53 73

24 27

53 73

100 160

36 41

100 160

36 41

100 160

250 305

50 60

250 305

50 60

250 305

Plugs

Table 4 Hex plugs

Thread size 0-6

Wrench

Threaded plugs with hex socket head

Torque Nm ±10%

Wrench

Torque Nm ±10%

Introduction METRIC

M6x1 M8x1 M10x1 M10x1.25 M10x1.5 M12x1.25 M12x1.5 M12x1.75 M14x1.5 M14x2 M16x1.5 M16x2 M18x1.5 M18x2.5 M20x1.5 M22x1.5 M24x1.5 M24x2 M27x2 M28x1.5 M30x1.5 M32x1.5 M35x1.5 M40x1.5 G 1/8” G 1/4” G 3/8” G 1/2” G 5/8” G 3/4” G 1”

10 13 13 13 13 17 17 17 19 19 22 22 17 17 19 – 22 22 22 – 22 – – – 14 19 22 19 22 22 22

10 12 14 14 14 30 30 30 40 40 48 48 58 58 65 – 80 80 100 – 130 – – – 13 37 53 73 85 100 160

– – 5 – – – 6 – 6 – 8 – 10 – – 12 12 – – 17 – 19 22 24 – – – – – – –

– – 14 – – – 30 – 40 – 48 – 58 – – 73 80 – – 110 – 150 180 225 – – – – – – –

Fittings with seal at 37° Table 5

Thread size 7/16” - 20 1/2” - 20 9/16” - 18 3/4” - 16 7/8” - 14 1 1/16” - 12 1 3/16” - 12 1 5/16” - 12 1 5/8” - 12 1 7/8” - 12 2 1/2” - 12

Wrench 14 16 17 22 27 32 36 36 38 50 60 75

Torque Nm ±10% 13 19 28 47 76 110 110 138 155 215 290 345

0-7

Introduction Fittings for pipes with banjo union These tightening torques refer to tightening the fitting with new copper sealing washers.

Table 6 Unions for one-way fittings

Thread size

Wrench

M8x1 M8x1.25 M10x1 M10x1.25 M12x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x1.5 M26x1.5 M28x1.5 M30x1.5 M35x2 M38x1.5 M42x2 M45x1.5 M50x2 M52x1.5 M65x2

– 13 – 13 17 – 19 22 22 27 – 32 – 36 – 41 – 50 – 60 – –

Torque ±10% 14 – 20 30 – 40 48 58 65 – 80 – 110 – 180 – 250 – 320 – –

Unions for three-way fittings Unions for four-way fittings

Nm Wrench 12

Torque ±10% 14

14 – – 17 19 22 24 – 27 – 32 – 36 – 46 – 55 – 60 75

20 – – 30 40 48 58 – 73 – 95 – 130 – 200 – 280 – 320 450

Nm Wrench –

Torque ±10% –

14 – – 17 19 22 24 – 27 – 32 – 36 – 46 – 55 – 60 75

20 – – 30 40 48 58 – 73 – 95 – 130 – 200 – 280 – 320 450

Nm

0.1.6 - Threadlockers, adhesives, sealants and lubricants Table 7

FUNCTION THREADLOCKER

0-8

NAME DESCRIPTION Loctite 222 Colour: opaque fluorescent Anaerobic product suitable for low-strength locking of retaining, purple adjustment and precision fasteners. All traces of lubricant must first be removed using the specific activator. Loctite 242 Colour: fluorescent blue Anaerobic product that prevents loosening of all types of nut and bolt; used in place of conventional mechanical locking systems. Used for medium-strength locking. All traces of lubricant must first be removed using the specific activator. Loctite 243 Colour: opaque fluorescent Alternative product to 242 ; oil tolerant and so can be used on blue lightly lubricated surfaces without prior use of activator. Loctite 270 Colour: fluorescent green Anaerobic product for high-strength locking of bolts and studs that do not normally require disassembly. Parts must be heated to approximately 80°C for removal. All traces of lubricant must first be removed using the specific activator.

Introduction DEGREASERS Loctite 703 AND ACTIVATORS

SEALANTS (for faces and fittings)

INSTANT SIVES

ADHE-

SEALANTS CONE

SILI-

SEALANTS URETHANE

POL-

Product used for degreasing and cleaning parts prior to application of Loctite anaerobic products; after drying, promotes uniform curing of threadlockers Loctite 747 Product used specifically for treatment of passive metals prior to use of slow-cure anaerobic threadlockers (series 5 and 6). Can also be used to increase cure speed at low temperatures or in applications where there are large gaps between the parts. Loctite 510 Colour: red Super-rapid anaerobic sealant for sealing between rigid metal faces; can eliminate the need for conventional gaskets as it can fill gaps up to 0.4 mm. Does not shrink and therefore fasteners do not need re-tightening to specified torque values after curing. Loctite 542 Colour: Brown Anaerobic product used as a liquid sealant for threaded fittings up to 3/4” gas; rapid curing and parts may be disassembled with ordinary tools. Loctite 554 Colour: red Anaerobic sealant and locking compound used for sealing cooling and industrial fluid circuits. Slow curing, also suitable for use on non-ferrous alloys Loctite 572 Colour: White Anaerobic sealant and locking compound used for sealing pipes and threaded fittings up to 2” in diameter. Very slow curing on most metal surfaces. Loctite 573 Colour: green Thixotropic anaerobic product used for sealing joints between metal faces. Ensures total contact between surfaces with maximum tolerance of 0.10 mm, filling microvoids caused by flatness errors. Very slow curing on most metal surfaces and requires prior application of an activator. Loctite 576 Colour: brown Anaerobic product used as a liquid thread sealant for large diameter threaded fittings (up to 2”). Very slow curing; also suitable for non-ferrous alloys and parts requiring subsequent removal. Loctite 401 Colour: colourless Cyanoacrylate instant adhesive suitable for bonding a wide range of acidic and porous materials including, ceramics, wood, rubber and plastic (excluding polyolefin). Curing takes place in a few seconds as an effect of the condensed humidity present on the surfaces to be bonded, and is independent of environmental conditions. Loctite 495 Colour: colourless Cyanoacrylate instant adhesive suitable for bonding a rubber, plastics and metal in any combination. Silastic 738 (Dow Corning) Colour: milky One-part silicone adhesive/sealant, non dhrinking, ready for use. white Cures on exposure to air to form a rubbery solid and obviates the need for conventional seals on flexible joints, filling gaps greater than 1 mm. Dirko Transparent Colour: transparent One-part silicone adhesive/sealant, shrinking, ready for use. Cures rapidly when exposed to humidity in the air to form a rubbery solid; resistant to high temperatures. Betaseal HV3 (Gurit Essex) Colour: black Polyurethane prepolymer based adhesive/sealant, high viscosity, suitable for permanent, high-strength flexible bonding. Slow curing, used for bonding glass to frames, wire mesh, metal plates, etc. surfaces must be degreased with primer.

0-9

Introduction RETAINING COM- Loctite 601 Colour: fluorescent green POUNDS

LUBRICANTS

Anaerobic, fast-curing, high-strength adhesive. Suitable for sealing and retaining cylindrical assemblies with gap clearances of up to 0.10 mm; used for retaining rotors, gears, bearings, pulleys, bushes etc. on shafts. Loctite 638 Colour: fluorescent green Anaerobic structural adhesive, quick-curing, very high strength; suitable for bonding cylindrical parts in non-ferrous alloys. Loctite 648 Colour: fluorescent green Anaerobic structural adhesive, quick-curing, high-strength; suitable for bonding cylindrical parts, permanent retention of threaded parts, sealing of refrigeration systems, retention of bearings, etc. Alternative to Loctite 601 in high-temperature applications. Loctite 986/AVX Colour: Fluorescent red Anaerobic sealant/retaining compound for metal cylindrical parts. Slow-curing, high-strength, heat-resistant and resistant to chemical attack. Parts must be first treated with an activator. Grease (NLGI 2 EP ASTM D217: 265/295) Multi-purpose Lithium grease used for lubrication of seals, to prevent oxidization and to facilitate assembly operations. Molikote (Dow Corning) Anti-wear compound, contains Molybdenum bisulphate, used neat or diluted with engine oil for assembly of main engine bearings. Vaseline Neutral pH compound used to protect battery terminals against oxidization and corrosion. Engine oil 10W - 30 Used to dilute Molikote anti-wear lubricant during assembly of main engine bearings.

0.1.7 - Conversion factors Conversion from British to metric units

Table 8 inch x 25.40 foot x 0.305 yard x 0.914 Eng.miles x 1.609 Sq.in. x 6.452 Sq.ft. x 0.093 Sq.yard x 0.835 Cu.in. x 16.39 Cu.ft. x 28.36 Cu.yard x 0.763 Imp.gall. x 4.547 US gall. x 3.785 pint x 0.568 quart x 1.137 US.gpm x 3.785 oz. x 0.028 lb. x 0.454 lb.ft. x 0.139 lb.in. x 17.87 psi x 0.070 lb./Imp.gall x 0.100 lb./US.gall x 0.120 lb./cu.ft. x 16.21 lb.ft. x 1.356 psi x 1.379

= mm =m = km = cm² = m² = cm³ = m³ = litres

= ,/min = kg = kgm = kg/m = kg/cm² = kg/, = kg/m³ = Nm = bar

Conversion from metric to British units

Table 9 mm x 0.0394 m x 3.281 m x 1,094 km x 0.622 cm² x 0.155 m² x 10.77 0-10

= inch = foot = yard = Brit.miles = Sq.in. = Sq.ft.

Introduction m² x 1.197 cm³ x 0.061 m³ x 0.035 m³ x 1.311 litres x 0.220 litres x 0.264 litres x 1.762 litres x 0.880 ,/min x 0.2642 kg x 35.25 kg x 2.203 kgm x 7.233 kg/m x 0.056 kg/cm² x 14.22 kg/, x 10.00 kg/, x 8.333 kg/m³ x 0.062 Nm x 0.737 bar x 14.503

= Sq.yard = Cu.in. = Cu.ft = Cu.yard = Imp.gall. = US gall. = pint = quart = US.gpm = oz. = lb. = lb.ft. = lb.in. = psi = lb./Imp.gal. = lb./US.gal. = lb./cu.ft. = lb.ft. = psi

0-11

Introduction 0.2 - Tightening torques for nuts and bolts of electrical connections Tighten all nuts and bolts of wiring harnesses, leaving the battery negative cable until last. l

For closing torque, where not specified use class 9 N.93810

0.2.1 - Standard tightening torques Table 10

General table Pitch

6x1 8x1 8x1.25 10x1 10x1.5 12x1.25 12x1.75 14x1.5

Torque

5.5 14.4 13.4 29.5 26.5 50 46 79

Table 11 General table Pitch

14x2 16x1.5 16x2 Tolerance ±20%

Torque

73 121 113

0.2.2 - Battery terminal tightening torques

Fig. 2

0-12

Introduction 0.2.3 - Starter motor tightening torques

Fig. 3

0.2.4 - Alternator tightening torques

Fig. 4

0-13

Introduction 0.3 - Wheel rim to hub screws and nuts tightening torques DANGER These tightening torques are not applicable to special self-locking fixing systems.

Table 12 p/n

2.0122.511.6 2.0122.615.2 2.0399.235.6 2.0399.129.6 2.0399.140.6 2.0399.003.6/10 2.1011.308.6 01101323 2.1099.175.6 0.012.8307.0 2.1019.176.6 2.1099.083.0/20 01104070 2.1099.085.0/20 2.1099.177.6

0-14

Description

Screw M14x1.5 Screw M16x1.5 Screw M16x1.5 Screw M18x1.5 Screw M18x1.5 Screw M20x1.5 Nut M14x1.5 Nut M18x1.5 Nut M18x1.5 Nut M20x1.5 Nut M20x1.5 Nut M20x1.5 Nut M20x1.5 Nut M22x1.5 Nut M22x1.5

Class

8.8 8.8 10.9 10.9 10.9 10.9 8 10 10 10 10 10 10 10 10

Tightening torque

120 Nm (12.2 kgm) 184.5 Nm (18.8 kgm) 271 Nm (27.6 kgm) 395 Nm (40.3 kgm) 395 Nm (40.3 kgm) 550 Nm (56 kgm) 120 Nm (12.2 kgm) 395 Nm (40.3 kgm) 395 Nm (40.3 kgm) 550 Nm (56 kgm) 550 Nm (56 kgm) 550 Nm (56 kgm) 550 Nm (56 kgm) 745 Nm (76 kgm) 650 Nm (66.2 kgm)

Tolerance

± 5% ± 5% ± 5% ± 5% ± 5% ± 5% ± 5% ± 5% ± 5% ± 5% ± 5% ± 5% ± 5% ± 5% ± 5%

Introduction 0.4 - Introduction

The purpose of this workshop manual is to provide instructions for repair technicians and a practical guide for improvement of the quality of repairs. This manual enables repair technicians to acquire a thorough knowledge of the engine, indicating the correct methods for fault diagnosis, for working in safety and for accurate dimensional checks and visual inspections of parts subject to repair. The instructions also indicate the products to use, the tightening torques and the adjustment data. The technical material contained in this manual is reserved for Authorised Dealers and Service Centres who will be duly informed of any technical changes to the engines in question through the issue of documents regarding modifications, updates and supplements for optional equipment. All technicians and their colleagues are expressly forbidden from reproducing any part of this manual in any form or from communicating the contents to third parties without the express written permission of the Manufacturer, which remains the sole owner of this document with all rights reserved in accordance with applicable laws.

0.4.1 - Safety notes

To ensure that engines entrusted to Authorised Service Centres for repair or overhaul continue to function correctly, it is very important that all repair work is carried out in the prescribed manner. The procedures for checks and repairs indicated in this manual are safe and effective. Some of the operations described require the use of special tools and equipment; these tools have been specifically designed for the intended purpose and may be ordered directly from the Manufacturer. DO NOT USE MAKESHIFT TOOLS; not only is there a risk of personal injury, but such tools are rarely suited to the purpose for which they are used. In potentially hazardous situations, always give priority to personal safety and take the necessary actions to eliminate the danger

0.4.2 - General safety rules l

l l

l

l

l

l

l l l l l

l

l

Even if you have a thorough knowledge of the engine as regards its components, operation and controls, always take particular care when carrying out manoeuvres or movements; Remember that the engine you are working on is in need of repair or overhaul and consequently may not always behave as expected. Before starting work, clean the engine thoroughly to remove all mud, dust and road dirt. When carrying out checks and repairs, wear close-fitting clothing, safety goggles and protective gloves that are suitable for the task (cleaning, draining fluids, repairs). When working near moving parts, long hair should be gathered up and tied back safely under a cap to prevent the risk of entanglement and severe injury. Do not allow anyone who is not directly involved in the work to come near the engine; ensure that they remain at a safe distance. Keep well clear of moving parts; when the engine is running, some moving parts are not easily visible and therefore present a risk of entanglement, even if protected by safety guards. Ensure that the area is well ventilated before starting the engine in order to avoid the formation of dangerous concentrations of toxic gases; always connect suitable fumes extraction equipment to the exhaust pipe. Do not start the engine with the safety guards removed under any circumstances; all repair and adjustment operations must be carried out with the engine stopped. Do not top up fuel, oil or coolant levels when the engine is running. Never smoke and ensure there are no naked flames nearby when topping up fuel or oil. Before checking or removing the battery, stop the engine and remove the key from the starter switch. Remove the battery and recharge in a well-ventilated area where the temperature exceeds 0°C. When checking or recharging the battery, do not smoke or allow naked flames in the vicinity as the hydrogen gas given off by the battery is highly explosive. The liquid (electrolyte) contained in the battery is very harmful if it comes into contact with the skin and the eyes; for this reason, always wear gloves and safety goggles with side shields when checking or topping up the battery. Should any electrolyte accidentally come into contact with your skin, wash the affected areas immediately with plenty of fresh water; if electrolyte comes into contact with your clothing, this should be removed as soon as possible. In case of accidental ingestion of electrolyte, drink plenty of water, milk or vegetable oil, take antacids such as magnesium, bicarbonate, etc. and seek medical attention immediately. Before working on the electrical systems, always disconnect the battery terminals. DANGER Always disconnect the negative lead (--) before the positive lead (+); when re-connecting the battery on completion of the work, first connect the positive terminal (+) and then the negative (--).

l l l

No welding is permitted on the engine. When topping up lubricants, always wear suitable protective gloves. Do not wear clothing contaminated by engine oil or hydraulic oil; prolonged contact with the skin can be harmful and may cause allergic reactions.

0-15

Introduction l

l l l

l

l

l

l l

l

l

l

l

l

Used engine oil and hydraulic oil must be disposed of properly; recover used lubricants and dispose of them in accordance with the applicable regulations. Before carrying out any work on the hydraulic or pneumatic systems, discharge all residual pressure from the circuits. Before carrying out any work on the hydraulic system or engine, allow the oil and engine coolant to cool down. When removing and refitting certain assemblies, it will be necessary to support the engine; use stands, jacks or blocks capable of supporting the weight and arrange them in a triangular pattern to prevent the engine from overturning. To lift heavy components, use a hoist or crane. Check that wire ropes, chains or fibre slings are not worn and that hooks are not damaged. Always use lifting equipment of suitable capacity for the weight of the components to be removed. Ensure lifting equipment is attached correctly. When lifting or supporting an assembly or component, manoeuvre the parts slowly and carefully to avoid swinging movements or collision with other components. Never work on components suspended from a hoist or crane. When removing the retaining bolts of a component that could fall, always leave two opposing bolts in place for safety; before removing these last two screws, attach the component to suitable lifting equipment or position support blocks. Any oil or fuel spilled during removal or dismantling operations should be cleaned up as soon as possible to prevent the risk of slipping and fire. When refitting electrical wiring looms and wires, ensure that they are properly secured with their original retaining straps or brackets to prevent the possibility of damage caused by vibration. Never insert your fingers or hands to check the alignment between fixing holes in components; always use a suitable dowel of soft material. When refitting assemblies or components, always use the specified tightening torques; the tightening torques indicated in the headings regarding assembly/refitting operations have been determined through experimentation and must be scrupulously adhered to. When refitting parts that are subject to vibration or that rotate at high speed, take particular care when carrying out final installation checks.

0.4.3 - Safety precautions for removal and refitting operations When removing or refitting parts, always take the following safety precautions.

Precautions for removal operations l l l

l l l l l

l

After disconnecting hydraulic and fuel system pipes, always fit plugs to the open ends of the pipes to prevent ingress of dirt. Use containers of sufficient capacity when draining oil, coolant or fuel. Before removing a part from the machine, check for alignment markings indicating the correct assembly position. If necessary, make new markings to ensure correct assembly. When unplugging electrical connectors, always grip the connectors firmly to avoid pulling on the wires. Where necessary, label wires and pipes before removal to avoid confusion when reconnecting. Check the number and thickness of any shims removed and keep them together in a safe place. To lift the engine or any of its main components, use lifting equipment of suitable capacity. When using eyebolts for lifting components, first check that they are not deformed; screw them fully home and then turn the bolt so that the eye is aligned with the lifting hook. Before removing a part, clean the surrounding area and, after removing the part, cover it to protect it from dirt and dust.

Precautions for refitting operations l l l

l l

l

l l l

l

0-16

Tighten nuts and screws to the specified tightening torques. When refitting flexible pipes and cables, take care not to twist or tangle them. Always fit new seals, O-rings, split pins and safety stop rings; make sure that the ends of the split pins are separated and bent back so that the pin cannot be withdrawn from the hole. Ensure that circlips are correctly installed in their grooves. When applying threadlocking compound, first clean the part to remove all oil and grease, then cover the thread evenly applying a few drops of the compound. When applying sealant, first clean the surface removing all traces of oil and grease and check for dirt or indentations, then apply the sealant evenly making sure that it forms a continuous film around any fixing holes. Clean all parts, removing dirt, oxidisation, carbon deposits, burrs and indentations. Coat all moving parts with a thin film of engine oil. When reconnecting electrical wiring connectors, first remove all traces of oil, dust and water from the inside of the connector and then push the two halves together firmly; connectors with locking tabs should be pushed together until the tab engages the keeper. Bolt down flanged fittings evenly, tightening the screws gradually in a crosswise pattern.

Introduction Precautions to be taken on completion of removal/refitting operations l

l

l

l

If coolant has been drained from the engine, refit the drain plug and pour in new coolant to the correct level. Start the engine to circulate the coolant and then check the level again and top up. After removing hydraulic components, top up the hydraulic oil to the specified level. Start the engine to circulate the oil in the hydraulic circuits and then recheck the level and top up as necessary. After having removed a variable displacement pump, connect the drain pipe and fill the pump casing with oil through the filler hole provided. Grease stub axle housings, cylinder pivot mountings and drive shafts thoroughly after assembly.

0.4.4 - Lifting instructions DANGER Components weighing over 25 kg or of significant size must be supported and removed using suitable lifting equipment with wire rope or polyester slings.

Wire ropes - slings l

Use wire ropes or polyester slings of suitable capacity for the parts to be lifted, referring to the following tables:

Table 13 WIRE ROPES (standard twisted “S” or “Z” type) Ø rope mm Capacity (kg)

POLYESTER SLINGS (eye-and-eye - simple loop) Width (mm) Capacity (kg)

8 10 12 14 16 18

25 50 62 75 100 150

650 1000 1450 2000 2600 3300

620 1740 2500 3460 4500 5710

500 1420 2050 2820 3670 4660

500 1000 1250 1400 2000 2500

400 800 1000 1120 1600 2000

860 1730 2160 2420 3460 4330

700 1410 1760 1980 2820 3530

Lifting capacities are calculated with a safety coefficient.

l

l

The lifting hook should be attached to the central part of the rope or sling; if the hook is attached near the ends of the rope/ sling, this could cause the load to slip during lifting. Never lift a heavy load using a single rope; always use two or more symmetrically arranged ropes. DANGER Suspension of a load from a single rope could cause the load to start rotating and consequently cause the rope strands to untwist or the load to slip; this could lead to serious injury.

l

Never lift a heavy load when the two legs of the ropes form a wide angle. The permitted load (kg) decreases in inverse proportion to the angle of suspension; the table below indicates how the permitted load varies according to the angle of suspension for two Ø 10 mm ropes each with a load capacity of 1000 kg.

0-17

Introduction

Fig. 4

0.4.5 - Tightening torques Screws and nuts

DANGER The tightening torques for certain specific components and special tightening methods are indicated in the relative assembly headings. The tightening torques indicated below refer to screws and nuts assembled without lubrication and, where applicable, with anaerobic threadlocking compound. the values apply to tightening on steel or cast iron components; for soft materials such as aluminium, copper, plastic, sheet metal or panels, the indicated tightening torques must be reduced by 50%.

Table 14 SCREW SIZE

FINE

0-18

M6x1 M8x1.25 M10x1.5 M12x1.75 M14x2 M16x2 M18x2.5 M20x2.5 M22x2.5 M24x3 M27x3 M8x1 M10x1.25 M12x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x2

SCREW CLASS 8.8 Nm lb.ft. 8.0 - 8.8 5.9 - 6.5 19.4 - 21.4 14.3 - 15.8 38.4 - 42.4 28.3 - 31.2 66-5 - 73-5 49.0 - 54.2 106 - 117 78.1 - 86.2 164 - 182 120.9 - 134.1 228 - 252 168.0 - 185.7 321 - 355 236.6 - 261.6 441 - 487 325.0 - 358.9 553 - 611 407.6 - 450.3 816 - 902 601.4 - 664.8 20.8 - 23.0 15.3 - 17.0 40.6 - 44.8 29.9 - 33.0 72.2 - 79.8 53.2 - 58.8 69.4 - 76.7 51.1 - 56.5 114 - 126 84.0 - 92.9 175 - 194 129 - 143 256 - 282 188.7 - 207.8 355 - 393 261.6 - 289.6 482 - 532 355.2 - 392.1 602 - 666 443.7 - 490.8

10.9 Nm 11.8 - 13.0 28.5 - 31.5 56.4 - 62.4 96.9 - 107 156 - 172 241 - 267 334 - 370 472 - 522 647 - 715 812 - 898 1198 - 1324 30.6 - 33.8 59.7 - 65.9 106 - 118 102 - 112 168 - 186 257 - 285 375 - 415 523 - 578 708 - 782 884 - 978

lb.ft. 8.7 - 9.6 21.0 - 23.2 41.6 - 46.0 71.4 - 78.9 115.0 - 126.8 117.6 - 196.8 246.2 - 272.7 347.9 - 384.7 476.8 - 527.0 598.4 - 661.8 882.9 - 975.8 22.6 - 24.9 44.0 - 48.6 78.1 - 87.0 75.2 - 82.5 123.8 - 137.1 189.4 - 210.0 276.4 - 305.9 385.5 - 426.0 521.8 - 576.3 651.5 - 720.8

12.9 Nm 13.8 - 15.2 33.3 - 36.9 67.4 - 74.4 115 - 128 184 - 204 282 - 312 391 - 432 553 - 611 751 - 830 950 - 1050 1419 - 1569 35.8 - 39.6 71.2 - 78.6 126 - 140 121 - 134 199 - 220 301 - 333 439 - 485 611 - 676 821 - 908 1035 - 1143

lb.ft. 10.2 - 11.2 24.5 - 27.2 49.7 - 54.8 84.8 - 94.3 135.6 - 150.3 207.8 - 229.9 288.2 - 318.4 407.6 - 450.3 553.5 - 611.7 700.2 - 773.9 1045.8 - 1156.4 26.4 - 29.2 52.5 - 57.9 92.9 - 103.2 89.2 - 98.8 146.7 - 162.1 221.8 - 245.4 323.5 - 357.4 450.3 - 498.2 605.1 - 669.2 762.8 - 842.4

Introduction Fittings The tightening torques indicated below refer to fittings assembled on any material.

Table 15 METRIC

Straight end fittings

Thread

Wrench

M10x1.25

17 19 19 19 22 24 27 30 36 36 41 50 60 17 19 19 22 24 27 30 36 41 46 50 60

M12x1.25 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M26x1.5 M27x2 M33x2 M42x2 M48x2 G 1/8” G 1/4” G 3/8” G 1/2” G 3/4” G 1” G 1 1/4” G 1 1/2”

“T” end fittings

Torque Nm Wrench ±10% 14 14 14 17 30 17 40 19 48 22 58 24 65 27 73 30 95 36 100 36 160 41 250 50 305 60 13 14 13 37 19 37 53 24 73 27 73 100 36 160 41 160 250 50 305 60

“L” end fittings

90° end fittings

Torque Nm Wrench ±10% 14 14 14 17 30 17 40 19 48 22 58 24 65 27 73 30 95 36 100 36 160 41 250 50 305 60 13 14

Torque Nm Wrench ±10% 14 14 14 30 17 40 19 48 22 58 24 65 27 73 30 95 36 100 36 160 41 250 50 305 60 13 14

Torque Nm ±10% 14 30 40 48 58 65 73 95 100 160 250 305 13

37

19

37

19

37

53 73

24 27

53 73

24 27

53 73

100 160

36 41

100 160

36 41

100 160

250 305

50 60

250 305

50 60

250 305

Plugs

Table 16 Hex plugs

Thread

Wrench

Threaded plugs with hex socket head

Torque Nm ±10%

Wrench

Torque Nm ±10%

0-19

Introduction METRIC

M6x1 M8x1 M10x1 M10x1.25 M10x1.5 M12x1.25 M12x1.5 M12x1.75 M14x1.5 M14x2 M16x1.5 M16x2 M18x1.5 M18x2.5 M20x1.5 M22x1.5 M24x1.5 M24x2 M27x2 M28x1.5 M30x1.5 M32x1.5 M35x1.5 M40x1.5 G 1/8” G 1/4” G 3/8” G 1/2” G 5/8” G 3/4” G 1”

10 13 13 13 13 17 17 17 19 19 22 22 17 17 19 22 22 22 22 14 19 22 19 22 22 22

10 12 14 14 14 30 30 30 40 40 48 48 58 58 65 80 80 100 130 13 37 53 73 85 100 160

5 6 6 8 10 12 12 17 19 22 24 -

14 30 40 48 58 73 80 110 150 180 225 -

Fittings with seal at 37° Table 17

Thread 7/16” - 20 1/2” - 20 9/16” - 18 3/4” - 16 7/8” - 14 1 1/16” - 12 1 3/16” - 12 1 5/16” - 12 1 5/8” - 12 1 7/8” - 12 2 1/2” - 12

0-20

Wrench 14 16 17 22 27 32 36 36 38 50 60 75

Torque Nm ±10% 13 19 28 47 76 110 110 138 155 215 290 345

Introduction Fittings for pipes with banjo union These tightening torques refer to tightening the fitting with new copper sealing washers.

Table 18 Unions for one-way fittings

Thread

Wrench

M8x1 M8x1.25 M10x1 M10x1.25 M12x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x1.5 M26x1.5 M28x1.5 M30x1.5 M35x2 M38x1.5 M42x2 M45x1.5 M50x2 M52x1.5 M65x2

13 13 17 19 22 22 27 – 32 – 36 – 41 – 50 – 60 – –

Torque ±10% 14 20 30 40 48 58 65 – 80 – 110 – 180 – 250 – 320 – –

Unions for three-way fittings Unions for four-way fittings

Nm Wrench 12

Torque ±10% 14

14 17 19 22 24 27 – 32 – 36 – 46 – 55 – 60 75

20 30 40 48 58 73 – 95 – 130 – 200 – 280 – 320 450

Nm Wrench -

Torque ±10% -

14 17 19 22 24 27 – 32 – 36 – 46 – 55 – 60 75

20 30 40 48 58 73 – 95 – 130 – 200 – 280 – 320 450

Nm

0.4.6 - Threadlockers, adhesives, sealants and lubricants Table 19

FUNCTION THREADLOCKER

NAME DESCRIPTION Loctite 222 Colour: opaque fluorescent Anaerobic product suitable for low-strength locking of retaining, purple adjustment and precision fasteners. All traces of lubricant must first be removed using the specific activator. Loctite 242 Colour: fluorescent blue Anaerobic product that prevents loosening of all types of nut and bolt; used in place of conventional mechanical locking systems. Used for medium-strength locking. All traces of lubricant must first be removed using the specific activator. Loctite 243 Colour: opaque fluorescent Alternative product to 242 ; oil tolerant and so can be used on blue lightly lubricated surfaces without prior use of activator. Loctite 270 Colour: fluorescent green Anaerobic product for high-strength locking of bolts and studs that do not normally require disassembly. Parts must be heated to approximately 80°C for removal. All traces of lubricant must first be removed using the specific activator.

0-21

Introduction DEGREASERS Loctite 703 AND ACTIVATORS

SEALANTS (for faces and fittings)

INSTANT SIVES

ADHE-

SILICONE ANTS

SEAL-

POLYURETHANE SEALANTS

0-22

Product used for degreasing and cleaning parts prior to application of Loctite anaerobic products; after drying, promotes uniform curing of threadlockers Loctite 747 Product used specifically for treatment of passive metals prior to use of slow-cure anaerobic threadlockers (series 5 and 6). Can also be used to increase cure speed at low temperatures or in applications where there are large gaps between the parts. Loctite 510 Colour: red Super-rapid anaerobic sealant for sealing between rigid metal faces; can eliminate the need for conventional gaskets as it can fill gaps up to 0.4 mm. Does not shrink and therefore fasteners do not need re-tightening to specified torque values after curing. Loctite 542 Colour: brown Anaerobic product used as a liquid sealant for threaded fittings up to 3/4” gas; rapid curing and parts may be disassembled with ordinary tools. Loctite 554 Colour: red Anaerobic sealant and locking compound used for sealing cooling and industrial fluid circuits. Slow curing, also suitable for use on non-ferrous alloys Loctite 572 Colour: white Anaerobic sealant and locking compound used for sealing pipes and threaded fittings up to 2” in diameter. Very slow curing on most metal surfaces. Loctite 573 Colour: green Thixotropic anaerobic product used for sealing joints between metal faces. Ensures total contact between surfaces with maximum tolerance of 0.10 mm, filling microvoids caused by flatness errors. Very slow curing on most metal surfaces and requires prior application of an activator. Loctite 576 Colour: brown Anaerobic product used as a liquid thread sealant for large diameter threaded fittings (up to 2”). Very slow curing; also suitable for non-ferrous alloys and parts requiring subsequent removal. Loctite 401 Colour: colourless Cyanoacrylate instant adhesive suitable for bonding a wide range of acidic and porous materials including, ceramics, wood, rubber and plastic (excluding polyolefin). Curing takes place in a few seconds as an effect of the condensed humidity present on the surfaces to be bonded, and is independent of environmental conditions. Loctite 495 Colour: colourless Cyanoacrylate instant adhesive suitable for bonding a rubber, plastics and metal in any combination. Silastic 738 (Dow Corning) Colour: milky One-part silicone adhesive/sealant, non shrinking, ready for use. white Cures on exposure to air to form a rubbery solid and obviates the need for conventional seals on flexible joints, filling gaps of up to 1 mm or more. Dirko Transparent Colour: transparent One-part silicone adhesive/sealant, shrinking, ready for use. Cures rapidly when exposed to humidity in the air to form a rubbery solid; resistant to high temperatures. Betaseal HV3 (Gurit Essex) Colour: black Polyurethane prepolymer based adhesive/sealant, high viscosity, suitable for permanent, high-strength flexible bonding. Slow curing, used for bonding glass to frames, wire mesh, metal plates, etc. surfaces must be degreased with primer.

Introduction RETAINING COM- Loctite 601 Colour: fluorescent green POUNDS

LUBRICANTS

Anaerobic, fast-curing, high-strength adhesive. Suitable for sealing and retaining cylindrical assemblies with gap clearances of up to 0.10 mm; used for retaining rotors, gears, bearings, pulleys, bushes etc. on shafts. Loctite 638 Colour: fluorescent green Anaerobic structural adhesive, quick-curing, very high strength; suitable for bonding cylindrical parts in non-ferrous alloys. Loctite 648 Colour: fluorescent green Anaerobic structural adhesive, quick-curing, high-strength; suitable for bonding cylindrical parts, permanent retention of threaded parts, sealing of refrigeration systems, retention of bearings, etc. Alternative to Loctite 601 in high-temperature applications. Loctite 986/AVX Colour: fluorescent red Anaerobic sealant/retaining compound for metal cylindrical parts. Slow-curing, high-strength, heat-resistant and resistant to chemical attack. Parts must be first treated with an activator. Grease (NLGI 2 EP ASTM D217: 265/295) Multi-purpose Lithium grease used for lubrication of seals, to prevent oxidation and to facilitate assembly operations. Molikote (Dow Corning) Anti-wear compound, contains Molybdenum bisulphate, used neat or diluted with engine oil for assembly of main engine bearings. Vaseline Neutral pH compound used to protect battery terminals against oxidization and corrosion. Engine oil 10W - 30 Used to dilute Molikote anti-wear lubricant during assembly of main engine bearings.

0.4.7 - Conversion factors Conversion from British to metric units

Table 20 inch x 25.40 foot x 0.305 yard x 0.914 Brit.miles x 1.609 Sq.in. x 6.452 Sq.ft. x 0.093 Sq.yard x 0.835 Cu.in. x 16.39 Cu.ft. x 28.36 Cu.yard x 0.763 Imp.gall. x 4.547 US gall. x 3.785 pint x 0.568 quart x 1.137 US.gpm x 3.785 oz. x 0.028 lb. x 0.454 lb.ft. x 0.139 lb.in. x 17.87 psi x 0.070 lb./Imp.gall x 0.100 lb./US.gall x 0.120 lb./cu.ft. x 16.21 lb.ft. x 1.356 psi x 1.379

= mm =m = km = cm² = m² = cm³ = m³ = litres

= ,/min = kg = kgm = kg/m = kg/cm² = kg/, = kg/m³ = Nm = bar

Conversion from British to metric units

Table 21 mm x 0.0394 m x 3.281 m x 1.094 km x 0.622 cm² x 0.155 m² x 10.77

= inch = foot = yard = Eng.miles = Sq.in. = Sq.ft. 0-23

Introduction m² x 1.197 cm³ x 0.061 m³ x 0.035 m³ x 1.311 litres x 0.220 litres x 0.264 litres x 1.762 litres x 0.880 ,/min x 0.2642 kg x 35.25 kg x 2.203 kgm x 7.233 kg/m x 0.056 kg/cm² x 14.22 kg/, x 10.00 kg/, x 8.333 kg/m³ x 0.062 Nm x 0.737 bar x 14.503

0-24

= Sq.yard = Cu.in. = Cu.ft = Cu.yard = Imp.gall. = US gall. = pint = quart = US.gpm = oz. = lb. = lb.ft. = lb.in. = psi = lb./Imp.gal. = lb./US.gal. = lb./cu.ft. = lb.ft. = psi

10 - Technical characteristics

10-1

Technical characteristics 10.1 - Engine

10.1.1 - Motor description - construction type Engine type

These instructions concern the following engine types: l l

TCD 4.1 L4 TCD 6.1 L6

Table 22 TCD

T C D

Turbocharger Turbocharger Diesel

Table 23 4.1/6.1

4.1 6.1

Capacity in litres Capacity in litres

Table 24 L4/L6

L 4 6

in series Number of cylinders Number of cylinders

Exhaust gas emission regulation The engines described in this operating manual are compliant with the following exhaust emissions regulations

Table 25 With exhaust after-treatment system

USA UE

EPA Tier 4i Level IIIB

Table 26 Without exhaust gas after-treatment systems

The precise certification is stamped on the engine’s identification plate or is located on a separate plate for the concerned markets. DANGER The engine and the respective EAT system (Exhaust After Treatment) are combined together and connected reciprocally by suitable electronic control. They are certified by the competent authorities and are able to comply with the permitted exhaust gas emission limits only if provided in this combination. The engine may not be operated with other EAT systems DANGER The engines for this user manual may only be operated with the exhaust gas after treatment system functioning (if included in the DEUTZ supply)

10-2

Technical characteristics Model plate

Fig. 5

The engine type A, the engine number B and the data concerning the power are engraved on the plate Each spare part order must include the engine type and number.

Location of the model plate Plate C is fixed on the cylinder head cowling or on the crankcase.

10-3

Technical characteristics

C

Fig. 6

10-4

Technical characteristics

C Fig. 7

Engine number The engine number D is punched on the crankcase (arrow) and on the model plate.

10-5

Technical characteristics

xxxxxxx

D

Fig. 8

Serial numbers for the exhaust gas after treatment components 1. 2.

Serial numbers for the exhaust gas after treatment components Diesel particulate filter data plate

The serial numbers for the exhaust gas after treatment system components are stamped on the data plates

10-6

Technical characteristics

1

2

Fig. 9

10-7

Technical characteristics Cylinder numbering

Fig. 10

Cylinder layout The cylinders are numbered progressively from (1) from the flywheel side. Direction of rotation View from flywheel side. Left hand rotation: Anticlockwise. Engine sides View from flywheel side.

10-8

Technical characteristics 10.1.2 - Engine description - Images of engine 11

10

1

9 2 8

7

6

5

4

3

Fig. 11 - TCD 4.1 L4 Engine for agriculture - Right side view (example) l l l l l l l l l l l

1 - Combustion air intake 2 - Coolant outlet 3 - Ribbed V-belt 4 - Coolant inlet 5 - Lubricant oil drain screw 6 - Lubricant oil radiator 7 - Lubricant oil cartridge filter 8 - Fuel cartridge filter 9 - Rail 10 - Central connector (engine control) 11 - Exhaust gas outlet

10-9

Technical characteristics 1

2

3

4

Fig. 12 - TCD 4.1 L4 Engine for agriculture - Left side view (example) l l l l

10-10

1 - Combustion air intake 2 - Coolant outlet 3 - Lubricant oil filler cap 4 - Lubricant oil dipstick

Technical characteristics 11

10 1 9 8

2

7 3 6 4 5

Fig. 13 - TCD 4.1 L4 Industrial engine with regenerative burner - Right side view (example) l l l l l l l l l l l

1 - Combustion air intake 2 - Coolant outlet 3 - Ribbed V-belt 4 - Belt tensioner roller 5 - Lubricant oil drain screw 6 Remove the bearing pin. 7 - Lubricant oil dipstick 8 - Lubricant oil radiator 9 - Rail 10 - Lubricant oil filler cap 11 - Crankcase breather

10-11

Technical characteristics

1 2 3

4

Fig. 14 - TCD 4.1 L4 Industrial engine with regenerative burner - Left side view (example) l l l l l

10-12

1 - Burner 2 - Recirculated exhaust gas radiator 3 - Flexible pipe 4 - Compressor 5 - Exhaust gas outlet

5

Technical characteristics 11

1

10 2 9

8

7

6

5

4

3

Fig. 15 - TCD 6.1 L6 Engine for agriculture - Right side view (example) l l l l l l l l l l l

1 - Combustion air intake 2 - Alternator 3 - Ribbed V-belt 4 - Coolant inlet 5 - Lubricant oil cartridge filter 6 - Lubricant oil drain screw 7 - Lubricant oil radiator 8 - Fuel cartridge filter 9 - Rail 10 - Lubricant oil filler cap 11 - Crankcase breather

10-13

Technical characteristics 1

2

3

4 Fig. 16 - TCD 6.1 L6 Engine for agriculture - Left side view (example) l l l l l

10-14

1 - Combustion air intake 2 - Coolant outlet 3 - Exhaust gas outlet 4 - Lubricant oil filler cap 5 - Lubricant oil dipstick

5

Technical characteristics 10

1

9

8 7 6 5

2

3

4

Fig. 17 - TCD 6.1 L6 Industrial engine with regenerative burner - Right side view (example) l l l l l l l l l l

1 - Combustion air intake 2 - Ribbed V-belt 3 - Belt tensioner roller 4 - Lubricant oil drain screw 5 - Lubricant oil cartridge filter 6 - Lubricant oil dipstick 7 - Lubricant oil radiator 8 - Rail 9 - Lubricant oil filler cap 10 - Crankcase breather

10-15

Technical characteristics 1

2 3

4 5 6 Fig. 18 - TCD 6.1 L6 Industrial engine with regenerative burner - Left side view (example) l l l l l l

10-16

1 - Combustion air intake 2 - Coolant outlet 3 - Coolant inlet 4 - Burner 5 - Exhaust gas outlet 6 - Compressor

Technical characteristics 1 2 8 3 7 4

6 5

Fig. 19 - TCD 6.1 L6 PowerPack (complete DEUTZ solution consisting of engine and cooling system) - Right hand view (example) l l l l l l l l

1 - Coolant inlet 2 - Compensation container 3 - Charge air cooler 4 - Radiator 5 - Lubricant oil cartridge filter 6 - Fuel pre-filter 7 - Fuel cartridge filter 8 - Lubricant oil dipstick

10-17

Technical characteristics 6 1

5

4

Fig. 20 - TCD 6.1 L6 PowerPack (complete DEUTZ solution consisting of engine and cooling system) - Left hand view (example) l l l l l l

10-18

1 - Combustion air intake 2 - Lubricant oil filler cap 3 - Exhaust gas outlet 4 - Coolant inlet 5 - Coolant outlet 6 - Intake air cooler connections

2

3

Technical characteristics 10.1.3 - Engine description - Lubricant oil diagram

13

10

11

12

9 6

8

7

5

2

3

4

1

Fig. 21 - Lubrication oil system (Example) l l l l l l l l l l l l l

1 - Lubricant oil sump 2 - Lubricant oil pump 3 - Lubricant oil radiator 4 - Check valve 5 - Bypass valve 6 - Bypass valve 7 - Pressure regulator valve 8 - Lubricant oil filter 9 - Primary lubricant oil channel 10- Piston cooling nozzle 11 - Rocker 12 - Turbocharger 13 - Air compressor (optional)

10-19

Technical characteristics 7

8

9

6

10

5

Fig. 22 - Fuel circuit diagram (Example) l l l l l l l l l l l

10-20

1 - Fuel tank 2 - Fuel pre-filter 3 - Fuel delivery pump 4 - Fuel cartridge filter 5 - Fuel supply line for the fuel control unit (FCU) 6 - Fuel Control Unit (FCU) 7 - High pressure pump 8 - Lubricant oil filter 9 - Rail 10 - Injector 11 - Return line

11

4

3

2

1

Technical characteristics 10.1.4 - Engine description - Fuel circuit diagram 7

8

9

6

10

5

11

4

3

2

1

Fig. 23 - Fuel circuit diagram (Example) l l l l l l l l l l l

1 - Fuel tank 2 - Fuel pre-filter 3 - Fuel delivery pump 4 - Fuel cartridge filter 5 - Fuel supply line for the fuel control unit (FCU) 6 - Fuel Control Unit (FCU) 7 - High pressure pump 8 - Rail 9 - Injector 10 - Fuel return to tank 11 - Return line

10-21

Technical characteristics 10.1.5 - Engine description - Coolant diagram 6

7

x1

8

9

10

x2

x2

1

2

3

4

5

T

6 x1

5

4

Fig. 24 - Coolant diagram (Example) l l l l l l l l l l l

10-22

1 - Coolant pump 2 - Lubricant oil radiator 3 - Coolant feed line for cooling engine 4 - Cylinder sleeve/head cooling 5 - Air compressor (optional) 6 - Fitting for cab heater 7 - Recirculated exhaust gas radiator 8 - Temperature sender 9 - Thermostat 10 - Compensation container 11 - Radiator

3

2

1

11

Technical characteristics 10.1.6 - Engine description - Exhaust gas recovery 7

8

6

2

5

1

3

4 Fig. 25

External exhaust gas recirculation l l l l l l l l

1 - Recirculated portion of exhaust gas (not cooled) 2 - Coolant line leading to EGR radiator 3 - Adjuster (electrically actuated) 4 - Recirculated exhaust gas radiator 5 - Check valve 6 - Coolant return to thermostat 7 - Combustion air intake 8 - Recirculated portion of cooled exhaust gas

10-23

Technical characteristics 10.1.7 - Engine description - Exhaust gas after-treatment 8

7

6

5

9

4

10

3 11

Fig. 26 - Selective catalytic reduction (SCR) Example: l l l l l l l l l l l

10-24

1 - Engine control unit 2 - AdBlue® line 3 - AdBlue® delivery pump 4 - AdBlue® Tank 5 – Solenoid valve 6 - Coolant line for AdBlue® tank preheater 7 - Exhaust gas temperature sensor 8 - NOx sensor 9 - Selective catalytic reduction (SCR) system catalytic converter 10 - Metering unit 11 - Coolant line for cooling metering unit

1

2

Technical characteristics 1

3

2

5

4

7

6

9

8

Fig. 27 - Diesel particulate filter (DPF) - with active regeneration Example: l l l l l l l l l

1 - Burner 2 - Compressor 3 - Fuel metering unit 4 - Flexible pipe 5 - Exhaust gas temperature sensor 6 - Diesel oxidation catalytic converter 7 - Differential pressure sensor 8 - Diesel particulate filter 9 - NOx sensor

10-25

Technical characteristics 1

3

2

5

4

Fig. 28 - Diesel particulate filter (DPF) - with passive regeneration Example: l l l l l l

10-26

1 - Throttle valve 2 - Flexible pipe 3 - Exhaust gas temperature sensor 4 - Diesel oxidation catalytic converter 5 - Differential pressure sensor 6 - Diesel particulate filter

6

Technical characteristics 10.1.8 - Engine description - Electrical/electronic system 5 1

2

3

12

4

13 6

14 15 16 17 18 19 20

11

10

9

8

7

21 22

Fig. 29 - Electronic engine governor system l l l l l l l l l l l l l l l l l l l l

l l l l

Engine side 1 - Fuel pressure transducer 2 - Coolant temperature sensor 3 - Intake air pressure transducer, intake air temperature transducer TCD 6.1 L6 4 - Intake air pressure transducer, intake air temperature transducer TCD 4.1 L4 5 - Engine control unit 6 - Central connector (engine control) 7 - Crankshaft speed sensor 8 - Rail pressure sensor 9 - Lubricant oil pressure sensor transducer 10- Oil level glass (optional) 11 - Camshaft speed sensor From the side of the device 12 - Electric power feed (battery) 13 - Multifunction indicator lamps 14 - Signal outputs (e.g. for indicator lamps, rpm signal, engine run signal etc.) 15 - Inputs (e.g. override button) 16 - Accelerator 17 - Hand throttle 18 - Optional function converter, e.g. P curve, governor type, ceiling curve, fixed engine speed etc. May also be multiple position switch 19 - Key operated start/stop switch 20 - Diagnostics key 21 - Error warning light 22 - CAN bus diagnostic interface 10-27

Technical characteristics Recommendations for the engine electronics This engine is equipped with an electronic control device. The equipment for each system depends on the functions required and the type of engine use. The resulting wiring with the respective configuration of the connectors can be seen on the corresponding connection diagram. Also, the assembly instructions from DEUTZ AG must be followed.

Precautionary measures DANGER The control unit pin connections are dust and water resistant only when the counter piece is inserted (IP69K class of protection)! The control unit must be protected against spraying water and humidity until the counter piece is installed! Switching polarity can cause damage to the control unit. To avoid damaging the control unit, before welding remove the pin connections from the control unit. Any work on the electrical system that is not carried out in compliance with DEUTZ directives or by non-qualified personnel may damage the engine electronics in the long term, which is a condition not covered by the manufacturer’s warranty. DANGER The following is strictly prohibited: a) Making changes or connections to the electric control unit wiring or the data transmission line (CAN lines). b) Switching the control devices. Otherwise, the warranty rights shall be void! Diagnosis and maintenance may only be performed by authorised personnel using the tools and devices permitted by DEUTZ.

Assembly instructions The control devices are calibrated based on the respective engine and marked with a specific engine number. Each engine may only be operated with the respective control device. To operate the device, connect the nominal value transducers (pedal transducers) to the wiring of the device and calibrate them using the DEUTZ SERDIA (SERvice DIAgnose) diagnostics program. The connection and installation of the device wiring are shown in the connection diagram in the DEUTZ assembly instructions.

Supply voltage l l

12 Volts 24 Volts

A sufficient battery charge level must be guaranteed. Interrupting the supply voltage to the engine while it is operating may damage the electrical or electronic system. A drop in the supply voltage stops the engine. Voltages above 32 Volt destroy the control device.

Diagnostics The DEUTZ control devices are equipped with a self-diagnostics system. The active and passive error conditions are recorded in the error memory. Active errors are indicated by the fault indicator/diagnostic lamp. See para. 10.1.32 - Faults - Engine manage... - page 10-94 The diagnostics can be carried out using: l l l l

Error warning light (flashing code) CAN BUS DEUTZ electronic display diagnostics socket (SERDIA).

Device wiring Follow the DEUTZ AG assembly instructions. In particular, crimp the connector contacts correctly with commercially available tools. If necessary, the inserted contacts must be removed from their housings only using the specific tools.

10-28

Technical characteristics 10.1.9 - Use - Environmental conditions Low ambient temperatures

Fig. 30

Lubricant oil l l

Select the viscosity of the lubricant oil based on the ambient temperature. In the case of frequent cold starts, reduce the oil change times by half.

Fuel l

With a temperature below 0°C use winter fuel. See para. 10.1.18 - Operating materials - ... - page 10-53

Battery l

l

● A sufficient battery charge state is necessary to start the engine. See para. 10.1.30 - Care and maintenance w... - page 10-90 Heating the battery to approx. 20 °C improves the engine start behaviour. (Disassembly and storage of the battery in a warm room).

Accessories for cold starting l

Depending on engine configuration, a choice of different accessories are available for cold starting. These include pin-type glow plugs, a heater and a flame glow plug starting system See para. 10.1.11 - Usage - Starting proce... - page 10-35 10-29

Technical characteristics Coolant l

Observe the mixture ratio between antifreeze/cooling water. See para. 10.1.19 - Operating materials - ... - page 10-54

High ambient temperatures, high altitudes Note This engine is equipped with an electronic control device. For the operating conditions mentioned below, the fuel quantity is reduced automatically by the electronic control device. The quantity of fuel delivered to the engine must be reduced when operating in the following working and environmental conditions. l l

above 1000 m altitude Ambient temperatures above 30°C

Reason: as the altitude or ambient temperature increases, the air density decreases. As a result, the quantity of oxygen contained in the air aspirated by the engine also reduces, and the fuel/air mixture produced would be excessively rich unless the quantity of fuel injected is also reduced. The consequences would be: l l l l

black smoke in the exhaust gas high engine temperature reduction in engine power possible impairment of starting behaviour

If there are additional questions, contact your DEUTZ partner or equipment supplier.

10.1.10 - Use - First start-up

Preparations for the first start-up (Maintenance program E 10) l l l l

l l l

Eliminate the engine storage treatment. Remove any transport devices still present. Check the battery and cable connections and fit them if necessary. Check the belt tension. See para. 10.1.28 - Care and maintenance w... - page 10-84 Have authorised personnel check engine monitoring and the alarm system. Check the engine mount. Check that all flexible pipe connections and the clamps are correctly in their seat.

When performing a general overhaul on an engine, the following operations are also necessary: l l l l l

10-30

Check and if necessary replace the fuel prefilter and the main filter. Intake air filter (if installed, perform the maintenance based on the relative indicator). Drain the lubricant oil from the turbocharging air radiator and the condensate water. Add the engine lubricant oil. Fill the coolant system. See para. 10.1.35 - Technical data - Engin... - page 10-102

Technical characteristics Add the engine lubricant oil

Fig. 31

Note An too low or too high level of lubricant oil could damage the engine.

Note In general, engines are delivered with no lubricant oil. Before filling it, select the quality and viscosity of the lubricant oil. Order DEUTZ lubricant oils from your DEUTZ partner. l l

Pour the lubricant oil into the engine through the filler. Pay attention to the lubricant oil filler cap. See para. 10.1.35 - Technical data - Engin... - page 10-102

10-31

Technical characteristics Load the fuel Note Only refuel when the engine is stopped. Ensure maximum cleanliness. Do not scatter the fuel. It is necessary to bleed the fuel system again by carrying out a test cycle for 5 minutes at idle speed or at a reduced load l

The fuel low pressure system must be bled after filling with the manual delivery pump after the 1st start-up.

Use only commercially available, clean diesel fuel. Pay attention to fuel quality. Use summer or winter fuel depending on the external temperature.

Filling the AdBlue® system

AdBlue® Diesel Exhaust Fluid

Fig. 32

NOTE Only fill the system with the engine off. Only fill with AdBlue®! Even very small quantities of other fluids (such as diesel, for example) will damage the system. If any other fluid, such as diesel fuel, for example, is accidentally put into the tank and reaches the system, the entire AdBlue® injection system must be replaced! If another fluid (such as diesel) has been put into the tank but has not reached the delivery lines and delivery pump/metering module of the system, the AdBlue® tank may be simply drained and thoroughly cleaned. Ensure maximum cleanliness.

10-32

Technical characteristics Fill the coolant system

3

2 1

Fig. 33

NOTE The coolant must have the required concentration of the cooling system protective action! Never use the engine without the coolant, not even briefly! NOTE The cooling system protective agents must be ordered from your DEUTZ partner.

l

l l l l l l

Connect the coolant outlet (2) and the coolant inlet (1) to the cooling system. Connect the delivery line between the compensation container and the coolant pump or the coolant inlet line (3). Connect the engine’s breather lines and if necessary the radiator lines to the compensation container. Fill the cooling system through the compensation container. Close the compensation container with the valve. Start the engine and heat it until the thermostat opens (line 2 heats up). Engine cycle with the thermostat open 2 - 3 minutes. Check the coolant level, top up if necessary

10-33

Technical characteristics DANGER Risk of scalding caused by contact with very hot coolant. The cooling system is pressurised! Open the plug only after it has cooled down. When handling coolant observe the safety directives and specific local regulations. l l l l

Repeat the cycle with the engine started if necessary. Fill the coolant up to the MAX notch on the compensation container and close the cooling system cover. Turn on the heating if present and set it to the maximum level so the heating circuit fills up and bleeds. Pay attention to the filling quantity in the cooling system. See para. 10.1.35 - Technical data - Engin... - page 10-102

Operating test NOTE It is necessary to bleed the fuel system again by carrying out a test cycle for 5 minutes at idle speed or at a reduced load. After preparations, perform a brief test cycle up to the operating temperature (approx. 90 °C). If possible, do not load the engine during the test. Work with the engine stationary: l l l

check the engine tightness. Check the engine lubricant oil level and top up if necessary. Check the coolant level and top up if necessary.

Work during the test cycle: l

10-34

check the engine tightness.

Technical characteristics

Fig. 34

NOTE Do not place loads on the cover.

10.1.11 - Usage - Starting procedure DANGER Before starting the engine, make sure no one is located too near the engine or the machine. After the repair work: make sure all the protective devices have been refit and no tool has been forgotten on the engine. If starting is performed with flame glow plugs, pin-type glow plugs or a heater, do not use any other accessories for cold starting (e.g. Startpilot). Danger of accidents! If the engine fails to start correctly once the heater has activated automatically (because the starter motor receives no power due to an engine control system fault), stop the starting procedure completely by turning the ignition switch to OFF (which also cuts power to the heater).

10-35

Technical characteristics NOTE If the engine fails to start and the fault indicator lamp flashes, this indicates that the electronic control system has inhibited starting to protect the engine. The starter block is eliminated by deactivating the system with the ignition key for approx. 30 s. Run the starter motor for no longer than 20 seconds at a time. If the engine does not start, wait one minute before repeating the starting manoeuvre. If the engine does not start after two attempts, identify the cause of the problem by referring to the table. When the engine is still cold, avoid revving immediately to high engine speeds either under load or with no engine load. See para. 10.1.31 - Malfunctions - Malfunc... - page 10-92 NOTE If possible separate the engine by decoupling the device lines.

With the starter device cold

P 0

1 2 Fig. 35

l

10-36

Insert the key m Position 0 = no operating voltage.

Technical characteristics l

l

l

l

Turn the key to the right. m Position 1 = operating voltage. m The check lamps (A), (B) and (C) illuminate. Position 2 = pre-heat. m Continue pre-heating until the indicator lamp extinguishes. If the pre-hear lamp flashes, this indicates that a fault, such as a stuck pre-heat relay, has caused the battery to drain completely while the engine was off. m The engine is ready to operate. Press the key and turn it again to the right, pushing it against the spring. m Position 3 = start. As soon as the engine starts, release the key m The warning lights turn off.

If the starter motor is checked by an electronic regulator relay from the engine: l l

l

the maximum duration is limited. pause is made between two starting attempts m The starting procedure continues therefore automatically another start is prevented with the engine running.

If the pulse starting function is programmed, a single start signal is sufficient with the ignition key in position 2, or if present, with the starter button.

10.1.12 - Usage - Controlling engine operation Electronic engine governor system

The statuses are signalled by the error warning light: The system controls its own status and the engine status. l

l

l

Operation check m With the ignition active, the error warning light will flash for approx. 2 seconds. m If there is no reaction during ignition, check the error warning light. The warning light does not turn on m After the lamp test, a warning light that is off signals a possible condition that is correct and without errors during the checks that can be carried out. Permanent light m System error. m Operation continues with certain limitations. m Have a check performed by a DEUTZ service partner. m If the light is fixed, this means that a controlled unit of measure (e.g. the coolant temperature, the lubricant oil pressure) exceeded the permitted interval.

Depending on the type of problem, the electronic engine regulator can reduce the engine power to protect the engine. l

Flashing m Serious system error. m Deactivation request for the operator. Note: Failure to respect this causes the warranty to be voided! m The switching off condition for the engine was not reached. m To cool the engine, forced operation with power reduced, if necessary with automatic switching off. m Switching off process. m After the engine has stopped, there may be a starter block. m The starter block is eliminated by deactivating the system with the ignition key for approx. 30 s. m Other control warning lights may turn on, e.g. for oil pressure or temperature. m With the optional override key on the instrument panel for avoiding critical situations, power reduction can be excluded, automatic deactivation can be delayed or a starter block can be excluded. This brief deactivation of the engine protection functions is recorded in the control unit.

The overload cutout is established together with the manufacturer and DEUTZ consultants and can be fixed in a customised manner. Therefore it is absolutely necessary to follow what is indicated in the user manual provided by the system manufacturer.

10-37

Technical characteristics Signalling instrument

Fig. 36

Possible warning lights: l

Colour scale m Operating status warning light with coloured sectors: m Green = normal operating status. m Red = critical operating.

Adopt suitable measures. l

10-38

Measurement value scale m The effective value can be read directly. The nominal value can be obtained form the technical data. See para. 10.1.35 - Technical data - Engin... - page 10-102

Technical characteristics Instruments and symbols Table 27

Instruments/symbols

Designation

Possible warning lights

Measurement

Coolant temperature

Coolant temperature too high

stop the engine

Lubricant oil temperature

Lubricant oil temperature too stop the engine high

Lubricant oil pressure warning Lubricant oil pressure in the red stop the engine light zone

Lubricant oil pressure warning Lubricant oil pressure below stop the engine lamp minimum limit Lubricant oil change necessary Lubricant oil change: (flashing)

Lubricant oil level

Lubricant oil level too low

Add the lubricant oil

10-39

Technical characteristics Instruments/symbols

10-40

Designation

Possible warning lights

Measurement

Coolant level

Coolant level too low

Turn off the engine, let it cool and top up the coolant

Operating counter

Indicates current total of engine Comply with the maintenance operating hours intervals

Acoustic signal

In case of an acoustic signal

See fault table. 10-102

SCR operating warning light

Permanent light flashing (0.5 Hz) flashing (1 Hz) flashing (2 Hz)

Check the AdBlue® filling level Check SCR system 10-43

Engine warning light

Permanent light

If accompanied by rapidly flashing function check lamp, engine power is reduced by two steps 10-43

Technical characteristics Instruments/symbols

Designation

Ash warning light

Possible warning lights

Measurement

Permanent light

The soot indicator lamp indicates that diesel particulate filter is permanently clogged and cannot be regenerated within the system.

With active regeneration Table 28

Instruments/symbols

DPF operating warning light

Designation

Permanent light flashing (0.5 Hz) flashing (2 Hz)

Possible warning lights

Measurement

Engine warning light

Permanent light Flashing

See active regeneration 10-45

Possible warning lights

Measurement

See active regeneration 10-45

With active regeneration Table 29

Instruments/symbols

Designation

DPF operating warning light

Permanent light

flashing (0.5 Hz) flashing (2 Hz)

Engage regeneration when stationary 10-47

10-41

Technical characteristics Instruments/symbols

Designation

Engine warning light

Possible warning lights

Permanent light Flashing

Measurement

Engage regeneration when stationary 10-47

DEUTZ Electronic Display

Fig. 37

A CAN display may be integrated into the driver’s instrument cluster to view the parameters and error signals relative to the EMR control system. The following data can be displayed if they are transmitted by the control unit. l l l

10-42

Engine speed Engine torque (current) Coolant temperature

Technical characteristics l l l l l l l l l l l l l l

Intake air temperature Exhaust gas temperature Lubricant oil pressure Coolant pressure Supply air pressure Fuel pressure Status of the diesel particulate filter regeneration Particulate filter function check Errors in the exhaust gas after-treatment system AdBlue® tank level Battery voltage Accelerator pedal position Fuel consumption Operating hours

The error messages are signalled by a text and acoustically, the control device error memory can be read. A detailed description is provided in the instruction manual provided with the DEUTZ Electronic Display.

10.1.13 - Use - exhaust gas after-treatment systems Selective catalytic reduction (SCR) NOTE The basic urea solution AUS 32 is known in North America as Diesel Exhaust Fluid (DEF). The DEUTZ SCR system continuously reduces the nitrogen oxide (NOx) emissions produced by the engine. The reduction agent AdBlue® is injected into the exhaust system and reacts with the nitrogen oxide compounds (NOx) in the exhaust gases within the SCR catalytic converter, breaking them down into nitrogen (N2) and water (H2O). The quantity of AdBlue® injected is controlled by the electronic control system of the engine.

SCR system fault warning strategy NOTE The warning light and monitoring of the exhaust gas after-treatment system can consist, depending on the engine version, or a control warning light or a CAN interface with a corresponding display. Follow the user manual provided by the device manufacturer. In compliance with the directives of the European Union (EU) and the Environmental Protection Agency (EPA), the DEUTZ SCR system responds to malfunctions of the exhaust gas after-treatment with a fault warning strategy. The following emissions-related faults may be indicated by the system: l l l l

AdBlue® filling level Efficiency of the catalytic converter/Adblue® quality Handling System errors NOTE An audible warning sound must be produced to warn of a malfunction. When a DEUTZ display is used, the display unit must emit a specific warning signal. Where an SCR function indicator lamp or a display installed by the client is used, a warning buzzer must also be included in the installation.

Power reduction In the event of a severe fault or should it not be possible to rectify the fault, the system responds by reducing engine power. Depending on the type of fault, engine power may be reduced by one or two steps.

Table 30 Power reduction

Level 1 Level 2

Torque reduced by 20% Torque reduced by 20% + engine speed limited to 1200 rpm 10-43

Technical characteristics AdBlue® filling level Warning signal activation when level in AdBlue® tank drops below 15%.

Table 31 AdBlue® filling level

SCR operating warn- Engine warning light DEUTZ CAN display ing light

<15%

Permanent light

off

<10%

flashing (0.5 Hz)

off

<5%

flashing (0.5 Hz)

Permanent light Acoustic signal

<5%

flashing (1 Hz)

Permanent light Acoustic signal

0%

flashing (2 Hz)

Permanent light Acoustic signal

SCR symbol Text message SCR symbol Text message SCR symbol Text message Acoustic signal SCR symbol Text message Acoustic signal SCR symbol Text message Acoustic signal

Power reduction

None None Level 1 after the prealarm period Level 2 after the prealarm period Level 2 after the prealarm period

Efficiency of the catalytic converter/Adblue® quality In the event of poor catalytic converter function (conversion percentage) even though the tank has been filled recently, warning signals are sent to the SCR function warning lamp or optional CAN display. Warning signals are also generated if an incorrect reduction agent is used.

Table 32 Efficiency of the SCR operating warn- Engine warning light DEUTZ CAN display catalytic converter/ ing light Adblue® quality

Too low

Permanent light Acoustic signal

Permanent light

SCR symbol Text message Acoustic signal

Power reduction

Level 2 after the prealarm period

Handling If the system detects that a component in the system itself has been tampered with or filled with an incorrect reducing agent, engine power is reduced. Power reduction is implemented progressively and in relation to engine power demand.

Table 33 Handling

SCR operating warn- Engine warning light DEUTZ CAN display ing light

recognised

Permanent light Acoustic signal

Permanent light

not solved

Permanent light Acoustic signal

Permanent light

not solved

Permanent light Acoustic signal

Permanent light

SCR symbol Text message Acoustic signal SCR symbol Text message Acoustic signal SCR symbol Text message Acoustic signal

Power reduction

Level 1 after the prealarm period Level 2 after the prealarm period Level 2

System errors A system error may consist of an error concerning an individual component of the SCR, such as an implausible value received from one of the NOx or temperature sensors. In the event of a system error which may compromise the AdBlue® injection cycle, engine power is reduced.

Table 34 System errors

recognised

10-44

SCR operating warn- Engine warning light DEUTZ CAN display ing light

Permanent light Acoustic signal

Permanent light

SCR symbol Text message Acoustic signal

Power reduction

Level 2 after the prealarm period

Technical characteristics Diesel oxidation catalytic converter The diesel oxidation catalytic converter has a catalytic surface, through which the harmful substances that are contained in the exhaust gas are transformed into a harmless substance. This causes the carbon monoxide and unburned hydrocarbons to react with oxygen and are transformed into carbon dioxide and water. Furthermore, nitric oxide is transformed into nitrogen dioxide. For better performance, temperatures of > 250 °C are required.

Diesel particulate filter When diesel fuel is burnt, soot is produced, which is separated in the diesel particulate filter. When the load of soot increases, it must be regenerated. This means that the soot is burnt in the diesel particulate filter. Regeneration is a continuous process, which is activated as soon as the exhaust gas temperature at the inlet side of the exhaust gas after-treatment system exceeds 250 °C. The load of the soot filter is monitored permanently by the engine control unit.

Regeneration When necessary, the active particulate filter system burns off the soot accumulated in the filter using residual oxygen contained in the exhaust gases. This process requires temperatures exceeding 600°C, which are achieved during active regeneration by catalytic combustion. The active particulate filter includes a burner. The passive particulate filter system burns off soot in the filter using nitrogen oxides contained in the exhaust system (oxidised previously in the DOC). This process occurs continuously as soon as the exhaust gas temperature exceeds 250°C. The passive particulate filter system does not include a burner. An adequate ratio between nitrogen oxides and soot must exist in the untreated exhaust gases in order for continuous passive regeneration to take place.

10.1.14 - Usage - Active regeneration Diesel particulate filter regeneration DANGER During regeneration, temperatures close to 600°C are created at the end of the exhaust pipe. These temperatures are not related to engine output, and may also be generated with the engine running at idle speed. Burn hazard!

Automatic mode In automatic mode, the DPF system is activated with no input from the operator. When the filter load has reached 100% of the normal load, regeneration must be carried out. The filter regeneration indicator lamps starts to flash The regeneration cycle starts after a delayed engine start. During the regeneration phase, the regeneration warning light remains on constantly. On average, regeneration lasts 30 minutes. Once regeneration has been completed correctly, the regeneration warning light turns off. Should it be necessary to disable regeneration or interrupt a regeneration cycle that is already in progress (e.g. when vehicle is operating in an indoor environment), the operator must use the regeneration disable switch. If the regeneration cycle is not performed, the request for regeneration remains active. The regeneration warning light starts to flash. The regeneration cycle cannot be performed as long as the regeneration disable switch is active. Soot will continue to accumulate in the filter if the regeneration disable switch is left permanently on. The engine warning lamp lights continuously and engine power is reduced. The engine alarm warning light flashes, then there is a reduction in power and finally a reduction in the maximum engine speed. This action is recorded as an error in the control unit. If the request for generation is not taken into consideration and the DPF is overloaded to an extend that is not permitted, the filter may only be generated by DEUTZ customer service.

10-45

Technical characteristics Manual mode When the filter load has reached 100% of the normal load, regeneration must be carried out. The regeneration warning light starts to flash. Regeneration must be enabled by the operator using the enable button. Regeneration starts immediately after enabling. During the regeneration phase, the regeneration warning light remains on constantly. On average, regeneration lasts 30 minutes. Once regeneration has been completed correctly, the regeneration warning light turns off. The operator may press the enable button again to stop the regeneration cycle if necessary. If the regeneration cycle is not performed, the request for regeneration remains active. The regeneration warning light starts to flash. The regeneration cycle must be started again by the operator. Regeneration starts immediately after enabling. During the regeneration phase, the regeneration warning light remains on constantly. If the operator fails to press the regeneration cycle enable button for a prolonged period when there is an active regeneration request, soot will continue to accumulate in the filter. The engine warning lamp lights continuously and engine power is reduced. The engine alarm warning light flashes, then there is a reduction in power and finally a reduction in the maximum engine speed. This action is recorded as an error in the control unit. If the request for generation is not taken into consideration and the DPF is overloaded to an extend that is not permitted, the filter may only be generated by DEUTZ customer service.

Replacing the diesel particulate filter It will probably be necessary to change the diesel particulate filter after a prolonged period of filter use, because non-combustible residuals collect in the filter (the so-called ash). If the ash load exceeds a certain value, this is indicated by the ash warning light. The diesel particulate filter must be replaced. The machine can be operated normally until it is replaced by customer service. Eventually the interval between two generation requests when stationary will be reduced. Contact your DEUTZ partner. In the DEUTZ replacement program, the diesel particulate filter is removed and replaced with a clean one.

Regeneration control warning light The warning light and monitoring of the exhaust gas after-treatment system can consist, depending on the engine version, or a control warning light or a CAN interface with a corresponding display.

Table 35 Instruments/symbols Regeneration warn- Engine warning light Ash warning light ing light

off flashing (0.5 Hz)

off off

off off

flashing (2 Hz) flashing (2 Hz)

off Permanent light

off off

10-46

Power reduction

Regeneration

-30 %

Normal operation Automatically enabled Operator authorisation Operator authorisation Operator authorisation

Technical characteristics Instruments/symbols Regeneration warn- Engine warning light Ash warning light ing light

Power reduction

Regeneration

flashing (2 Hz)

Flashing

off

flashing (2 Hz)

Flashing

Permanent light Ash load 100 %

-30 % Authorisation only by the + limitation of engine DEUTZ partner speed 1200 rpm -30 % No regeneration possible + limitation of engine speed 1200 rpm

10.1.15 - Usage - Passive regeneration Normal operation

Under normal operating conditions (exhaust gas temperature > 250 °C) the load of the filter with soot remains within a permitted interval and no further actions are required. The regeneration warning light turns off.

Support mode If engine operating conditions do not permit passive regeneration, soot will continue to build up in the particulate diesel filter. If the necessary conditions for passive regeneration are not met during normal operation, a butterfly valve in the combustion air inlet and controlled by the engine control unit is used to increase the exhaust gas temperature and permit regeneration of the diesel particulate filter. This may be the case when: l

The engine has only operates for brief periods. Low engine demand.

This process is activated automatically by the engine control unit, no interventions are required by the user. The regeneration warning light turns off. NOTES During this process, the engine sound changes perceptibly

Regeneration when stationary DANGER During regeneration, temperatures close to 600°C are created at the end of the exhaust pipe. During regeneration when stationary, a special engine operation status is activated and it is not possible to use the machine during active regeneration when stationary. Burn hazard! When the support mode does not reach a sufficient reduction in the soot load, the filter will be loaded again with soot and a new regeneration when stationary will be necessary. This is signalled by a flashing regeneration warning light. Regeneration when stationary must be started manually by the operator. It is advisable to perform the necessary idle regeneration cycle as soon as possible, as soot will otherwise continue to accumulate in the diesel particulate filter. If the idle regeneration cycle is not performed, the engine control unit will implement engine protection strategies in relation to the degree of clogging of the diesel particulate filter. Each idle regeneration cycle causes the engine oil to be diluted slightly with fuel. The oil quality must therefore be checked regularly. Do not ignore oil change requests from the system. 10-47

Technical characteristics Carrying out regeneration when stationary The engine must be brought to a “safe state” for regeneration: l l l l

l

Stop the engine on an empty terrain at a safe distance from inflammable objects. Warm the engine to a coolant temperature of at least 75°C. Idle the engine. The engine control unit now requires a signal indicating that the machine is parked safely (stationary signal). This takes place based on the application, for example by: m Activating the parking brake. m Engaging a defined ratio in the gearbox. Confirming with the authorisation key. Position based on the application, see the device manual.

The regeneration indicator lamp lights continuously. Once idle regeneration is enabled, the engine speed is increased automatically. Do not use the machine when the idle regeneration cycle is in progress. On average, regeneration lasts 30 minutes. The idle regeneration cycle may be stopped at any time by pressing the regeneration button again or by disabling regeneration. The idle regeneration cycle is stopped if the machine is used while the cycle is in progress. The idle regeneration request remains active until the cycle has been completed successfully. Certain engine faults cause the engine to produce excessive quantities of soot, which is not visible however as it is captured by the diesel particulate filter. In these cases, the diesel particulate filter will become clogged very rapidly, even to the extent at which it can no longer be regenerated by the operator using the idle regeneration cycle. Very short intervals between idle regeneration requests (<10 h) may be indicative of such faults. Contact the DEUTZ technical support service. Once regeneration has been completed correctly, the regeneration warning light turns off. If the idle regeneration request is ignored and the DPF is clogged beyond maximum permissible limits, the filter may only be regenerated by the DEUTZ technical support service.

Replacing the diesel particulate filter It will probably be necessary to change the diesel particulate filter after a prolonged period of filter use, because non-combustible residuals collect in the filter (the so-called ash). If the ash load exceeds a certain value, this is indicated by the ash warning light. The diesel particulate filter must be replaced. The machine can be operated normally until it is replaced by customer service. Eventually the interval between two generation requests when stationary will be reduced. Contact your DEUTZ partner. In the DEUTZ replacement program, the diesel particulate filter is removed and replaced with a clean one.

Regeneration control warning light The warning light and monitoring of the exhaust gas after-treatment system can consist, depending on the engine version, or a control warning light or a CAN interface with a corresponding display.

Table 36 Instruments/symbols Regeneration warn- Engine warning light Ash warning light ing light

off off 10-48

off off

off off

Power reduction

Regeneration

Normal operation Support mode

Technical characteristics Instruments/symbols Regeneration warn- Engine warning light Ash warning light ing light

Power reduction

Regeneration

flashing (0.5 Hz)

off

off

flashing (2 Hz)

Permanent light

off

flashing (2 Hz)

Flashing

off

flashing (2 Hz)

Flashing

Permanent light Ash load 100 %

Regeneration when stationary Operator authorisation -30 % Regeneration when stationary Operator authorisation -30 % Regeneration when stationary + limitation of engine Authorisation only by the speed 1200 rpm DEUTZ partner -30 % No regeneration possible + limitation of engine speed 1200 rpm

10-49

Technical characteristics 10.1.16 - Use - Stop procedure Stop

P 0

1 2 Fig. 38

NOTE It should be avoided to stop from operating at full speed (coking/clogging with residuals of lubricant oil in the turbocharger bearing body). This inhibits the supply of turbocharger lubricant oil! This compromises the useful duration of the turbocharger. After the discharge, let the engine run at a low speed for approx. one minute. Turn the key to position 0. l l l l

10-50

P = switching level: park 0 = switching level: stop the engine 1 = switching level: Ignition activated 2 = switching level: start the engine

Technical characteristics Inertia time NOTE The control device remains active for another 40 seconds to store the system data (inertia) and then is deactivated automatically. On engines with the SCR system, this process may take up to 2 minutes, as the SCR lines must first be completely emptied by the pumps. Do not cut power to the engine with the ignition switch during this process.

10.1.17 - Operating materials - lubricant oil In general

Modern diesel engines require lubricant oils with very high performance requisites. The continuous increase in the specific performance of diesel engines in recent years has led to an increase in the thermal stress oil sustained by the oil. Furthermore, reduced oil consumption and longer oil change intervals have meant that the lubricant oil itself is subject to greater contamination. For this reason it is necessary to comply with what is described in this user manual and observe the recommendations in order not to compromise engine duration. Lubricant oils always consists of a base oil and a mixture of additives. The primary functions of a lubricant oil (e.g. protection against wear and corrosion, neutralising acids produced during combustion, preventing carbon coke and soot encrustation on engine components) are performed by these additives. The characteristics of the lubricant oil are equally a decisive index of product quality, with regard to thermal load, for example. Substantially, all engine oils with the same specifications can be mixed together. However, it is advisable not to mix engine oils considering that the worst characteristics in the mix will always predominate. The lubricant oils authorised by DEUTZ have been thoroughly tested with every engine type. The additives they contain have been combined together with great care. Therefore, it is not permitted to use other additives for lubricant oils in DEUTZ engines. The quality of the lubricant oil has great influence on the duration, performance and therefore also the economic aspect of the engine. Substantially, the following applies: a better lubricant oil quality means that these characteristics are better. The viscosity of the lubricant oil describes the sliding behaviour of the lubricant oil based on temperature. The viscosity of the lubricant oil has a limited influence and repercussions on the quality of the lubricant oil. Synthetic lubricant oils are used more and offer specific advantages. These oils are more temperature and oxidant resistant, and have a relatively low viscosity at low temperatures. As some procedures are important for determining the lubricant oil change intervals and depend substantially on the quality of the lubricant oil (for example, outflow of soot and other impurities), the lubricant oil change interval must not be increased beyond what is indicated in the lubricant oil change intervals even if you are using synthetic lubricant oils. Biodegradable lubricant oils can be used with DEUTZ engines if they satisfy the requirements of this manual.

Quality The lubricant oils are divided by DEUTZ based on their performance and their quality class (DQC: DEUTZ Quality Class). Substantially, the following applies: in higher quality classes (DQC I, II, III, IV) the lubricant oils have higher performance and characteristics. The DQC quality classes are integrated with the DQC-LA categories, which include the modern low ash content lubricant oils (LA = Low Ash). Or see the website www.deutz.com

Table 37 http://www.deutz.com

de en

\SERVICE \Betriebsstoffe und Additive\Deutz Quality Class\ DQC-Freigabeliste \SERVICE \Operating Liquids and Additives\Deutz Quality Class\ DQC Release List

The selection of the lubricant oil depends basically on the exhaust gas after-treatment system. For the engines in this user manual, the following lubricant oils may be used: Reliable quality classes l

SCR Selective Catalytic Reduction m DQC III m DQC III LA m DQC IV m DQC IV LA

10-51

Technical characteristics l

DPF Diesel particulate filter m DQC III LA m DQC IV LA

For low ash content engine oils, authorised according to the DQC system, a list of authorised oils is provided.

Table 38 Lubricant oils DEUTZ DQC III TLX - 10W40 FE Not with DPF Drums

5 litre container 20 litre container 209 litre drum

Order code:

0101 6335 0101 6336 0101 6337

Table 39 DEUTZ DQC III LA low ash content lubricant oils DEUTZ Oil Rodon 10W40 Low SAPS Drums

20 litre container 209 litre drum

Order code:

0101 7976 0101 7977

Table 40 DEUTZ DQC IV synthetic lubricant oils DQC IV - 5W30-UHP Not with DPF Drums

20 litre container 209 litre drum

Order code:

0101 7849 0101 7850

Lubricant oil change intervals l

The intervals depend on: m Lubricant oil quality m Sulphur content in the fuel m Type of engine use m Number of idle regeneration cycles

l

The lubricant oil change interval must be reduced by half if at least one of the following conditions occurs: m Permanent ambient temperatures below -10 °C (14 °F) or lubricant oil temperature below 60 °C (84 °F). m Sulphur content in the Diesel fuel >0.5 of the % in weight. If the oil change intervals are not reached within one year, the oil change must be carried out at least 1 time a year.

l

Viscosity The ambient temperature in the installation site (where the engine is used) plays a crucial role in determining the correct viscosity grade. Too high viscosity can lead to ignition difficulties, too low viscosity can place the lubricating effect at risk and cause elevated consumption of the lubricant oil. In the case of ambient temperatures of below -40 °C the lubricant oil must be preheated (e.g. if the vehicle or work machine is parked in a shed). Viscosity is classified according to SAE. Substantially, polyvalent lubricant oils must be used. In closed and heated environments where the temperature is above >5 °C monovalent lubricants can also be used. NOTE When selecting the viscosity class, it is essential to comply with the prescribed lubricant oil quality.

Based on the ambient temperature, we recommend the following customary viscosity classes:

10-52

Technical characteristics

Fig. 39

10.1.18 - Operating materials - Fuel Homologated fuels

In order to comply with standards regarding emissions, diesel engines equipped with an exhaust gas after-treatment system can only run on sulphur-free fuels. The operating safety as well as the durability of individual exhaust gas after-treatment systems cannot be guaranteed if this instruction is ignored.

10-53

Technical characteristics Table 41 Exhaust gas after-treatment systems:

SCR DPF DOC

Selective Catalytic Reduction Diesel particulate filter Diesel oxidation catalyst

Fuels that meet the following specifications are permitted: Diesel fuels l l

DIN 51628 EN 590

Sulphur <10 mg/kg l l

ASTM D 975 Grade 1-D S15 ASTM D 975 Grade 2-D S15

Sulphur <15 mg/kg Light fuel oils l

EN 590 quality

Sulphur <10 mg/kg The use of other fuels that do not meet the requirements stipulated in this manual will void the warranty. Measurements for the purposes of certification of compliance with the legal emission limits are made using legally-defined test fuels. These fuels correspond to those described in this manual and refer to the standards EN 590 and ASTM D 975. For other fuels mentioned in this manual, the emission values cannot be guaranteed. To ensure compliance with national emissions requirements, use the fuels prescribed by law (e.g. sulphur free fuels). Contact your DEUTZ partner.

Table 42 http://www.deutz.com

de en

\SERVICE\Betriebsstoffe und Additive\ Kraftstoffe \SERVICE\Operating Liquids and Additives\ Fuels

Winter operation with diesel fuel Special demands are made on the cold behavior of fuel (temperature limit value of filterability) for winter operation. During winter, suitable fuels are made available at service stations. NOTE For engines with DEUTZ Common-Rail DCR® injection the addition of petrol or other additives to ensure the fluidity of the fuel is not permitted. At low ambient temperatures, the precipitation of paraffin solids in diesel fuel can cause clogging of the fuel system and consequent operating anomalies. When the external temperature falls below 0 °C (down to -20 °C) winter fuel should be used (which can be purchased at filling stations from the beginning of the cold season). l

Special diesel fuels are available for arctic climate zones for use in temperatures down to -44 °C.

10.1.19 - Operating materials - Coolant In general

DANGER Never use the engine without the coolant, not even briefly! In the case of water cooled engines, coolant must be prepared and controlled, otherwise damage may be caused to the engine due to: l l

10-54

corrosion cavitation

Technical characteristics l l

freezing overheating

Water quality The correct water quality is fundamental when treating the coolant. Basically, clean water that does not lie outside the following analysis values must be used:

Table 43 Analysis values

pH value Chlorine (Cl)

min

[mg/l]

Sulphate (SO4) [mg/l] Total hardness (CaCO3) [mmol/l] [mg/l] [°dGH] [°e] [°fH]

max

6.5 -

8.5 100

-

100 3.56 356 20.0 25.0 35.6

ASTM

D 1293 D 512 D 4327 D 516 D 1126 -

The water quality data is provided by local supply companies. In the case of differences from the analysis values, the water must be treated. l

l

l

pH value too low Add caustic soda or diluted caustic potash. It is recommended to make small test mixtures. Overall hardness too high: mix with softened water (pH neutral condensate or water softened by means of ion exchangers). Chloride and/or sulphates too high: mix with softened water (pH neutral condensate or water softened by means of ion exchangers).

Cooling system protective agent DANGER If mixing nitrite based agents that protect the cooling system with amine based products, nitrosamines are formed that are harmful to health! NOTE The cooling system protective agents must be disposed of in an environmentally friendly manner. Follow the instructions on the safety data sheet. The coolant for compact liquid cooled DEUTZ engines is treated by mixing an antifreeze with ethylene glycol and water based corrosion inhibitors.

Table 44 DEUTZ cooling system protective product Drums

5 litre container 20 litre container 210 litre drum

Order code:

0101 1490 0101 4616 1221 1500

This cooling system protective agent does not contain nitrites, ammonia, phosphates and is suitable for the materials in our engines. It can be ordered from your DEUTZ partner. If you do not have a DEUTZ cooling system protective agent available, please contact your DEUTZ partner. Or see the website www.deutz.com

Table 45 http://www.deutz.com

de en

\SERVICE\Betriebsstoffe und Additive\ Kühlsystemschutz \SERVICE\Operating Liquids and Additives\ Cooling System Conditioner

The cooling system must be checked periodically. This includes, in addition to checking the coolant level, also checking the concentration of the cooling system protective agent. 10-55

Technical characteristics The check of the cooling system protective agent concentration can be done using a commercial test (for example refractometer).

Table 46 Percentage of the cooling system protective agent

min. 35 % 40 % 45 % max. 50 %

Water percentage

Protection from cold up to

65 % 60 % 55 % 50 %

-22 °C -28 °C -35 °C -41°C

In the case of temperatures below -41 °C contact your DEUTZ support service. The use of other cooling system protective agents (e.g. chemical anti-corrosive agents) is permitted in exceptional cases. Contact your DEUTZ partner.

10.1.20 - Fluids - SCR reduction agent AdBlue® (AUS 32 urea solution) NOTES The basic urea solution AUS 32 is known in North America as Diesel Exhaust Fluid (DEF). DANGER Before using AdBlue®, wear protective gloves and safety goggles. Do not swallow. Ensure that the area is well ventilated. Ensure maximum cleanliness. AdBlue® residues must be disposed of responsibly. Observe the indications of the safety data sheet.

Table 47 Exhaust gas after-treatment systems:

SCR

Selective Catalytic Reduction

AdBlue® is a 32.5% solution of extremely pure urea in water, which is used as an NOx reduction agent in SCR exhaust after-treatment systems to reduce the nitrogen oxide emissions produced by diesel engined vehicles. This product is denominated AdBlue® or AUS32 (AUS: Aqueous Urea Solution) and is compliant with the standard ISO 22241-1 NOx reduction agent AUS 32. The shelf life of AdBlue® without quality impairment depends on storage conditions. The product crystallizes at -11°C, and triggers a hydrolysis reaction above +35°C, causing its gradual decomposition into ammonia and carbon dioxide. Unprotected storage containers must be kept away from direct sunlight. Do not keep containers in storage for more than one year! Ensure that all the materials and containers used to store AdBlue® are resistant to urea. AdBlue® freezes at -11 °C. The selective catalytic system must be preheated in ambient temperatures below 11 °C.

Table 48 AdBlue® Drums

10 litre container 210 litre barrels

10-56

Order code:

0101 7982 0101 7983

Technical characteristics AdBlue® tank

Fig. 40

The AdBlue® tank must only be filled with AdBlue®. Filling with any other fluids will damage the system. In case of accidental filling with incorrect fluid, replace the metering pump. AdBlue® may be left in the tank for up to 4 months. Keep proof of the last filling date. If the machine is not used, drain and clean the AdBlue® tank. Contact your DEUTZ partner.

Table 49 http://www.deutz.com

email:

[email protected]

10-57

Technical characteristics 10.1.21 - Maintenance - Maintenance schedule Associating service levels with service intervals Table 50

Regular maintenance schedule TCD 4.1 L4/TCD 6.1 L6 Stage Activity

E10

First start-up

E20

Daily check

E30 E40 E50 E55 E60 E70

Maintenance Extended maintenance I Extended maintenance II Extended service III Intermediate overhaul General overhaul

To be performed by

Maintenance interval every ..... Operating hours (o.d.e)

Authorised technical personnel When commissioning new or overhauled engines Operator Once per day, or every 10 operating hours in case of continuous operation Specialised personnel 1) 2) 500 1,000 Authorised technical personnel 2,000 4,500 6.000 3) 8.000

Table 51 Comments

1)

Based on use case, the stress on the lubricant oil may be high. In this case, halve the oil change interval See para. 10.1.17 - Operating materials - ... - page 10-51 Lubricant oil change intervals in reference to DQC III quality.

2)

Table 52 General overhaul

3)

The optimum time for performing a general overhaul depends substantially on load, operating conditions, environmental conditions and on engine care and maintenance during operation Your DEUTZ partner will be happy to advise you on defining the optimum time for performing a general overhaul.

Maintenance operations Table 53 Stage

Activity

E20

Check

E10

10-58

Measurement

The operations are described in chapter 3. Lubricant oil level (top up if necessary) Coolant level (top up if necessary) Engine, to check for leaks and damage (visual inspection) Intake air filter/dry air filter (if installed, perform the maintenance based on the relative indicator)

Document

10-30

10-60 10-30

10-80

Technical characteristics Stage

E30

Activity

Renewal

Check E40

Check

Renewal

E50

Adjustment Renewal Check

E55

Renewal

E60 Annual

Renewal Check

Renewal

Every 2 years

Renewal

Measurement

Lubricant oil. The DEUTZ oil diagnosis system may be used to determine the ideal oil usage and change interval strategy for the specific engine application. For this purpose, contact your DEUTZ partner. Lubricant oil filter cartridge (at each lubricant oil change) AdBlue® feed pump filter cartridge Coolant (concentration of additive) Charge air cooler intake surface (drain lubricant oil/condensation) Battery and cable connections V-belt, ribbed V-belt and belt tensioner Engine mount (tighten it if necessary, replace if damaged) Fasteners, hose connections / clamps (replace if damaged) Fuel filter cartridge Fuel pre-filter Intake air filter/dry air filter (if installed, perform the maintenance based on the relative indicator) Valve clearance Toothed belt Exhaust gas recovery, adjuster rod play Butterfly valve Ribbed V-belt and belt tensioner roller DPF burner ignitor Crankcase breather valve Engine monitoring, horn. Maintenance must only be carried out by authorised service personnel! Fuel filter cartridge Fuel pre-filter Lubricant oil Lubricant oil filter cartridge (at each lubricant oil change) Dry air filter Toothed belt Coolant

Document

10-51 10-60

10-60 10-76 10-77

10-90 10-84

10-68 10-68 10-80

10-88 10-84 [LNK] 10-84 [LNK]

T.$84.21.B0.00.04.00.21 10-68 10-51 10-60

10-80 10-84 10-54 10-77 AdBlue® feed pump filter car- 10-76 tridge

10-59

Technical characteristics Stage

Based on the status

Activity

Renewal

Draining

Measurement

Intake air filter/dry air filter (if installed, perform the maintenance based on the relative indicator) Diesel particulate filter - depending on engine version, the soot indicator lamp or electronic display indicates when replacement is necessary. Lubricant oil and filter - depending on engine version, the flashing oil pressure warning lamp or electronic display indicates when replacement is necessary. Fuel pre-filter with water separator Drain the water separator bowl immediately if the relative alarm is activated (warning lamp/buzzer).

Document

10-80

10-45 10-47

10-51 10-60

10-68

Maintenance diagram A self-adhesive maintenance diagram is provided with each engine. It must be stuck in a visible position on the engine or on the machine. Order code: 0312 3775 (TCD 4.1 L4/TCD 6.1 L6)

10.1.22 - Care and maintenance work - Lubricant oil system Directives for work on lubricant oil systems DANGER Never perform the work while the engine is running! Smoking and open flames prohibited! Pay attention in the case of hot lubricant oil. Burn hazard! NOTE Maximum cleanliness is essential when working on the lubricating oil system. Thoroughly clean the area around the components to be worked on. Dry any wet areas with a compressed air jet. When handling lubricating oils, observe safety standards and all applicable local regulations. Dispose of the exiting lubricant oil and the filter elements in compliance with law. Do not let the exhausted lubricant oil permeate the ground. Perform a test cycle after each intervention. At the same time, guarantee the seal and pressure of the lubricant oil and then check the lubricant oil level.

10-60

Technical characteristics Check the lubricant oil level

Fig. 41

NOTE An too low or too high level of lubricant oil could damage the engine. The oil level can only be checked with the engine horizontal and stationary. Once it is hot, stop the engine and check the oil level after 5 minutes. If the engine is cold, the check can be made immediately. DANGER Pay attention in the case of hot lubricant oil. Burn hazard! Do not remove the dipstick while the engine is running. Risk of injury! l l l l

Remove the dipstick and clean it with a clean cloth that does not leave fibres. Insert the lubricant oil dipstick to the stop. Remove the dipstick and read the level of the lubricant oil. The lubricant oil level must always be between the MIN and MAX notches! Top up to the MAX notch if necessary.

10-61

Technical characteristics Lubricant oil change: NOTE On engines with passive regeneration, all active oil change requests must be cancelled in order to reset the idle regeneration cycle counter. l l l l l l l

l l l

Heat the engine (lubricant oil temperature > 80 °C). Position the engine or vehicle on a horizontal surface. Stop the engine. Position the collector bowl under the lubricant oil drain screw. Unscrew the lubricant oil discharge auger, drain the lubricant oil. Fit and tighten the drain hole screw, fitted with a new seal (tightening torque 55 Nm). Add the lubricant oil. m Quality/viscosity data See para. 10.1.17 - Operating materials - ... - page 10-51 m Fill capacity See para. 10.1.35 - Technical data - Engin... - page 10-102 Heat the engine (lubricant oil temperature > 80 °C). Position the engine or vehicle on a horizontal surface. Check the engine lubricant oil level and top up if necessary.

Cancelling oil change request Misuse of this function may cause engine damage. Only cancel an oil change request after effectively changing the lubricant oil. Using the button l l l l l

Press and hold the enable button for 10 seconds with the engine off and the ignition on. At the end of this period, the regeneration indicator lamp lights briefly. Release the button. The oil change request is now cancelled. If the button is not released within the following two seconds, the cancel request is ignored.

Via CAN device l

The procedure or cancelling requests from a CAN device is defined by the manufacturer of the device.

Follow the user manual provided by the device manufacturer.

10-62

Technical characteristics Replace the lubricant oil cartridge filter

Fig. 42

NOTE The filter cartridge must never be pre-loaded. Risk of fouling!

l l l l

If the anti-twist safety is installed, remove the tightening clamps (optional). Loosen the filter using the tool (order no.: 0189 9142) and remove Collect any exiting lubricant oil. Clean the filter holder sealing surface with a clean cloth that does not leave fibres.

10-63

Technical characteristics

Fig. 43 l l l

10-64

Lightly oil the seal on the new cartridge for the original DEUTZ filter. Manually screw in the new filter until it is sealed and tighten to a torque of: 15-17 Nm Tighten the tightening clamps of the anti-twist safety (optional).

Technical characteristics

Fig. 44

10-65

Technical characteristics Replace the lubricant oil filter cartridge

1

5 3

4 Fig. 45

l l l l l l

1 - Cover 2 – O-ring 3 – Body 4 - Drive 5 - Filter cartridge 6 - Bracket NOTE The filter cartridge must never be pre-loaded. Risk of fouling!

l l l l

10-66

Stop the engine. Loosen the cover by 2 -3 turns and wait 30 seconds. Unscrew the cover with the filter cartridge in an anticlockwise direction. Disengage the filter cartridge upwards from the guide in the body.

Technical characteristics

1 6 5

Fig. 46 l l l

Collect any exiting lubricant oil. Bend the sides of the filter cartridge gently into the collector bowl until the tab is released from the bracket. Clean the components.

10-67

Technical characteristics

1 2

5 4

3 Fig. 47 l l l l

Replace the O-ring, oiling lightly. Press the new filter cartridge in the bracket and delicately insert everything into the guide. Tighten the cover in a clockwise direction (25 Nm). Start the engine.

10.1.23 - Care and maintenance work - Fuel distribution system Directives for work on the fuel system DANGER The engine must be stationary! Smoking and open flames prohibited! In general, the injection lines/high pressure lines must not be disconnected while the engine is running. Pay attention to hot fuel! During refuelling and while working on the fuel distribution system always maintain conditions of the maximum cleanliness. Thoroughly clean the area around the components to be worked on. Dry any wet areas with a compressed air jet. When handling fuel observe the safety directives and specific local regulations. Dispose of the exiting fuel and the filter elements in accordance with law. Do not permit the fuel to permeate the ground. After performing all the work on the fuel distribution system, it must be bled, subjected to a test cycle and its tightness must be checked. In the case of a new start-up, after the maintenance work or after empting the fuel tank, the fuel system must be bleed.

10-68

Technical characteristics NOTE It is necessary to bleed the fuel system again by carrying out a test cycle for 5 minutes at idle speed or at a reduced load. In consideration of the high precision production of the system, ensure maximum cleanliness! The fuel system must be watertight and closed. Visually inspect for system leaks/damage. NOTE Before starting work, fully clean and dry the engine and the engine compartment. Cover areas of the engine compartment from which dirt may separate using a new clean film. Work on the fuel distribution system may only be carried out in a completely clean environment. Avoid impurities in the air, such as dirt, dust, humidity, etc.

Change fuel filter element

Fig. 48

NOTE The filter cartridge must never be pre-loaded. Risk of fouling!

l l l

If the anti-twist safety is installed, remove the tightening clamps (optional). Loosen the filter using the tool (order no.: 0189 9142) and remove Collect any fuel that escaped. 10-69

Technical characteristics l

Clean the filter holder sealing surface with a clean cloth that does not leave fibres.

Fig. 49 l l l l

10-70

Lightly oil the seal on the new cartridge for the original DEUTZ filter. Manually screw in the new filter until it is sealed and tighten to a torque of: 10-12 Nm Tighten the tightening clamps of the anti-twist safety (optional). Bleed the fuel distribution system.

Technical characteristics

Fig. 50

Replacing the fuel filter cartridge NOTE The filter cartridge must never be pre-loaded. Risk of fouling!

10-71

Technical characteristics

1

5 3

4 Fig. 51

l l l l l l l l l l

10-72

1 - Cover 2 – O-ring 3 – Body 4 - Drive 5 - Filter cartridge 6 - Bracket Stop the engine. Loosen the cover by 2 -3 turns and wait 30 seconds. Unscrew the cover with the filter cartridge in an anticlockwise direction. Disengage the filter cartridge upwards from the guide in the body.

Technical characteristics

1 6 5

Fig. 52 l l l

Collect any fuel that escaped. Bend the sides of the filter cartridge gently into the collector bowl until the tab is released from the bracket. Clean the components.

10-73

Technical characteristics

1 2

5 4

3 Fig. 53 l l l l

10-74

Replace the O-ring, oiling lightly. Press the new filter cartridge in the bracket and delicately insert everything into the guide. Tighten the cover in a clockwise direction (25 Nm). Start the engine.

Technical characteristics Cleaning/replacing/bleeding the filter cartridge

9 8 7 6

1 2 3 4 5 Fig. 54

Deutz Common Rail (DCR) l l l l l l l l l

1 - Bleed screw 2 - Pump fuel supply 3 - Fuel return from the fuel control unit (FCU) 4 - Fuel delivery pump 5 - Electric connection for the water level sensor 6 – Drain plug 7 - Filter cartridge 8 - Fuel tank inlet 9 - Fuel return to tank

Emptying the water collector bowl l l l

l l

Stop the engine. Position a suitable collector bowl. Electrical connection m Disconnect the cable connections. Loosen the discharge auger Drain the fluid until pure diesel fuel starts to exit 10-75

Technical characteristics l l

Fit the drain plug (tightening torque 1.6 ± 0.3 Nm). Electrical connection m Connect the cable connections.

Replacing the fuel filter cartridge l l l l

l l l l

l l

l

Stop the engine. Block the feed of fuel to the engine (if the tank is positioned at the top). Position a suitable collector bowl. Electrical connection m Disconnect the cable connections. Loosen the drain plug and release the fluid. Disassemble the filter element. Clean any dirt from the sealing surface of the new filter cartridge and the side opposite the filter head. Slightly moisten the sealing surface of the filter cartridge with fuel and screw the filter head back on in a clockwise direction (17-18 Nm). Fit the drain plug (torque 1.6 ± 0.3 Nm). Electrical connection m Connect the cable connections. Open the fuel shut-off valve and bleed the system (see “Bleeding the fuel system”).

Bleed the fuel distribution system l l

l l l l

Loosen the bleed screw. Release the bayonet closure on the fuel delivery pump by pressing and at the same time turning it anticlockwise. The pump piston is now pushed out by the spring. Pump until no more air comes out of the bleed screw. Fully tighten the bleed screw (torque 6.5 ± 1.3 Nm). Block the bayonet closure on the fuel delivery pump by pressing and at the same time turning it clockwise. Start the engine for approx. 5 minutes at idle speed or with a reduced load. Check the prefilter seal.

10.1.24 - Care and maintenance - SCR

Replace the AdBlue® delivery pump filter cartridge DANGER Wear protective gloves when working on components of the Selective Catalytic Reduction (SCR) system. Ensure maximum cleanliness.

1

2

3 Fig. 55

l l l

10-76

1 - Cover 2 - Compensator 3 - Filter cartridge

Technical characteristics l l

l l l l l l

l

Stop the engine. Electrical connection m Disconnect the cable connections. Position a suitable collector bowl. Remove the cover (27 mm socket wrench insert). Remove the filter element and the compensator. Fit the new filter element and the compensator. Fit the cover (tightening torque 22.5 ± 2.5 Nm). Electrical connection m Connect the cable connections. Start the engine

10.1.25 - Care and maintenance work - Cooling system Directives for work on the cooling system DANGER Danger of burns due to very hot coolant! The cooling system is pressurised! Open the plug only after it has cooled down. The coolant must have the required concentration of the cooling system protective action! When handling coolant observe the safety directives and specific local regulations. In the case of an external radiator, proceed following the manufacturer’s instructions. Dispose of the exiting coolant in compliance with the relative regulations and do not permit it to penetrate the ground. The cooling system protective agents must be ordered from your DEUTZ partner. Never use the engine without the coolant, not even briefly!

Check the coolant level, if engine is equipped with external radiator l l l

Add new coolant and bleed the system following the instructions of the cooling system manufacturer. Carefully open the cooling system plug. The lubricant oil level must always be between the MIN and MAX notches! Top up to the MAX notch if necessary.

10-77

Technical characteristics Check the coolant additive concentration

Fig. 56 l l

l

Carefully open the cooling system plug. Using a commercially available antifreeze tester (1) (e.g. hydrometer, refractometer) check the coolant additive - the concentration in the radiator/compensation container (2). Concentration of the coolant additive in proportion to the coolant mixture. See para. 10.1.19 - Operating materials - ... - page 10-54

The relative measurement device may be ordered from your DEUTZ partner with the part number: 0293 7499.

10-78

Technical characteristics Empty the cooling system

1 Fig. 57 l l l l l l l

Carefully open the radiator cap. Position a suitable collector bowl. Remove the crankcase hole blanking screw (1). Add the coolant. If the screw plug is not accessible, the coolant may be drained from the coolant line on the engine oil radiator. Refit the screw with sealant. Replace the radiator cap.

Filling and bleeding the cooling system DANGER Danger of burns due to very hot coolant! The system is pressurised! Only open the cap once the system has cooled.

l l l l l

Carefully open the cooling system plug (1). Loosen any coolant bleed screws. Top up the coolant up to the maximum notch or to the filling limit. Turn on the heating if present and set it to the maximum level so the heating circuit fills up and bleeds. Replace the radiator cap. 10-79

Technical characteristics l l l

Heat the engine up to the operating temperature (thermostat opening temperature). Stop the engine. Check the coolant level with a cold engine. If necessary, top up to the MAX marking or to the fill limit of the header tank.

10.1.26 - Care and maintenance work - Engine cleaning Cleaning operations NOTE For all cleaning work, pay attention to not damage the components (e.g. deformed radiator honeycomb, etc.). For engine cleaning, cover the electric/electronic components and connections (e.g. control devices, alternator, solenoid valves, etc.). Do not use a direct water/steam jet for cleaning. Then heat the engine. DANGER Clean the engine only when the engine is stationary. Remove the engine cover, the cooling air cover if present and refit it after cleaning.

General information The following causes of dirt make it necessary to clean the engine: l l l l l

high concentration of dust in the air chaff and straw in the engine area coolant leaks lubricant oil leaks fuel leaks

As operating conditions vary from application to application, clean as necessary in relation to degree of dirt and contamination

Cleaning with compressed air l

Remove the dirt with compressed air. Blow the air on the radiator and the cooling fins always from the exhaust air side towards the clean air side.

Clean with cold detergent l l l

Spray the engine with cold detergent and leave it on for approx. 10 minutes. Clean the engine with a strong jet of water. Rotate the engine until it heats up to evaporate the residual water.

Clean with a high pressure device l l l

Clean the engine with a jet of steam (maximum pressure 60 bar, maximum steam temperature 90°C, min. distance 1m). Rotate the engine until it heats up to evaporate the residual water. Clean the radiator and the cooling fins always from the exhaust air side towards the clean air side.

10.1.27 - Care and maintenance work - Intake system Directives for work on the intake system DANGER Never perform the work while the engine is running!

NOTE Maximum cleanliness is essential when working on the intake system. Close the intake openings if necessary. Used filter elements must be disposed of in compliance with law.

10-80

Technical characteristics Service the dry air filter

Fig. 58

DANGER Do not clean the filter element (3) with petrol or hot liquids! Replace damaged filter elements.

l l l l

Service the filtering element (3) based on the maintenance plan interval. Open the retaining bracket (1). Remove the filter cover (2) and withdraw the filter element (3). Filter element (3): m in the case of a low amount of contamination, blow dry compressed air on it from the inside towards the outside (max. 5 bar); m replace in the case of a large amount of contamination.

10-81

Technical characteristics Replace the dry air filter safety cartridge NOTE Never clean the safety cartridge (4).

l l

l

Replace the safety cartridge (4) based on the maintenance plan interval. For this purpose: m Unscrew the hexagonal nut (5), withdraw the safety cartridge (4). m Insert a new safety cartridge, tighten the hexagonal nut. Insert the filter element (3), fit the cover (2) and fasten with the tightening bracket (1).

Maintenance warning light for the dry air filter

1 Fig. 59 l l

l

10-82

Dry air filter maintenance is carried out based on the maintenance indicator or switch. Filter maintenance is necessary when: m the yellow maintenance switch control warning light turns on while the engine is running. m the red service field (1) of the maintenance indicator is completely visible. After performing the maintenance, press the maintenance indicator reset button. The maintenance indicator is again ready for use.

Technical characteristics Clean the dry air filter dust exhaust valve

Fig. 60 l l l

Empty the dust exhaust valve (1) by pressing the exhaust slot. Any dust incrustations inside the device can be removed by squeezing the upper part of the device with your fingers. Clean the exhaust slot.

10-83

Technical characteristics Clean the centrifugal pre-filter

1 2 3 4

Fig. 61

NOTES Never fill the dust bowl (3) with lubricant oil

l l l

Loosen the wingnut (1) and remove the housing cover (2). Remove the dust bowl (3) from the underside (4) and empty. Clean the bowl with a brush and new diesel fuel, then dry. Fit the dust bowl (3) onto the underside (4) and fasten the housing cover (2) with the wingnut (1).

10.1.28 - Care and maintenance work - Belt transmissions Check the belt transmission DANGER Perform work on the belt transmission only when the engine is stationary! After the repair work: make sure all the protective devices have been refit and no tool has been forgotten on the engine. l l

10-84

Visually inspect the entire belt transmission for damage. Replace damaged parts.

Technical characteristics l l

Refit the protections if necessary! In new belts are used, check the correct position; check the tension after 15 min. of operation.

Check the belt tension

1

5

4

3

2 Fig. 62

l l l l l l

Lower the indicator arm (1) in the tester. Place the guide (3) between the two pulleys on the V-belt (2). For this reason, the stop must be lateral. Uniformly press the button (4) in the right corner with respect to the V-belt (2) until you can hear the spring release. Delicately lift the tester without changing the position of the indicator arm (1). Read the value measured on the intersection point (arrow), indicator scale (5) and arm (1). Correct the tension if necessary and repeat the measurement.

Tool The belt tension tester (part number: 0189 9062) may be ordered from your DEUTZ partner.

10-85

Technical characteristics Replacing the belt

4 A B

1

2 3

Fig. 63 l l l l l l l l l

l

10-86

1 – Screw 2 – Screw 3 – Screw 4 - Adjustment wrench Unscrew the screw and check nut. Move the alternator above the adjustment wrench towards (B) until the belt loosens. Remove the belts and fit the new ones. Move the alternator above the adjustment wrench towards (A) until the belt is correctly tensioned. Check the belt tension. See para. 10.1.35 - Technical data - Engin... - page 10-102 Retighten the screw and check nut (torque 30 Nm).

Technical characteristics Replacing the ribbed V-belt

3

2

1 Fig. 64 l l l l

l l l l

1 - Belt tensioner roller 2 - Sealing pin 3 - Assembly hole Push the belt tensioner roller with the box spanner in the direction of the arrow until it is possible to fit a sealing pin in the assembly hole. Now the ribbed V-belt is tension free. First withdraw the ribbed V-belt from the smaller roller and from the belt tensioner roller. Fit the new ribbed V-belt. Retain the belt tensioner roller using a box spanner and remove the sealing pin. Retighten the ribbed V-belt using the belt tensioner and the box spanner. Check that the ribbed V-belt is resting correctly in its guide.

10-87

Technical characteristics 10.1.29 - Care and maintenance - Adjustments and settings Check valve clearance and adjust if necessary l

l l l l

Leave the engine to cool for at least 30 minutes before adjusting valve clearance: The engine oil temperature must be below 80 °C. Remove the electric line from the injectors. Remove the cylinder head cover. Fit the rotation tool on the pulley fastener screw. Turn the crankshaft into the valve overlap position.

Exhaust valve not yet closed, intake valve starts to open. The cylinder order for adjusting valve clearance is indicated in the respective diagram. TCD 4.1 L4

Table 54 Valve overlap angle

Adjustment

1 3 4 2

4 2 1 3

TCD 6.1 L6

Table 55 Valve overlap angle

Adjustment

1 5 3 6 2 4

6 2 4 1 5 3

Valve clearance adjustment

EX

2

1

IN

3

4 5

Fig. 65 l l l l l

10-88

1 - Self-locking nut 2 - Adjustment wrench 3 - Rotation angle gauge 4 - Socket wrench insert 5 - Magnet

Technical characteristics Table 56 Valve clearance

TCD 4.1 L4 TCD 6.1 L6 l l l l l l l l l l

In EX

Intake valve Exhaust valve

75° ± 15° 120° ± 15°

Fit the rotation angle gauge on the adjustment screw with the socket wrench insert. Fasten the magnet of the rotation angle gauge. Turn the rotation angle gauge clockwise until it stops (no rocker free play) and set the scale to zero. Turn the rotation angle gauge anticlockwise to reach the specified rotation angle Hold the rotation angle gauge to prevent it from turning. Tighten the check nut (tightening torque 20 Nm). Then adjust the other two valves on the rocker as described above. Perform the adjustment procedure for each cylinder. Refit the cylinder head cover (fitting a new gasket if necessary), following the removal procedure in reverse order. Tighten the screws (tightening torque 9 Nm).

Tool The rotation angle gauge (part number: 0189 9093) may be ordered from your DEUTZ partner.

Valve clearance adjustment diagram

Fig. 66

Crankshaft position 1 l l l l

Turn the crankshaft into the valve overlap position for cylinder 1. Exhaust valve not yet closed, intake valve starts to open. Adjust the black valves. Mark the respective rocker with chalk to check the adjustment made.

Crankshaft position 2 10-89

Technical characteristics l l

Turn the crankshaft again by a complete revolution (360°). Adjust the black valves.

10.1.30 - Care and maintenance work - Electrical system Directives for work on the electrical system DANGER Never touch live parts; immediately replace defective control warning lights.

NOTE Make sure the polarity of the connections is correct. For engine cleaning, cover the electric/electronic components and connections (e.g. control devices, alternator, solenoid valves, etc.). Do not use a direct water/steam jet for cleaning. Then heat the engine. Do not check the presence of voltage by tapping against ground. If it is necessary to perform electric welding work, the ground clamp of the welder must be directly connected to the part to be welded. Threephase current alternator: Do not interrupt the connection between the battery, alternator and regulator while the engine is running.

Battery NOTE Disconnecting the battery from the terminals could cause electronically stored data to be lost. Keep the battery clean and dry. Make sure that the battery is positioned correctly and safely. Dispose of depleted batteries in an environmentally friendly manner. DANGER Risk of explosion! The gas released from the battery is explosive! Flames, sparks, smoke and bare lights prohibited! Risk of corrosion! Wear safety footwear and protective goggles! Avoid contact with skin and clothes! Risk of short circuit! Do not place metal tools on the battery!

Check the voltage l

Test the battery voltage with a common voltmeter. The voltage provides information about the state of charge.

Table 57 Battery

12 Volts 24 Volts

Charge status (Volt)

12-14.4 24-28.4

Check the acid level l l

l l

10-90

Unscrew the plugs. Follow the manufacturer instructions regarding the level of the fluid. The fluid should normally be 1015 mm above the upper edge of the plate or the control device if present. Only use distilled water for topping up. Tighten the plug.

Technical characteristics Check the acid density

Fig. 67 l l

l l

Unscrew the plugs. Using a common densimeter to measure the density of the electrolyte in each battery element. The measured values can be used to find the battery charge. During the process it should correspond to 20°C. Before charging, the acid level must be tested. Tighten the plug.

Table 58 Acid density [kg/ l] Normal

1.28 1.20 1.12

Tropical

1.23 1.12 1.08

Charge status

Measurement

good half return

None charge charge

10-91

Technical characteristics Remove the battery l l

To disconnect, always disconnect the negative pole first. Otherwise there is a risk of short circuit! Remove the fastening element and the battery.

Charging the battery l l l

Unscrew the plugs. Charge the battery using a normal battery charger. Observe the manufacturer data! Tighten the plug.

Fitting the battery l l l

l

Use a new or charged battery and apply the retainers. Clean the connection terminals and the battery poles with fine sandpaper. For the connection, first connect the positive pole and then the negative one. Otherwise, risk of short circuit! Make sure that the terminal contact is correct. Tighten them manually. Apply acid-free and acid-resistant grease on the complete terminals.

10.1.31 - Malfunctions - Malfunction table Malfunctions and solutions Table 59

Malfunctions

Causes

The engine does not start or starts with dif- The clutch did not uncouple (if possible) Empty fuel tank ficulty Fuel intake line blocked Limit temperature for start-up not reached With the starter device cold Incorrect engine oil SAE viscosity class Fuel quality not compliant with specifications in instruction manual The battery is defective or discharged Starter cable connections loose or oxidised Starter faulty or the pinion does not engage Incorrect valve clearance

The engine does not start and the diagnostics warning light flashes The engine starts, however operates irregularly or loses strokes

There may be a change in the number of revolutions and the diagnostics warning light may turn on

10-92

Action

Check the clutch Empty fuel tank Check Check Check/replace Lubricant oil change: Changing the fuel

Check the battery Check the cable connections Check the starter Check the valve clearance, set it if necessary Dirty air filter/faulty turbocharger Check/replace Air in the fuel system Air Compression value too low Compression test Exhaust gas counterpressure too high Check Injection pipe not airtight Check the injection pipe The engine electronics prevent start-up Identify the fault from the error code and rectify the fault if necessary V-belt/ribbed V-belt (belt-driven fuel pump) Check if torn or loosened Incorrect valve clearance Check the valve clearance, set it if necessary Compression value too low Compression test With the starter device cold Check/replace Air in the fuel system Bleed Fuel pre-filter dirty Renew/change The fuel quality does not comply with the Changing the fuel instruction manual Faulty injector Renew/change Injection pipe not airtight Check the injection pipe The electronic engine control system has Identify the fault from the error code and identified an error and implemented a sub- rectify the fault if necessary stitute engine speed value

Technical characteristics Table 60 Malfunctions

Causes

The engine overheats. The temperature Breather pipe clogged Incorrect engine oil SAE viscosity class alarm trips Faulty lubricant oil radiator Oil filter fouled on air side and/or lubricant oil line side Lubricant oil level too high

Action

Clean Lubricant oil change: Check/replace Renew/change

Check the engine lubricant oil level and drain if necessary Lubricant oil level too low Fill with lubricant oil Incorrect valve clearance Check the valve clearance, set it if necessary Faulty injector Renew/change Coolant heat exchanger dirty Clean Coolant pump failure (toothed V-belt bro- Check if torn or loosened ken or loose) Insufficient coolant Top up Resistance in the cooling system too high/ Check the cooling system flow rate too low Cooling fan or exhaust gas thermostat fail- Check/replace/tighten ure, V-belts snapped or loose The turbocharging air pipe leaks Check the turbocharging air pipe Turbocharging air radiator dirty Check/clean Dirty air filter/faulty turbocharger Check/replace Air filter maintenance switch/indicator Check/replace faulty Coolant fan defective/belt broken or loose Check/replace the fan/V-belt if necessary The engine does not develop enough pow- Lubricant oil level too high Check the engine lubricant oil level and er drain if necessary Lubricant oil radiator blades dirty Clean Oxygen intake temperature too high Check system Fuel quality not compliant with specifica- Changing the fuel tions in instruction manual Dirty air filter/faulty turbocharger Check/replace Air filter maintenance switch/indicator Check/replace faulty Coolant fan defective/belt broken or loose Check/replace the fan/V-belt if necessary The turbocharging air pipe leaks Check the turbocharging air pipe Turbocharging air radiator dirty Clean Resistance in the cooling system too high/ Check the cooling system flow rate too low Injection pipe not airtight Check the injection pipe Faulty injector Renew/change The engine provides low power and the di- The engine electronics reduce the power Contact your DEUTZ partner. agnostics warning light turns on The engine does not operate all cylinders Injection line seal integrity compromised Check the injection pipe Faulty injector Renew/change The turbocharging air pipe leaks Check the turbocharging air pipe Lubricant oil level too high Check the engine lubricant oil level and drain if necessary

10-93

Technical characteristics Table 61 Malfunctions

Causes

The engine oil pressure is too low or it is Lubricant oil level too low The engine position is too sloped depressurised

Action

Add the lubricant oil Check the engine mount /reduce the slope Incorrect engine oil SAE viscosity class Lubricant oil change: The engine consumes too much lubricant Lubricant oil level too high Check the engine lubricant oil level and oil drain if necessary The engine position is too sloped Check the engine mount /reduce the slope Crankcase breather Check/replace Lubricant oil in the exhaust gas system Engine running continuously at excessively Check the load factor low load (<20-30%) The engine smoke is blue Lubricant oil level too high Check lubricant oil level and drain if necessary The engine position is too sloped Check the engine mount /reduce the slope The engine smoke is white Temperature limit for starting reached Check With the starter device cold Check/replace Incorrect valve clearance Check the valve clearance, set it if necessary The fuel quality does not comply with the Changing the fuel instruction manual Faulty injector Renew/change The engine smoke is black Dirty air filter/faulty turbocharger Check/replace Air filter maintenance switch/indicator Check/replace faulty Clogged filter engine stop function (accord- Check ing to air pressure differential) faulty Incorrect valve clearance Check the valve clearance, set it if necessary The turbocharging air pipe leaks Check the turbocharging air pipe Faulty injector Renew/change Selective catalytic reduction system error AdBlue® tank empty/gauge indicating full Check level gauge tank SCR not working Check plug connections of cables on pump and injector SCR not working (cold conditions) Lines frozen, clean lines Sensor signal is not plausible Check NOx sensor No regeneration occurring in diesel particu- Compressor power supply interrupted Check fuse and intake duct, replace shutlate filter ter Compressor faulty Check compressor, replace shutter Air filter clogged Clean/replace air filter, check compressor, replace shutter if necessary Fuel delivery interrupted Check lines, check metering unit Sensor signal is not plausible Check exhaust back-pressure sensor, differential pressure sensor on particulate filter and pressure sensors in metering unit Duct rusted Clean and identify cause of rusting

10.1.32 - Faults - Engine management

10-94

Technical characteristics Engine protection strategy of electronic engine management system

Fig. 68 l l l

1 - Diagnostics key 2 - Error warning light 3 - Electronic engine regulation (EMR) NOTE The warning light turns off as soon as all faults are eliminated. In the case of some anomalies, it is necessary to deactivate the ignition, wait 30 s and only then reactivate the ignition. If a sensor is faulty, all the corresponding monitoring functions are deactivated. Only the sensor fault is documented in the error memory.

Depending on the monitoring function instruments, electronic engine regulation could protect the engine in some error situations from possible damage by monitoring compliance with the important limit values during operation and checking correct operation of the system components. Depending on the seriousness of a detected anomaly, the engine can continue to operate with certain limits, with the error warning light remaining on, or the error light flashes, indicating a serious system error. In this case, the engine must be stopped as soon as it is possible to do so safely.

10-95

Technical characteristics Error warning light The error warning light is located near the driver’s seat in the vehicle. The error warning light could issue the following signals: l

l

l

l

Operation check m With the ignition active, the error warning light will flash for approx. 2 seconds. m If there is no reaction during ignition, check the error warning light. The warning light does not turn on m After the lamp test, a warning light that is off signals a possible condition that is correct and without errors during the checks that can be carried out. Permanent light System error m Operation continues with certain limitations. m Have a check performed by a DEUTZ service partner. m If the light is fixed, this means that a controlled unit of measure (e.g. the coolant temperature, the lubricant oil pressure) exceeded the permitted interval. m Depending on the type of problem, the electronic engine regulator can reduce the engine power to protect the engine. Flashing Serious system error. m Deactivation request for the operator. Note: Failure to respect this causes the warranty to be voided! m The switching off condition for the engine was not reached. m To cool the engine, forced operation with power reduced, if necessary with automatic switching off. m Switching off process. m After the engine has stopped, there may be a starter block. m The starter block is eliminated by deactivating the system with the ignition key for approx. 30 s. m With the optional override key on the instrument panel for avoiding critical situations, power reduction can be excluded, automatic deactivation can be delayed or a starter block can be excluded. This brief deactivation of the engine protection functions is recorded in the control unit.

In the case of operating anomalies and the need for spare parts, contact one of our competent support service dealers . In the case of a fault, our qualified personnel can make any repair in a quick and appropriate manner using original DEUTZ spare parts.

Diagnostics key The diagnostics key is used to display the errors currently present in the electronic engine regulation error memory, in the form of flashing codes. The flashing codes offer: l l

The present errors can be classified. a univocal signal of the error in the form of an optical signal. m The flashing codes can only be interpreted by a DEUTZ service partner.

Using the diagnostic key The flashing code signals all the errors present in the error memory, meaning active and passive errors. To start the request, turn off the control unit (ignition off). Then press and hold the diagnostic butting while switching the ignition on for approximately 1 s. Press the diagnostic button again to view the next error (next error stored in error memory). If the last error present is displayed, pushing the diagnostic key again the first error will be displayed. After emitting the flashing error code, the error warning light will turn off for five seconds.

10-96

Technical characteristics

1

2s

2

0,4 s 0,4 s

0,8 s

2s

0,8 s

0,4 s 0,4 s

Displaying a system error via a flashing code

8

Fig. 69

Example: Flashing code 1-2-8 l l l

1 x brief flash 2 x long flashes 8 x short flashes

This flashing code signals damage or a short circuit in the supply air temperature sensor cables. The time sequence of the flashing signals is indicated in the figure. The flashing codes can only be interpreted by a DEUTZ service partner.

10-97

Technical characteristics 10.1.33 - Transport and storage - Transport Suspension device

1

2

Fig. 70

DANGER The transport devices fit on this engine are calibrated based on the engine weight. If you want to transport the engine with additional components, the transport devices must be reconfigured. l l l

10-98

Only use the correct suspension device to transport the engine. It must be possible to adjust the suspension device (1) based on the engine barycentre. After transport/before start-up of the engine: Remove the transport eyelets (2).

Technical characteristics

1 2

2

Fig. 71

DANGER Danger of death! If errors are made when implementing the suspension, the engine could overturn or fall!

l l l

The fastening device may not be fastened securely to the barycentre (1). The fastening material could slip and the engine could overturn (1). A fastening device that is too short could cause the transport device (2) to bend, damaging it.

10.1.34 - Transport and storage - Transport and storage In general

All engines receive the following protection treatments: l l

Internal protection treatment External protection treatment NOTE DEUTZ partners have the following types of suitable protection products available.

10-99

Technical characteristics After placing the engine out of service, the following protection treatments satisfy the requirements for protecting for a 12 month period. The following procedures for applying protective treatment must only be performed by qualified personnel who has been adequately informed of the risks involved. Failure to comply with the instructions and exposing the engine or any parts treated with wax to any unfavourable conditions (placing outside or storage in humid and non-ventilated areas) or if there is any damage to the layer of the protective material, a shorter protection and treatment period must be considered for the device. The engine’s protective treatment must be checked approx. every 3 months by opening the covers. If traces of corrosion are found, a new treatment is necessary To prevent the protective product from being removed from bearings, bushes and the cylinder sleeves, do not rotate the crankshaft after applying the protective treatment. Before starting up a treated engine, remove the protective wax.

Internal protection treatment l

l

The internal protective treatment is done by wetting the interior walls with the protective product, using an engine treatment cycle. The treatment cycle may be carried out once to protect the various systems:

Fuel distribution system NOTE Close the fuel line leading from the tank to the engine to protect the system from contamination with dirt or dust. Protect the electronics from humidity/corrosion. l

l

Fill the fuel tank with a mixture of: m 90% fuel distillate. m 10% protective lubricant oil. Carry out the protection cycle with the engine not loaded, minimum cycle duration 5 minutes.

Lubrication oil system l l

l

Drain the lubricant oil with the engine hot. Use diesel fuel or detergent to thoroughly clean the lubricant oil sump, the cylinder head with rockers, the valves and the valve springs. Fill the engine with TITAN EM 2020 DEUTZ(SAE 20W-20) protective oil for running-in, then perform the treatment cycle (together with the fuel system treatment cycle) by warming the engine to approximately 60°C for at least minutes to coat all the components of the oil lubrication system.

or l

wet all accessible components with protective oil for running-in, and use a separate pump to circulate protective oil for runningin, heated to 60°C, throughout the engine until all the bearings and bushes are coated.

Cooling system l

l l

l

l

l

l

Depending on the series, the engines are equipped with air, oil or coolant (cooling water with a cooling system protective agent) based cooling systems. Cooling air system, see the External protection treatment section. For oil cooled engines, the lubricating oil in circulation also is used for cooling. In this way the cooling compartments are automatically treated with the oil lubrication system. If a protective product that has preserving characteristics is added to the cooling system for liquid cooled engines, once drained no other measures are required. Otherwise, the coolant must be drained and in order to create a protective layer on the inner surfaces of the cooling system, carry out a protective treatment with a mixture consisting of: m 95 % treated water m 5 % anti-corrosive agent The duration of the protective treatment cycle and the concentration of the anti-corrosive product must be decided based on the data provided by the anti-corrosive agent manufacturer. Then drain the coolant.

10-100

Technical characteristics Exhaust after-treatment system - Selective catalytic reduction l

l

l

l l l

Provided that the following conditions are met, the SCR system may remain out of use for up to 4 months after total shut-down of the engine (including all inertial functions): In the event of a prolonged periods out of use, the vehicle or engine must be stored in a covered location, such as a garage or factory shed. Fill the AdBlue® tank completely. The water contained in the AdBlue® solution must not be allowed to evaporate. Do not disconnect electric or hydraulic connections. Maximum storage time with ambient temperatures between - 40 °C and 40 °C: 2 months. Maximum storage time with ambient temperatures between - 40 °C and 25 °C: 4 months.

Proceed as follows once the maximum period of inactivity of 4 months is reached: l

l

AdBlue® m Drain the tank completely. m Fill the tank completely with new AdBlue®. m Replace the filtration element of the delivery pump. Warm the engine to operating temperature and load the engine until the AdBlue® system pressure and delivery rate increases.

If a fault occurs: l

l

Stop the engine Wait for the EDC (Electronic Diesel Control) system to shut down. Repeat the procedure several times if necessary.

If the fault cannot be rectified, contact your DEUTZ support service.

Intake air lines l

Spray the intake air duct with ANTICORIT VCI UNI O 40 anti-corrosion oil or TITAN EM 2020 DEUTZ (SAE 20W-20) protective oil for running-in.

External protection treatment l

Before carrying out the external protection treatment, the engine must be cleaned thoroughly with detergent. Eliminate any signs of corrosion or paint damage.

Glossy parts and external surfaces l

All glossy metal external surfaces and parts (e.g. flywheel, flange surfaces) must be painted or sprayed with the protective product.

Rubber parts l

Unpainted rubber parts (e.g. sleeves) are rubbed with talcum powder.

Belt transmissions l l

Disassemble the belts and the ribbed V-belt and store them packaged. Spray anti-corrosive liquid on the V-belt pulleys and on the belt tensioner rollers.

Engine openings l l l

To delay the evaporation of the protective substances, air and water tight covers must be placed on all engine openings. With the air compressor installed, close the intake and pressure connector with a plug. Block the air inlet again to avoid engine ventilation (chimney effect).

Storage and packaging l l

after applying the protective treatment, store the engine in a dry, well ventilated building under adequate cover. This cover must be placed on the engine with a certain clearance so that air can circulate around it and condensate water cannot form. Use a drier if necessary.

10-101

Technical characteristics Dewaxing l l l

Before starting, the engine must be dewaxed. The packaging and all covers on the closed openings must be removed. Eliminate any signs of corrosion or paint damage.

Fuel distribution system Drain the tank if it contains a mixture of diesel fuel and protective oil. l l

Connect the fuel tank line to the engine. Ensure maximum cleanliness. Fill the fuel tank and system with the specified fuel.

Fuel distribution system l l

Unscrew the lubricant oil discharge auger, drain the lubricant oil. Pour the lubricant oil into the engine through the filler.

Coolant system l

l

In the case of compatibility between the preserving agent with the protective product for the cooling system, this can be added directly to the coolant system based on the requirements. If you are not perfectly certain of compatibility between the anti-corrosive product to be used with the protective product for the cooling system, before adding it first perform a washing cycle with clean water for approx. 15 minutes.

Dewaxing the external parts l l l l

Wash all the surfaces and components covered with the preserving protect with fuel distillate or a suitable detergent. If necessary wash the toothed belt pulley grooves. Fit the belts and V-belts based on the instructions. Top up the coolant.

Preserving/cleaning products For information about reference products to be used for protecting or cleaning that comply with DEUTZ requirements, contact your DEUTZ partner. Or see the website www.deutz.com

Table 62 http://www.deutz.it

de

\SERVICE \Betriebsstoffe und Additive\ Motor \SERVICE\Operating Liquids and Additives\ Engine Corrosion Protection

en

10.1.35 - Technical data - Engine data and adjustment data Main technical data Table 63

Engine type

Operating mode Turbocharging Type of cooling Cylinder layout Number of cylinders Bore/stroke Total capacity Injection system Exhaust gas recirculation Exhaust gas after-treatment Valves per cylinder

Dimensions

[mm] [cm3]

TCD 4.1 L4

TCD 6.1 L6

4-stroke diesel engine Turbocharger with supply air cooling water cooled in series 4 6 101/126 4038 6057 Deutz Common Rail (DCR) without or external Selective Catalytic Reduction (SCR) or Diesel Particulate Filter (DPF) 4

*The lubricant oil quantities indicated are for standard versions. For engines with non-standard configurations, such as other oil sump/dipstick variants and/or special installations in inclined positions, the quantity of oil may vary. Always refer to what is indicated on the notch of the lubricant oil dipstick.

10-102

Technical characteristics Engine type

Valve clearance: intake/exhaust Adjustment with rotation angle gauge Engine firing order Direction of rotation viewed from the flywheel Engine power according to ISO 304 standard Number of revs (nominal number or revs) Coolant quantity (only contained in the engine without the radiator/pipes and lines) Industrial engines/agricultural technology Permitted constant temperature of the coolant Temperature difference between coolant inlet/outlet Start of thermostat opening Thermostat completely open Quantity of spare lubricant oil (with filter) Maximum temperature of the lubricant oil in the lubricant oil sump Minimum lubricant oil pressure (low number of revs, hot engine) Maximum temperature permitted for the combustive air after the turbocharging air radiator V-belt tension V-belt AVX 13 (width: 13 mm) Ribbed V-belt tension Weight without the cooling system in accordance with DIN 70020-A

Dimensions

[°]

TCD 4.1 L4

TCD 6.1 L6

1-3-4-2 on the left

1-5-3-6-2-4

75° ± 15° / 120° ± 15°

[kW]

See the engine identification plate

[rpm]

See the engine identification plate

[l]

5.9/5.0

[°C]

max. 110

[°C]

4-8

[°C] [°C]  [l]

86 102 11.5*

[°C]

125

[kPa/bar]

80/0.8

[°C]

50

[N]  [kg]

8.7/7.5

15.5*

pretension/tension correction 650±50/400±50 Spring belt tensioner with automatic tension 400 510

*The lubricant oil quantities indicated are for standard versions. For engines with non-standard configurations, such as other oil sump/dipstick variants and/or special installations in inclined positions, the quantity of oil may vary. Always refer to what is indicated on the notch of the lubricant oil dipstick.

10-103

Technical characteristics 10.1.36 - Technical data - Tools Tool order

The special tools described in this chapter can be purchased at: Contact your DEUTZ partner.

TORX tool

Fig. 72

Part number: 0189 9092 TORX type screws are also used in engines of this series. This screw system has been introduced as it offers many advantages: l l l

Excellent accessibility. Superior torque transmission when loosening and tightening. No risk of the tool slipping or breaking, causing operator injury.

10-104

Technical characteristics V-belt tension tester

Fig. 73

Part number: 0189 9062 Tester for checking the tension values specified for V-belts.

10-105

Technical characteristics Special wrench for loosening the cartridge filters

Fig. 74

Part number: 0189 9142 For loosening the cartridge filters.

10-106

Technical characteristics Rotation angle gauge

Fig. 75

Part number: 0189 9093 For adjusting valve clearance

10-107

Technical characteristics Socket wrench insert

Fig. 76

Part number: 0189 9096 For adjusting valve clearance

10-108

Technical characteristics Rotation device

Fig. 77

Part number: 0299 2028 For turning the engine. Applied to torsional vibration damper.

10-109

Technical characteristics Rotation device

Fig. 78

Part number: 0299 2464 For turning engine. Applied to gearbox.

10-110

Technical characteristics Refractometer

Fig. 78

Part number: 0293 7499 This test device can be used to evaluate the following operating materials: l l l

Coolant Battery acidity AdBlue®

10-111

Technical characteristics 10.2 - Engine accessories

10.2.1 - Pressure transducer (L3) Technical data 1. 2.

Readily available commercial tools: m Multimeter m Measurement prods Measurement size: Pressure Medium: Fluid

Fig. 79

Wiring diagram 1.

Power supply voltage (UDC): 5 (± 5%) V Signal (UDC): 0.5 - 4.5 V Measurement interval: 0 - 700 kPa

Table 64 Diagnostics

Overpressure Negative pressure Ground

Signal (UDC) Signal (UDC) Signal (UDC)

V

1

(+)

≤ 4.75 ≥ 0.25 ≥ 4.8

2

(S)

3 4

(-)

Fig. 80

Connector configuration 1.

Table 65 Pin / socket

1 2 3 4

Supply voltage Signal not used Ground

4 (-)

1 (+)

(S) 2

3

Fig. 81

10-112

Technical characteristics 10.2.2 - Pressure sensor (L3) Technical data 1.

Measurement size: Pressure/Temperature Medium: Air Type: NTC 1 2 3 4

2.

Readily available commercial tools: m Multimeter m Measurement prods

Fig. 82

Wiring diagram 1.

Temperature sender (S1) Power supply voltage (UDC): 5 (± 5%) V Signal (UDC): 0.5 - 4.5 V Measurement interval: -40 - 130 °C

(-)

1

Pressure transducer (S2)

(S1)

2

(+)

3

(S2)

4

Power supply voltage (UDC): 5 (± 5%) V Measurement range 50 - 400 kPa

Fig. 83

Connector configuration 1.

Table 66 Pin / socket

1 2 3 4

Ground Signal Supply voltage Signal

4 3 (S2) (+)

2 (S1)

1 (-)

DANGER Hot components! Burn hazard!

Fig. 84

10-113

Technical characteristics 2.

m

Measurement n Temperature sender

Table 67 Temperature °C

-40 -20 0 20 50 100

Pin / socket

Pin / socket

1 1 1 1 1 1

2 2 2 2 2 2

Nominal kΩ

48,150 (± 5%) 15,610 (± 5%) 5,880 (± 5%) 2,510 (± 5%) 0.850 (± 5%) 0.186 (± 5%)

Measurement l l

With ambient pressure of 100 kPa Pressure transducer

Table 68 Pressure kPa

100

Pin / socket

Pin / socket

3

4

Nominal kΩ

5.1 (± 8%)

10.2.3 - Temperature sender (L3) Technical data 1. 2.

Readily available commercial tools: m Multimeter m Measurement prods Measurement size: Temperature Medium: Fluid Type: NTC

Fig. 85

10-114

Technical characteristics Wiring diagram 1.

Power supply voltage (UDC): 5 (± 5%) V Measurement interval: -40 - 140 °C

(-) 1

(S) 2

Fig. 86

Connector configuration 1.

Table 69 Pin / socket

1 2

2 (S)

1 (-)

Ground Signal DANGER Hot components! Burn hazard!

Fig. 87

Measurement l

Temperature sender

Table 70 Temperature °C

-40 -20 0 20 25 100

Pin / socket

Pin / socket

1 1 1 1 1 1

2 2 2 2 2 2

Nominal kΩ

45,313 (± 10.5%) 15,460 (± 8%) 5,890 (± 7%) 2,500 (± 6%) 2,057 (± 5.5%) 0.186 (± 2.5%)

10.2.4 - Temperature sender (L3) Technical data 1.

Readily available commercial tools: m Multimeter m Measurement prods

10-115

Technical characteristics 2.

Measurement size: Temperature Medium: Air

Fig. 88

Wiring diagram 1.

Power supply voltage (UDC): 5 (± 5%) V Measurement interval: -40 - 150 °C 1 (-)

2 (S)

Fig. 89

Connector configuration 1.

Table 71 Pin / socket

1 2

Ground Signal

1 (-)

2 (S)

DANGER Hot components! Burn hazard!

Fig. 90

10-116

Technical characteristics 2.

m

Measurement n Temperature sender

Table 72 Temperature °C

Pin / socket

Pin / socket

-40 25 50

1 1 1

2 2 2

39,656 (± 6.7%) 2,000 (± 3.3%) 0.833 (± 2.4%)

Value table Temperature °C

Nominal kΩ

Idle kΩ

Maximum kΩ

Table 73

-40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 40 50 60 70 75 80 90 100 110 120 130 140 150

39,656 30,080 23,026 17,781 13,846 10,867 8,594 6,845 5,490 4,432 3,601 2,943 2,420 2,000 1,662 1,166 0.833 0.605 0.447 0.387 0.338 0.255 0.197 0.154 0.121 0.097 0.078 0.063

37,013 28,173 21,639 16,783 13,092 10,305 8,172 6,526 5,248 4,247 3,458 2,833 2,334 1,934 1,610 1,133 0.812 0.593 0.439 0.380 0.331 0.252 0.195 0.152 0.119 0.095 0.076 0.062

Nominal kΩ

42,298 31,986 24,414 18,800 14,600 11,429 9,015 7,154 5,732 4,618 3,743 3,053 2,505 2,067 1,715 1,198 0.853 0.618 0.456 0.393 0.341 0.259 0.199 0.155 0.123 0.098 0.079 0.085

10-117

Technical characteristics 10.2.5 - Temperature sender (L3) Technical data 1. 2.

Readily available commercial tools: m Multimeter m Measurement prods Measurement size: Temperature Medium: Air Type: PT200

Fig. 91

Wiring diagram 1.

Power supply voltage (UDC): 5 (± 0.1%) V Measurement interval: -40 - 950 °C

Rv

ϑ

(S) 2

(-) 1

Fig. 92

Connector configuration 1.

Table 74 Pin / socket

1 2

Ground Signal

1 (-)

DANGER Hot components! Burn hazard!

4

1

2

3

(S) 2

Fig. 93

10-118

Technical characteristics 2.

m

Measurement n Temperature sender

Table 75 Temperature °C

0 25 100 600 850

Table 76

Pin / socket

Pin / socket

1 1 1 1 1

2 2 2 2 2

Value table Temperature °C

-40 0 25 50 100 200 300 400 500 600 700 800 850

Nominal kΩ

0.169 (± 1.1%) 0.200 (± 1%) 0.219 (± 0.9%) 0.238 (± 0.8%) 0.275 (± 0.7%) 0.349 (± 0.5%) 0.419 (± 0.5%) 0.488 (± 0.5%) 0.554 (± 0.5%) 0.617 (± 0.6%) 0.679 (± 0.6%) 0.738 (± 0.6%) 0.766 (± 0.6%)

Nominal kΩ

0.200 (± 1%) 0.219 (± 0.9%) 0.275 (± 0.7%) 0.617 (± 0.6%) 0.767 (± 0.6%)

Idle kΩ

0.725 0.835 0.900 0.963 1,081 1,293 1,478 1,640 1,783 1,909 2,022 2,123 2.170

10.2.6 - Temperature sender (L3) Technical data 1. 2.

Readily available commercial tools: m Multimeter m Measurement prods Measurement size: Temperature Medium: Air Type: PT200

Fig. 94

10-119

Technical characteristics Wiring diagram 1.

Power supply voltage (UDC): 5 (± 0.1%) V Measurement interval: -40 - 950 °C

Rv

ϑ

(S) 2

(-) 1

Fig. 95

Connector configuration 1.

Table 77 Pin / socket

1 2

Ground Signal

1 (-)

DANGER Hot components! Burn hazard!

4

1

2

3

(S) 2

Fig. 96

10-120

Technical characteristics 2.

m

Measurement n Temperature sender

Table 78 Temperature °C

0 25 100 600 900

Table 79

Pin / socket

Pin / socket

1 1 1 1 1

2 2 2 2 2

Value table Temperature °C

-40 -20 0 25 50 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

Nominal kΩ

0.169 (± 1.1%) 0.185 (± 1.1%) 0.200 (± 1%) 0.219 (± 0.9%) 0.238 (± 0.8%) 0.276 (± 0.7%) 0.313 (± 0.7%) 0.349 (± 0.5%) 0.384 (± 0.5%) 0.419 (± 0.5%) 0.454 (± 0.5%) 0.488 (± 0.5%) 0.521 (± 0.5%) 0.554 (± 0.5%) 0.617 (± 0.6%) 0.679 (± 0.6%) 0.738 (± 0.6%) 0.795 (± 0.6%) 0.849 (± 0.6%)

Nominal kΩ

0.200 (± 1%) 0.219 (± 0.9%) 0.276 (± 0.7%) 0.617 (± 0.6%) 0.795 (± 0.6%)

Idle V

0.725 0.781 0.835 0.900 0.963 1,081 1,191 1,293 1,389 1,478 1,562 1,640 1,713 1,783 1,909 2,022 2,123 2,214 2,296

10.2.7 - Speed indicator (L3) Technical data 1. 2.

Readily available commercial tools: m Multimeter m Measurement prods Measurement size: Speed passive: without power supply

Fig. 97

10-121

Technical characteristics Wiring diagram 1.

Signal (UDC): 1.65 V

(S1)

1 3

(S2)

2

Fig. 98

Connector configuration 1.

Table 80 Pin / socket

1 2 3

Signal Signal Shielding

(S1) 1 (S2) 2

3

Fig. 99

2.

m

Measurement n Speed indicator

Table 81 Condition °C

20

Pin / socket

Pin / socket

1

2

Nominal Ω

880 (± 10%)

DANGER Hot components! Risk of injury! 3.

m

Measurement n Speed indicator

Table 82 Condition

Pin / socket

The crankshaft turns 1 with a number of starter revolutions

10-122

Pin / socket

2

Nominal V

1.65

Polarity

+

Technical characteristics 10.2.8 - NOx sensor (L3) Technical data 1. 2.

Readily available commercial tools: m Multimeter m Measurement prods Measurement size: Nitrogen oxide/lambda value Medium: Air

Table 83 Power supply voltage 12 (± 5%) (UDC) Measurement interval 0 - 500 -40 - 105 (NOx)

V ppm °C

Fig. 100

Connector configuration 1.

Table 84 Pin / socket

1 2 3 4

Bus CAN high Bus CAN low Ground Supply voltage

4 (+)

3 (-)

2 (CAN-low) 1 (CAN-high)

DANGER Hot components! Burn hazard!

Fig. 101

10.2.9 - NOx sensor (L3) Technical data 1.

Readily available commercial tools: m Multimeter m Measurement prods

10-123

Technical characteristics 2.

Measurement size: Nitrogen oxide/lambda value Medium: Air

Table 85 Power supply voltage 12 (± 5%) (UDC) Measurement interval 0 - 500 -40 - 105 (NOx)

V ppm °C

Fig. 102

Connector configuration 1.

Table 86 Pin / socket

1 2 3 4

Bus CAN high Bus CAN low Ground Supply voltage

4 (+)

3 (-)

2 (CAN-low) 1 (CAN-high)

DANGER Hot components! Burn hazard!

Fig. 103

10.2.10 - Removing and fitting fuel lines (fuel delivery pump - fuel control block) (L3) Special tools: l

Plugs and caps: 170160 DANGER Never work on the fuel system when the engine is running. The fuel system is under high pressure - risk of death. The pressure in the fuel system may still be as high as several hundred bar even after the engine has been switched off. In this case, the fuel pressure can only be reduced by opening the fuel system to allow fuel to escape. WARNING During work on the fuel system always maintain conditions of the maximum cleanliness. Before proceeding with removal, remove any paint residue or debris. Thoroughly clean the area around the components to be worked on. Dry any wet areas with a compressed air jet. When handling fuel observe the safety directives and specific local regulations. All fuel lines and unions should be closed immediately after opening using new, clean plugs or caps. Remove plugs and caps only immediately prior to assembly. Collect auxiliary materials in suitable containers and dispose of them in compliance with the applicable regulations. After any operation, bleed the fuel distribution system - see the user manual, chapter “6 Fuel distribution system”.

10-124

Technical characteristics Removal of fuel lines 1.

1.1. 1.2. 1.3. 1.4. 1.5. 1.6. 1.7. 1.8. 1.9.

Fuel line Fuel line Fuel line Hex valve Pipe retaining clip O-ring Hollow screw Pressure transducer Flexible pipe support Flexible pipe support

Fig. 104

2.

Fuel line with connection fitting Note The release procedure is the same for all the fuel line connection fittings. To release the connection fittings: m

Squeeze the retaining springs (1) on both sides of the of the connection fitting.

1 1

Fig. 105

3.

m m m

Remove screw (1). Release and disconnect the connection fittings (2). Remove fuel line (3).

Fig. 106

10-125

Technical characteristics 4.

m m m

Release and disconnect the connection fittings (1). Remove the fuel line (2) from the hose mount (3). Remove fuel line (2).

Fig. 107

5.

m m m m m m

Unlock the wiring connector. Unplug the connector. Unscrew banjo bolt (1) Remove oil seals (2). Remove the fuel line (3) from the hose mount (4). Remove fuel line (3).

Fig. 108

6.

m m m

Restrain adapter (1). Unscrew pressure sender (2). Remove the O-ring.

Fig. 109

10-126

Technical characteristics Refitting fuel lines. 1.

m m m m

Fit a new O-ring. Restrain adapter (1). Screw in pressure sender (2). Tighten the pressure transducer: 30 Nm

Fig. 110

2.

WARNING When installing the fuel line, make sure it is not under tension. Make sure the assembly position is correct. m

Position fuel line (1). Note Tab (2) should rest on the pilot block. Check the installation position is correct.

m m m m

Fit new seals (3). Screw in banjo bolt (4). Tighten the hollow screw (4): 39 Nm Fit the fuel line (1) in the hose mount (5). Fig. 111

3.

WARNING When installing the fuel line, make sure it is not under tension. Make sure the assembly position is correct. m m

Fit fuel line (1). Connect and lock the connection fittings (2). Note Check that the connection is made correctly.

m

Fit the fuel line (1) in the hose mount (3). Fig. 112

10-127

Technical characteristics 4.

WARNING When installing the fuel line, make sure it is not under tension. Make sure the assembly position is correct. m m

Fit fuel line (1). Connect and lock the connection fittings (2). Note Check that the connection is made correctly.

m m

Locate the hose clip. Tighten the screw (3): 30 Nm Fig. 113

Technical data Tightening torque

Table 87 ID no.

Designation

A07 090

Fuel pressure sender in correspondence with the adapter Tightening of pipe, annu- Hollow screw M14x1.5 lar piece Pipe retaining clips, fixing M8x16-10.9 screw

A12 093 A12 096

Screws type

Indications/observa- Value tions

Use a new seal.

30 Nm 39 Nm 30 Nm

Note When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

10.2.11 - Fitting and removing the temperature sender (exhaust gas) (L3) Removal of the temperature sender 1.

m m

1 - Exhaust gas temperature sender 950 - Hole blanking screw

Fig. 114

10-128

Technical characteristics 2.

m m m m

Remove cable tie. Unlock and detach the connectors. Unscrew temperature sensor (1) Carry out a visual inspection of the component.

Fig. 115

Refitting the temperature sender 1.

m m m

Screw down temperature sensor (1). Tighten the temperature sender (1): 45 Nm Connect and lock the wiring connector. Note Check that the connection is made correctly.

m

Fix the cable tie.

Fig. 116

Technical data Tightening torque

Table 88 ID no.

Designation

A13 048

Temperature transmitter (exhaust gas) on exhaust pipe Closing screw (temperature transmitter, exhaust gas) on exhaust pipe

A13 049

Screws type

Indications/observa- Value tions

45 Nm 32 Nm

Note When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

10-129

Technical characteristics 10.2.12 - Temperature sender (L3) 1.

m

1 - Temperature sender

Fig. 117

2.

m

1 - Temperature sender: 25 Nm

Fig. 118

10.2.13 - Removing and fitting NOx sensor (L3) Special tools: l l l

Plugs and caps: 01899144 Crow’s foot wrench: 02992345 Assembly product: DEUTZ S1 DANGER High temperature components! Risk of burns/risk of explosion! Let the engine/components cool down sufficiently (at least to ambient temperature). The duration of the so-called post-operation time depends on the application; in engines with the SCR system, for example, it can last up to 2 minutes, which is the time necessary to completely empty the SCR pipes. Filter regeneration must be deactivated before carrying out the service operations, or cannot be activated in systems with filter regeneration request. WARNING Ensure maximum cleanliness during all work. Before proceeding with removal, remove any paint residue or debris. Thoroughly clean the area around the components to be worked on. Dry any wet areas with an air jet. All fuel lines and unions should be closed immediately after opening using new, clean plugs or caps. Remove plugs and caps only immediately prior to assembly.

10-130

Technical characteristics Disassembly of the sensor 1.

Note The following procedure illustrates how to select, remove and fit a single sensor. Follow the same procedure to remove/fit other sensors. Mark the cables and the respective connections before continuing with disassembly. m m m m

Unlock and disconnect the connectors. Unscrew the connector screw (1) with the crow’s foot wrench. Remove the sensor (2). Carry out a visual inspection of the components.

Fig. 119

Assembly the sensor 1.

m m

Apply the assembly product on the thread (1). Fit the sensor (2).

Fig. 120

2.

WARNING Do not twist the cable. Check that the cables are positioned correctly. m m

Hold the sensor with one hand. Tighten the connector screw (1) with the crow’s foot wrench: 50 Nm

Fig. 121

10-131

Technical characteristics 3.

WARNING Ensure that the correct sensor is installed in the correct position. m

n

1

NOx sensor installation:

Table 89 Installation location

Diesel particulate filter

Pin connection colour (1)

Black

SCR (Selective Catalytic Reduction) upstream of catalytic converter Grey downstream of catalytic converter Black 4.

m

Fig. 122

Route the cable between the NOx sensor and the NOx ECU, with an additional loop of cable for safety. X

WARNING Check that the cables are positioned correctly. Route the cables without friction or tension points. The length of the additional loop of cable must be as indicated in the documentation provided by the manufacturer of the vehicle/machine.

Table 90 Position

1 2 3 4 X

m

10-132

180° 1 2 4 3

Note/Name

Last fastener point Safety loop Exhaust system NOx sensor Length

Connect and lock the wiring connector.

Value

180° at least 100 mm

Fig. 123

Technical characteristics Technical data Tightening torque

Table 91 ID no.

Designation

A71 068

NOx sensor, fastening

Screws type

Indications/observa- Value tions

Install with DEUTZ S1 50 Nm sealant.

Note When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

10.2.14 - Temperature sender (exhaust gas) (L3) 1.

DANGER High temperature components! Risk of burns/risk of explosion! Let the engine/components cool down sufficiently (at least to ambient temperature). The duration of the so-called post-operation time depends on the application; in engines with the SCR system, for example, it can last up to 2 minutes, which is the time necessary to completely empty the SCR pipes. Filter regeneration must be deactivated before carrying out the service operations, or cannot be activated in systems with filter regeneration request. WARNING

2.

Ensure maximum cleanliness during all work. Before proceeding with removal, remove any paint residue or debris. Thoroughly clean the area around the components to be worked on. Dry any wet areas with an air jet. When handling fuel observe the safety directives and specific local regulations. All fuel lines and unions should be closed immediately after opening using new, clean plugs or caps. Remove plugs and caps only immediately prior to assembly. Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations. m

Temperature sender 45 Nm

Fig. 124

10-133

Technical characteristics 10.3 - Transmission

10.3.1 - Transmission (7210 TTV Agrotron ->WSXW830400LD50010) Introduction l

The tractors in this series are equipped with an infinitely variable hydrostatic/mechanical POWER SPLIT transmission The main feature of this transmission is the ability control and manage tractor travel speed from 0 to 50 km/h in accordance with operator commands and the traction effort to which the tractor is subjected Transmission management is fully automatic and controlled by an electronic control unit The transmission can be divided into the following sections: m A. Gearbox B. Rear axle C. Rear PTO D. Auxiliary hydraulic oil tank

A

B

C

D

D0060110

Fig. 125 - Transmission section

10-134

Technical characteristics Main components

6

7

1

5

2 3

4

D0060120

Fig. 126 - Main components 1/5 Key 1. 2. 3. 4. 5. 6. 7.

Hydrostatic transmission assembly PTO mode selection lever (normal/eco) PTO output shaft PTO speed selection lever (normal: 540/100; eco: 750/1400) PTO engagement solenoid valve 4WD engagement control solenoid valve Final drive oil filler and level check plug

10-135

Technical characteristics 6 5

4

2

3 4 1

Fig. 127 - Main components 2/5 Key 1. 2. 3. 4. 5. 6.

LH trumpet housing Oil filler plug “PARK LOCK” release button Brake assembly Hydrostatic transmission assembly Rx axle housing

10-136

Technical characteristics 3 2

1 D0060150

Fig. 128 - Main components 3/5 Key 1. 2. 3.

PTO revs sensor Rear PTO engagement solenoid valve Differential lock control solenoid valve

1 5

3

2

4 D0060160

Fig. 129 - Main components 4/5 Key 1. 2. 3.

Parking brake lever Rear PTO speed sensor “PARK LOCK” release button 10-137

Technical characteristics 1 5

3

2

4 D0060160

Fig. 129 - Main components 4/5 4. 5.

Final drive oil filler and level check plug Auxiliary hydraulic oil tank level indicator light

10-138

Technical characteristics

3

1

4

2

5

1

3

D0060170

Fig. 130 - Main components 5/5 Key 1. 2. 3. 4. 5.

Auxiliary hydraulic oil tank drain plug Transmission oil drain plug Final drive oil drain plug Rear axle differential oil drain plug Rear PTO oil drain plug

10.3.2 - Transmission (50 Km/h) (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Introduction

10-139

Technical characteristics l

The tractors in this series are equipped with an infinitely variable hydrostatic/mechanical POWER SPLIT transmission The main feature of this transmission is the ability control and manage tractor travel speed from 0 to 50 km/h in accordance with operator commands and the traction effort to which the tractor is subjected Transmission management is fully automatic and controlled by an electronic control unit The transmission can be divided into the following sections: m A. Gearbox B. Rear axle C. Rear PTO D. Auxiliary hydraulic oil tank

A

B

C

D

D0068890

Fig. 131 - Transmission section

10-140

Technical characteristics Main components

3

1

2

D0068900

Fig. 132 - Main components 1/5 Key 1. 2. 3.

Complete hydrostatic transmission assembly Oil filler plug for final reduction gear unit PTO output shaft

10-141

Technical characteristics

3 1

2

4 5

6

9

7

8

10 2 11

D0068910

Fig. 133 - Main components 2/5 Key 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Complete hydrostatic transmission assembly Brake device RH wheel mount Oil filler plug PTO 1000E mode selector control solenoid valve PTO 1000N mode selector control solenoid valve PTO 540E mode selector control solenoid valve Rear PTO engagement control solenoid valve Differential lock engagement control solenoid valve Brake cooling solenoid valve LH wheel mount

10-142

Technical characteristics 2

1

3

D0068920

Fig. 134 - Main components 3/5 Key 1. 2. 3.

PTO speed sensor Rear PTO engagement control solenoid valve Transmission oil level warning light

1 4

2

3 D0068930

Fig. 135 - Main components 4/5 Key 1. 2. 3.

Parking brake lever Rear PTO speed sensor Oil filler plug for final reduction gear unit 10-143

Technical characteristics 1 4

2

3 D0068930

Fig. 135 - Main components 4/5 4.

Auxiliary hydraulic oil tank level warning light

10-144

Technical characteristics

3

1

4

2

5

1

3

D0068940

Fig. 136 - Main components 5/5 Key 1. 2. 3. 4. 5.

Auxiliary hydraulic oil tank drain plug Transmission oil drain plug Planetary reduction gearbox oil drain plugs Rear axle differential oil drain plug Rear PTO oil drain plug

10.3.3 - Transmission (60 Km/h) (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Introduction

10-145

Technical characteristics l

The tractors in this series are equipped with an infinitely variable hydrostatic/mechanical POWER SPLIT transmission The most important characteristic of this transmission is the ability to control and manage tractor speed from 0 to 60 Km/h in relation to operator commands and the traction strain to which the tractor is subjected Transmission management is fully automatic and controlled by an electronic control unit The transmission can be divided into the following sections: m A. Gearbox B. Rear axle C. Rear PTO D. Auxiliary hydraulic oil tank

A

B

C

D

D0068890

Fig. 136 - Transmission section

10-146

Technical characteristics Main components

3

1

2

D0068900

Fig. 136 - Main components 1/5 key 1. 2. 3.

Complete hydrostatic transmission assembly Oil filler plug for final reduction gear unit PTO output shaft

10-147

Technical characteristics

3 1

2

4 5

6

9

7

8

10 2 11

D0068910

Fig. 136 - Main components 2/5 Key 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Complete hydrostatic transmission assembly Brake device RH wheel mount Oil filler plug PTO 1000E mode selector control solenoid valve PTO 1000N mode selector control solenoid valve PTO 540E mode selector control solenoid valve Rear PTO engagement control solenoid valve Differential lock engagement control solenoid valve Brake cooling solenoid valve LH wheel mount

10-148

Technical characteristics 2

1

3

D0068920

Fig. 136 - Main components 3/5 Key 1. 2. 3.

PTO speed sensor Rear PTO engagement control solenoid valve Transmission oil level warning light

1 4

2

3 D0068930

Fig. 136 - Main components 4/5 Key 1. 2. 3.

Parking brake lever Rear PTO speed sensor Oil filler plug for final reduction gear unit 10-149

Technical characteristics 1 4

2

3 D0068930

Fig. 136 - Main components 4/5 4.

Auxiliary hydraulic oil tank level warning light

10-150

Technical characteristics

3

1

4

2

5

1

3

D0068940

Fig. 136 - Main components 5/5 Key 1. 2. 3. 4. 5.

Auxiliary hydraulic oil tank drain plug Transmission oil drain plug Planetary reduction gearbox oil drain plugs Rear axle differential oil drain plug Rear PTO oil drain plug

10-151

Technical characteristics 10.3.4 - System diagram (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Cartridge

SG C

ZW

E

HA

ZA

R

GS HY

K1

P

K2

KR

B

ZK

K4 K3

KV

D B

nMotor

nSt1_2

P1P2

P3 P4

nSt3_4

nPTO

nAbtrieb1 nAbtrieb2

P5 P6

P A S

F1

F2

R

Fig. 137 - Cartridge Table 92 Section

Description

S

Accumulator planetary gear unit

F1

4 Sections - Planetary reduction unit with dog clutches

F2

2 Sections - Planetary reduction unit with dog clutches

HY GS

Hydrostatic gearbox Lubrication and system pressure pump

Components

Planetary gear P1 Planetary gear P2 Ranges I-IV Planetary gear P3 Planetary gear P4 K1 clutch K2 clutch K3 clutch K4 clutch Forward/reverse ranges Planetary gear P5 Planetary gear P6 Clutch KV Clutch KR

Table 93 Designation

ZW C E

10-152

Description

Connector housing between input shaft (drive shaft nEngine) and PTO transmission Cartridge Engage/disengage system (rear axle)

Technical characteristics Designation

R P B D A ZA ZK HA SG

Description

Rear wheel axle Rear planetary gear unit axle Brake Rear axle of differential with lamellar clutch 4WD clutch PTO transmission PTO clutch Rear axle Gearbox

Transmission with cartridge Continuously variable hydrostatic/mechanical power split transmission. Gearbox with cartridge Gearbox l l l

Drive shaft for vehicle transmission and for PTO transmission Output to rear axle Transmission for front wheel drive (DT - selectable under load) integrated in transmission. m Transmission for front wheel drive with oil bath lamellar clutch, disengaged electrohydraulically and engaged mechanically by Belleville washers. m The front axle transmission is incorporated completely in the engine sump, but sealed to prevent fluid pressure loss.

Cartridge l

Selector, engaged automatically throughout entire range of forward and reverse speeds without interrupting power transmission, consisting of: m Accumulator planetary reduction unit 2 planetary gears m Planetary reduction unit for ranges I-IV 2 planetary gears with 4 dog clutches The dog clutches are synchronised. These clutches are engaged by system pressure and disengaged by Belleville washers. m Planetary reduction unit for forward/reverse ranges 2 planetary gears with 2 dog clutches The dog clutches are synchronised. These clutches are engaged by system pressure and disengaged by Belleville washers.

Hydrostatic gearbox l

Variable displacement pump and fixed displacement motor. m Actuated by stepper motor with hydraulic regulator to compensate for high pressure feedback effects.

Gearbox electronics l

Including transmission sensors for controlling and regulating the transmission via the TCU (electronic transmission control unit)

Transmission hydraulics (with independent fluid delivery system) l

With integrated pressure and lubrication circuits and oil filtration m Transmission and lubrication pump m Control hydraulics m Pick-up filter m Pressurized filter

Transmission control TCU l

Transmission Control Unit

VDC l

Vehicle Control Unit

Driving characteristics

10-153

Technical characteristics l l l

l l l l

Transmission ratio varied continuously to maintain optimum vehicle speed independently of engine speed. Greater operating comfort. A choice of different operating modes for different applications: constant vehicle speed for precision applications, harvesting and pulling; constant engine speed for working with PTO. Automatic guidance system which keeps engine power and torque at optimum fuel efficiency. Increased yield per hectare by making optimum use of the power available. Reduced emissions through optimised engine management. Approximately equivalent draft in both forward and reverse.

Maximum gradient at operating temperature and with max. oil level l

l

Uphill/downhill m 25° Left/right m 35°

Rear axle HA = rear axle P = planetary gear B = brake D = differential with lamellar clutch

Fig. 138

Table 94 PTO rotation speed (rpm)

540 E 1000 1000 E l l l

Engine speed (rpm)

1580 1943 1605

Engine power (kW)

100 171 171

Rear axle differential with electrohydraulically actuated lamellar clutch. Final output with simple planetary reduction unit. Brakes. m Service brakes - Hydraulically actuated integrated oil bath lamellar brakes. - Lubrication oil disabled for transfer. m Parking brakes - Mechanically actuated integrated oil bath lamellar brakes.

PTO E = PTO transmission ZK= PTO clutch ZS= PTO output shaft

Fig. 139

10-154

Technical characteristics l

PTO clutch m Oil bath PTO coupling clutch with electrohydraulic engagement and thrust spring disengagement. Activate arms with link for mechanical drive.

10.3.5 - Description of function (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Description of selector function

On one side, torque from the input shaft drives the ring gear of the accumulator planetary gear set via a face gear, providing purely mechanical power transmission. A hydrostatic unit is driven simultaneously by another face gear on the rear input shaft. Within the unit, the fixed displacement pump is driven directly by the oil flow delivered by the variable displacement hydrostatic pump. The swashplate inside the hydrostatic pump is moved electrohydraulically to alter both the speed and direction of rotation of the hydrostatic motor. By rotating the regulator unit on the pump, the speed of the hydrostatic motor can be varied within a range from the maximum negative value of the hydraulic pump to the maximum positive value of the pump. Torque from the hydrostatic motor is transmitted via a face gear to the central pinion on the accumulator planetary gear set. To ensure adequate gear spacing and limit the hydrostatic power element, a planetary reduction unit is included for ranges I-IV, with four different mechanical ratio ranges. Four dog clutches enable the use of the four ranges in both forward and reverse operation. A forward/reverse planetary reduction unit is connected after the continuously variable range gearbox. Direction inversions are performed by 2 integrated dog clutches. By operating the KV (forward) and KR (reverse) dog clutches simultaneously, direction inversion manoeuvres are performed with no interruption in drive through the transmission, which therefore remains engaged throughout the manoeuvre.

10-155

Technical characteristics

Fig. 140

Table 95 Colour

10-156

Pos. No.

Description

1

Input speed nEngine (mechanical)

2

Input speed nHydrostatic (hydrostatic)

3

Input speed - planet gear carrier in accumulator planetary reduction unit

4

Input speed - central pinion in accumulator planetary reduction unit

5

Input speed - ring gear in accumulator planetary reduction unit

-

Output speed, ranges I-IV

-

Reverse output speed

Technical characteristics Colour

-

Pos. No.

Description

-

Output to rear axle

P1-P6 K1-K4 KV KR nEngine nSt1 2 nSt3 4 nOutputs (1 and 2)

Planet gear carriers P1, P2, P3, P4, P5 and P6 Clutches K1, K2, K3 and K4 Forward drive clutch Reverse drive clutch V Inductive transducer measuring input speed from engine Inductive transducer measuring planetary gear unit P1/P2 output speed Inductive transducer measuring K3/K4 clutch output speed Inductive transducer measuring output speed

STD ranges (Standard) Table 96

Power shift planetary gear sets Clutches P1 P2 P3 P4 P5 P6 K1 K2 K3 K4 KV Forward X X X X X X X X X X X X X X X X X Reverse: X X X X X X X X X X X X X X X X X X X X X (*) = Speeds calculated with theoretical tyre diameter and without excessive transmission slippage.

-

KR X X X X

Speed* Km/h 0.00-9.07 9.07-16.58 16.58-31.89 31.89-58.33 0.00-8.18 8.18-14.96 14.96-28.79 28.79-52.64

KR X X X X

Speed* Km/h 0.00-7.75 7.75-14.16 14.16-27.24 27.24-49.82 0.00-6.99 6.99-12.78 12.78-24.58 24.58-44.96

H.D. (Heavy Duty) ranges Table 97

Power shift planetary gear sets Clutches P1 P2 P3 P4 P5 P6 K1 K2 K3 K4 KV Forward X X X X X X X X X X X X X X X X X Reverse: X X X X X X X X X X X X X X X X X X X X X (*) = Speeds calculated with theoretical tyre diameter and without excessive transmission slippage.

-

10-157

Technical characteristics Description of function of accumulator planetary gear unit The accumulator planetary gear unit consists of a set of 5 shafts with two input shafts and three output shafts, and allows the mechanical and hydrostatic power transmission components to overlap seamlessly. The ring gear (1) is driven directly by the input shaft via a face gear. The central pinion (2) is driven by the hydrostatic motor. Two narrow planet gears between the ring gear and the central pinion mesh with two broad planet gears to invert the direction of rotation of the planetary gear unit. These broad planet gears mesh on the output side with the ring gear (5) and the central pinion (4) to transmit the output power. Output power may also be transmitted through the shaft connected to the planet gear carrier (3). These three possible outputs from the accumulator planetary reduction unit (ring gear, central pinion and gear carrier) create four different multiplication ranges. This achieves the gear spacing between ratios necessary for vehicles with both high draft requisites and high final drive speeds.

4

2

5

1 3

Fig. 141

Power split by accumulator planetary gear unit The operating principle of power overlapping in an accumulator planetary reduction unit is illustrated by the three points highlighted in the following figure: The hydrostatic power component is transmitted via the central pinion (2). The central pinion is driven by the hydrostatic motor. By adjusting the swashplate on the hydrostatic pump, the rotation speed of the central pinion may therefore be varied within a range from the maximum possible counter-rotating speed to the same speed and direction as the ring gear. If the output power is transmitted via the ring gear of planetary reduction unit P2, by configuring the gear ratios appropriately, the speed of the ring gear P2 may be varied from zero (active hold) up to the maximum possible speed (synchronisation between central pinion (2) and ring gear (1)), independently of engine speed. This functionality makes it possible to actively hold the vehicle in a stationary position even under load, as well as ensuring smooth starts without “Stick-Slip” effects, even in extreme conditions. State I

1

Output 0% Mechanical +100% Hydrostatic -100%

2

Fig. 142

State II

1

Output 50% Mechanical +100% Hydrostatic 0%

2

Fig. 143

10-158

Technical characteristics State III

1

Output 100% Mechanical +100% Hydrostatic +100%

2

Fig. 144

10.3.6 - Transmission control (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Function

The S-Matic transmission is fed with pressurised oil from a system pump unit consisting of a variable displacement pump and a fixed displacement lubrication pump. The system circuit (system pressure) feeds the hydrostatic transmission, the 3/2 way solenoid valves for the clutches and front wheel drive, and the 20 bar circuit. The 20 bar circuit feeds the deviators for the differential locks, the PTOs and the external deviators. Oil from the lubrication pump is routed through the radiator. The radiator is bypassed if the radiator pressure differential limiting valve exerts excessive resistance, and the oil is sent directly to the lubrication circuit. Lubrication oil is sent via lines from the radiator return line to the lubrication unions and to the lubrication pressure limiting valve. The lubrication circuit feeds the selector, the rear differential, the PTO transmission and the PTO engagement clutch. Excess oil is dumped from the lubrication circuit by the lubrication pressure limiting valve and used to cool the brakes and lubricate the ring gear/pinion connection. At higher speeds, the delivery rate of the lubrication pump exceeds the demand for lubrication oil of the utilities. The resulting excess oil is discharged into the pick-up channel via brake lubrication pressure limiting valve situated after the pick-up filter, and aspirated again by the pumps. This allows the system to warm to operating temperature more rapidly in the case of cold starting. At higher operating temperatures and speeds, the pickup oil temperature is kept low by the proportion of the delivery flow routed through the radiator. Oil is picked up by the delivery pumps from the bottom of the gearbox sump via a pick-up filter with a filtration size of 15 µm (or 125 µm in bypass mode). The bypass valve opens at a pressure differential across the filter of 0.2 bar. The hydraulic system consists of two oil circuits: Lubrication circuit The lubrication pump (metering unit) sends all the oil through the oil radiator. At a resistance exceeding 6.5 bar between the unions to and from the radiator, a proportion of the flow is bypassed by the pressure differential limiting valve. The lubrication points are fed by the return flow from the radiator, which is also connected to the lubrication pressure limiting valve (calibrated at 2 bar). After leaving the lubrication pressure limiting valve, the oil is used to cool the braked and lubricate the ring gear/ pinion connection. If the pressure in this duct exceeds 2 bar, the excess oil flow in the pickup channel is deviated and aspirated again by the pumps. A proportion of the flow is always directed from the cooling circuit to the pickup channel, and only the quantities required by the utilities (losses from hydrostatic transmission, lubricant etc.) are aspirated from the oil sump via the pick-up filter. As a result, the oil heats rapidly in the event of cold starting, and once at operating temperature, the temperature of all the oil aspirated is lower than the temperature in the oil sump. At temperatures below 65°C, the operating temperature regulator system sends only a part of the oil to the radiator. At oil temperatures of 65°C and above, the cooling circuit is completely open, allowing the system to reach operating temperature rapidly. System circuit The variable displacement pump (rotary vacuum pump) delivers the quantity of oil necessary to cover hydrostatic transmission losses (variable displacement axial pump + variable displacement axial piston motor) and the hydrostatic transmission flush volume, and to feed the directional solenoid valves for the clutches and the 20 bar circuit, which in turn feeds the clutches with pressurised oil. The hydrostatic transmission losses increase with increasing load, while the hydrostatic transmission flush volume is evacuated by the low pressure difference between the hydrostatic transmission and the tank, and is used to cool and lubricate the gear teeth (on hydrostatic motor side). The flow of flush oil is generated by a low hydrostatic pressure differential. Oil for this utility is directed through 10-159

Technical characteristics the filter (ß10 µm(c) = 200) under pressure and, in the event of high oil viscosity, is deviated via a bypass valve. The bypass valve opens at a pressure differential across the filter of 7 bar. At low temperatures, the pressure differential across the filter may reach values as high 10 bar. A check valve with an aperture pressure of 0.5 bar is installed after the pressurised filter. This valve prevents backflow returning through the filter to protect the filter element.

System diagram A = Valve block II Clutch solenoid valves. B = Valve block I Filter unit. C = Valve block IV Front wheel drive solenoid valve. D = Valve block III Pressure reducing valve solenoid valve.

Fig. 145

Sensors Inductive transducer 2 = Engine speed (n Engine) 3 = P1/P2 planet gear carrier speed (n St1_2)

Fig. 146

Inductive transducer 1 = Output speed (n Output 1 and 2) 4 = P3/P4 planet gear carrier speed (n St3_4)

Fig. 147

10-160

Technical characteristics Inductive transducer 5 = PTO output shaft speed

Fig. 148

Pressure sensors 1 = system pressure 2 = lubrication pressure

Fig. 149

Delivery valves Directional valves Filter Switches Electric deviator

10-161

Technical characteristics 10.4 - Front axle

10.4.1 - Front axle - Version with disc brakes

Fig. 150 - Front axle - Version with disc brakes Characteristics key l l l

Track (A): 1900 mm Toe-in: See drawing Overall drive ratio (pinion revolutions/wheel revolutions): 17,60/1

10-162

Technical characteristics Table 98 Steering angle “B”

30° 35° 40° 45° 50° 53°

Dimension “C”

79 mm 66 mm 52 mm 37 mm 23 mm 16 mm

Components key 1. 2. 3. 4. 5.

Connection for differential lock engagement Connector for steering angle sensor Differential oil filler and level inspection cap Differential drain plug Oil filler and drain plug for final reduction gear unit

10-163

Technical characteristics 10.5 - Bodywork - Cab - Platform 10.5.1 - Air conditioning system Charging the A/C system -

Table 99 2,000 g. 200 g.

R-134A Refrigerant gas: SUN-OIL SP20 oil:

System diagram, general

2

3

1a

1

4 8

5

A

7 6 9 Fig. 151 - System diagram, general Colour key l l l

A = Low gas pressure B = High gas pressure C = High liquid pressure

10-164

B C

Technical characteristics Table 100 Position

Description

1

Compressor

1a

Pulley with electromagnetic clutch

2

Condenser

3 3rd 4

Liquid reservoir (Dryer component) Dryer Pressure switch

5 6

Expansion valve Evaporator

7 8

Temperature sensor Fan

9

Air shroud

Notes

Draws in refrigerant in the gas phase from the evaporator and compresses it. During this procedure the refrigerant tends to heat up (pressure increase) The compressor is driven via a V-belt, pulley, and electromagnetic clutch. When the electromagnetic clutch is disengaged the compressor is decoupled from the drive In the condenser the compressed refrigerant is cooled, thus being transformed to a liquid state (i.e. the gas condenses) Collects liquid refrigerant Removes any moisture (water) present in the refrigerant 2 or 3 stage switch used to disengaged the compressor electromagnetic clutch when the pressure in the refrigerant circuit is too high or too low, or to engage / disengage the supplementary electric fan mounted in front of the condenser Here the refrigerant expands and evaporates completely so that it is transformed into a gas. The necessary energy (heat) for this process is removed from the ambient air that flows through the evaporator fins and is hence cooled. The cooled air is drawn in by the fan and delivered to the cab Measures the temperature at the coldest point of the evaporator Draws in cold air through the evaporator and routes it to the interior of the cab -

10-165

Technical characteristics 10.5.2 - Supplementary heating - Webasto - General description General description

4

3

r

e Th

2

9 mo

0S 5

1

6 7 9 11

Fig. 152 - Thermo 90 S heater Key 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Combustion air fan Fuel connection Temperature sensor Temperature limiter Heat exchanger Coolant inlet Circulation pump Coolant outlet Exhaust gas outlet Combustion air inlet ECU (may also be situated externally, within vehicle).

10-166

10

8

Technical characteristics

4 3 1

2 5

6

11

9

8

7

10

Fig. 153 - Thermo 90 ST heater Key 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Combustion air fan Fuel connection Temperature sensor Temperature limiter Heat exchanger Coolant inlet Circulation pump Coolant outlet Exhaust gas outlet Combustion air inlet Control unit

The Thermo 90 S and Thermo 90 ST water heaters work in conjunction with the heating system of the vehicle to: l l l

heat the cab defrost the windows and screens of the vehicle and to pre-heat a water-cooled engine.

The water heater functions independently from the engine of the vehicle and is connected to the cooling system, the fuel system and the electrical system of the vehicle. The heater, an evaporator system, is controlled to operate intermittently by a temperature sensor. The output of the burner is adjusted between 1.8 and 7.6 kW (for both diesel and petrol fuelled heaters) in relation to the discrepancy between the effective coolant temperature measured by the temperature sensor and the nominal temperature value. When a parti10-167

Technical characteristics cular high thermal output is needed (engine pre-heat), diesel fuelled heaters are capable of producing a maximum of 9.1 kW for a maximum period of 2 hours after activation. Thermo 90 S and Thermo 90 ST heaters consist essentially of the following components: l l l l

combustion air fan heat exchanger burner insert with burner tube circulation pump

The heater is controlled and monitored by: l l l l l

an external ECU a flame sensor a glow plug a temperature sensor a temperature limiter installed in the device itself

In the case of the Thermo 90 S heater, the ECU may also be fitted onto the combustion air fan with a flange. The Thermo 90 ST heater is supplied with the ECU already mounted onto the combustion air fan with a flange. Fuel delivery is controlled by an external metering pump. Combustion air fan The combustion air fan delivers the air necessary for combustion to the combustion air inlet of the burner insert.

Fig. 154

Heat exchanger Inside the heat exchanger, the heat generated by combustion is transferred to the cooling circuit. l l

1

Temperature limiter (1) Temperature sensor (2) 2

Fig. 155

Temperature sensor The temperature sensor measures the coolant temperature at the coolant outlet of the heater as an electrical resistance value. This signal is received and processed by the ECU. Temperature limiter The (Bimetal) overheat protection device prevents the heater from operating at excessively high temperatures. The overheat protection device is activated when the heat exchanger exceeds a temperature of 127 ±7 °C, and cuts out the heater. Burner insert In the burner insert, fuel is distributed via the cross section of the burner into the burner tube.

10-168

Technical characteristics Glow plug The glow plug ignites the fuel-air mixture when the heater is switched on. The glow plug is an electrical resistor situated inside the burner insert facing towards the flame source. l l l

1 2

Burner insert (1) Glow plug (2) Flame sensor (3)

3

Fig. 156

Flame sensor The flame sensor is a low voltage PTC Ohmic resistor with variable resistance in relation to the temperature produced by the flame. The signals are received and processed by the ECU. The flame sensor monitors the state of the flame throughout the entire operation of the heater. Burner tube The fuel/air mixture combusts in the burner tube, heating the heat exchanger.

Fig. 157

Circulation pump The circulation pump delivers coolant to the vehicle circuit or to the heater circuit. The pump is activated by the ECU and continues to run throughout the entire operation of the heater, even during temperature regulation standby states.

Fig. 158

Control unit The ECU is the central component controlling combustion and the operation of the system as a whole. The ECU is mounted onto the combustion air fan via a flange, although in the case of the Thermo 90 S, it may also be installed externally, inside the vehicle. Metering pump An external metering pump delivers and meters the fuel to the heater. This pump also acts as a cut-off valve when the heater is switched off. The magnetic coil of the metering pump receives control signals from the microprocessor of the ECU.

10-169

Technical characteristics 10.5.3 - Supplementary heating - Webasto - Description of operation Description of operation

Functions of heater in ADR vehicles The heater is switched on with the relative switch

Fig. 159 - Operating process of Thermo 90 S and ST Key 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Power on Component query cycle 40 sec. pre-heat cycle (with controlled interval pulses) Metering pump, 5-7 sec. delivery (1) Metering pump / Partial load (1/4) Flame sensor detection Stabilisation period Full load Vehicle fan “On” Adjustment range Temperature regulation standby Flame sensor “cold” (0) End of inertial operating state 15 -20 sec. pre-heat cycle (with controlled interval pulses) Metering pump, 5-7 sec. delivery (1) Metering pump / Partial load (1/4) Flame sensor detection Stabilisation period Drop in coolant temperature Full load Power off (inertial operation) Flame sensor “cold” (0)

10-170

Technical characteristics

Fig. 159 - Operating process of Thermo 90 S and ST 23.

End of inertial operating state l l l l l l l l

A - Glow plug B - Metering pump C - Combustion air fan D - Flame sensor E - Indicator lamp F - Circulation pump G - Vehicle fan * If combustion is not detected, the start cycle is repeated automatically (20 second pre-heat with controlled interval pulses followed by 90 second safety period)

Power on When the operator presses the “Immediate heating” button, the indicator lamp on the pre-selector timer illuminates or when the system is switched on from the switch, the indicator lamp incorporated in the switch itself illuminates. The system activates the circulation pump, glow plug and combustion air fan. Heating Combustion is initiated after approximately 60-140 seconds. Automatically controlled heating now commences, with the heater operating at full load for a maximum of 2 hours. The vehicle heating system fan only activates when the heat exchanger (coolant) has heated sufficiently. Once the predetermined nominal operating temperature is reached (see regulation temperature table), the heating output of the burner is reduced gradually and precisely to reach the minimum operating partial load. Temperature regulation function The coolant temperature continues to increase until the temperature regulation standby threshold is reached. The heater now enters standby mode. The circulation pump, vehicle heating fan and indicator lamp remain active even during the temperature regulation 10-171

Technical characteristics standby state. The heater restarts when the coolant has cooled to the preset reactivation temperature. Diesel heaters If after reaching the nominal value, the water temperature in the heater exceeds the nominal value without reaching the temperature regulation standby threshold, and then drops again to the nominal value within 10 minutes, the heater output is increased to 9.0 kW again. Once the nominal temperature has been reached, the heater will only reactivate automatically in 7.6 kW heating mode. Petrol heaters The maximum power output is always 7.6 kW with petrol heaters. Power off When the heater is switched off, the indicator lamp on the pre-selector timer/switch extinguishes. Combustion is stopped and the heater starts to operate in inertial mode. The circulation pump and combustion air fan continue to operate to cool the heater (inertial operation), and deactivate automatically after approximately 105 seconds. The operator may restart the heater at any time during inertial operation. Temperature regulation with the vehicle heating system fan may also be controlled by an ambient temperature thermostat. An ADR situation (forced shutdown) occurs in the following conditions: l l

the engine of the vehicle is switched off an external power consumer is connected to one of the electrical power sockets of the vehicle

In these cases, the resulting short duration inertial operation state ends after 20 seconds (Thermo 90 S) or 40 seconds (Thermo 90 ST). At the end of this period, the ECU is in “error lockout” state. Turn the On/Off switch to “Off” before turning the heater back on. The emergency cut-off switch must only be used in the event of real danger, as it switches the heater off immediately without a subsequent inertial operating state, and may cause the system to overheat.

10.5.4 - Supplementary heating - Webasto - Faults Fault diagnosis

Shutdown due to fault In the event of failed flame formation, fuel delivery continues for a maximum period of 240 seconds. In the case of the flame extinguishing during operation, fuel delivery continues for a maximum period of 240 seconds. In the event of overheating (temperature limiter triggered), fuel delivery is cut off. Once the cause of the fault has been resolved, the lockout state is reset by switching the heater off and on again. In the event of shutdown by the undervoltage protection system for more than 20 seconds, fuel delivery is cut off.

Table 101 Thermo 90 S and Thermo 90 ST 10.5 V - 0.5 V 21 V -1 V

12 Volts 24 Volts

Diagnosis in case of automatic shutdown due to fault for Thermo 90 S and Thermo 90 ST Check fuses and pin connectors. Heater with standard selector timer If the heater is equipped with the standard timer, any faults are indicated by an error message on the display of the selector timer:

Table 102 F F F F F F

01 02 03 04 05 06

F F

07 08

F

09

10-172

Failed start (after 2 attempts) Combustion cut-out Under or overvoltage Premature combustion detected Broken flame sensor connection or flame sensor short circuit Broken temperature sensor connection or temperature sensor short circuit Broken metering pump connection or metering pump short circuit Broken fan motor connection, fan motor short circuit or fan motor speed sensor fault Broken glow plug connection or glow plug short circuit

Technical characteristics F F

10 11

Overheating Broken circulation pump connection or circulation pump short circuit

Heater button In the case of a switch operated heater, the type of fault is indicated while the heater is operating in inertial mode by a flashing code indicated by the power-on lamp. To determine the error code, count the number of long flashes following the initial sequence of five short flashes:

Table 103 1x 2x 3x 4x 5x 6x 7x 8x

Failed start (after 2 attempted starts) Combustion cut-out Under or overvoltage Premature combustion detected Broken flame sensor connection or flame sensor short circuit Broken temperature sensor connection or temperature sensor short circuit Broken metering pump connection or metering pump short circuit Broken fan motor connection, fan motor short circuit or fan motor speed sensor fault Broken glow plug connection or glow plug short circuit Overheating Broken circulation pump connection or circulation pump short circuit

9x 10x 11x

10.5.5 - Supplementary heating - Webasto - Technical specifications Technical Data

Where limit values are not specified, a tolerance of ±10 % is applicable for the following technical specifications. This is the standard tolerance for heaters at an ambient temperature of +20°C and operating at rated voltage. Electrical components The ECU, combustion air fan and circulation pump motors, glow plug, switch and selector timer (for ADR operation, timer function is not applicable) are specific for 12 of 24 V voltages. The temperature limiter, temperature sensor and flame sensor are the same for both 12 and 24 V heaters. Fuel for Thermo 90 S / Thermo 90 ST Petrol Use the fuel specified by the manufacturer of the vehicle. The heater may operate with both leaded and unleaded petrol. Fuel for Thermo 90 S / Thermo 90 ST and Thermo 90 S-ADR /Thermo 90 ST-ADR (Diesel) Use the fuel specified by the manufacturer of the vehicle. No adverse affects of using additives are known. When the heater is fed from the same fuel tank as the vehicle, observe the indications of the vehicle manufacturer regarding fuel/additive mixtures. When changing over to cold weather fuel, run the heater for 15 minutes to fill the fuel line and pump with the new fuel.

Table 104 Heater

CE type approval mark Construction Heat flow

Operation

Thermo 90 S Petrol

Thermo 90 ST Petrol

Thermo 90 S Diesel Thermo 90 SADR

Thermo 90 ST Diesel Thermo 90 STADR

~S299 ~S298 Water heater with Ferro-Tec technology Max. adjustment 2.0 kW - 7.6 kW 9.1 kW 1.8 kW - 7.6 kW range Fuel petrol diesel Fuel consumption Max. adjustment 0.25 l/h -1.0 l/h 1.1 l/h 0.19 l/h - 0.9 l/h range Rated voltage 12 Volts 12 or 24 Volts Operating voltage range 10 ... 15 Volts 10 ... 15 or 20 ... 30 Volts Rated power absorption with circu- Max. adjustment 37 W - 83 W 90 W 37 W - 83 W lation pump active (without vehicle range fan)

10-173

Technical characteristics Heater

Permitted range: Heater

Operation

ambient

Thermo 90 S Petrol

Thermo 90 ST Petrol

temperature

- operation -in storage Control unit - operation -in storage Metering pump - operation -in storage Permitted operating overpressure Low (heat transfer fluid) Fill volume of heat transfer fluid Max. incoming combustion air temperature Minimum quantity in circuit Flow capacity of circulation pump at 0.15 bar CO2 in exhaust gas (permitted oper- Low ating range) CO2-value at approximately +20 °C Low and altitude above sea level Heater dimensions (tolerance ± 3 mm) * ECU mounted on heater Weight

Thermo 90 S Diesel Thermo 90 SADR

-40° ... +110 °C (90°C with ECU mounted on heater) -40° ... +110 °C (90°C with ECU mounted on heater) -40° ... +75 °C -40° ... +85 °C -40° ... +75 °C -40° ... +85° C -40° ... +20° C -40° ... +40 °C -40° ... +85 °C 2.0 Bar

6.00 l 1,650 l/h 10 ... 12.0 Vol .-% 0 m: 10 % / 500 m: 10.6 % / 1,000 m: 11.3 % Length 310 (355*) mm Width 131 mm H 232 mm 4.8 kg

Length 307 (352*) mm Width 131 mm H 232 mm

Length 310 (355*) mm Width 131 mm H 232 mm

General information

These wiring diagrams show the possible connection solutions for the Thermo 90 ST heater with: l l l

standard selector timer standard selector timer and separate circulation pump control ADR configuration with switch ADR configuration with switch, without power take off

10-174

-40° ... +85 °C

0.15 l +40 °C

10.5.6 - Supplementary heater - Webasto - Wiring diagrams

l

Thermo 90 ST Diesel Thermo 90 STADR

Length 307 (352*) mm Width 131 mm H 232 mm

Technical characteristics

ϑ

7,5 - 15 m < 7,5 m 0,75 mm 2 1,0 mm 2 1,0 mm 2 0,75 mm2 1,0 mm 2 1,5 mm 2 1,5 mm 2 2,5 mm 2 4,0 mm 2 2,5 mm 2 6,0 mm 2 4,0 mm 2

ϑ

COLOURS TABLE bl

Blue

sw Black

br

Brown

vi

ge Yellow gn Green or Orange

Violet

ws White Red rt

Fig. 160 - Wiring diagram with standard selector timer Table 105 1

Temperature setting (water outlet temperature):

2

Selector timer P2: with positive on connection 10 connection 10 open

3 4

Vehicle fuse Vehicle fan switch

see table “Supplementary heating - Webasto - Description of operation - Operating process of Thermo 90 S and ST” = continuous operation with immediate heating = user settable programmable heating period (from 10 min to 120 min); default setting 120 min

Table 106 Pos.

A1 A2 B1 B2 B3 B4 E F1 F2 F3

Designation

Heater Control unit Flame sensor Temperature sensor Temperature limiter/overheat protection Ambient temperature thermostat Glow plug 20A fuse 5A fuse 20A fuse

Note

Flat fuse SAE J 1284 Flat fuse SAE J 1284 Flat fuse SAE J 1284 10-175

Technical characteristics Pos.

Designation

H1 H3 H6

“Heating” symbol on display Symbol lighting Red LED

K5 M1 M2 M3 P2 S8 X1 X2 X3 X4 X5 X6 X8 X9 X10 X11 Y1

Relay Engine Engine Engine Standard selector timer Push-on/push-off button Pin connector, 4 poles Pin connector, 2 poles Pin connector, 2 poles Pin connector, 2 poles Pin connector, 2 poles Pin connector, 2 poles Pin connector, 12 poles Pin connector, 12 poles Pin connector, 2 poles Pin connector, 2 poles Metering pump

Note

Power-on indicator lamp (pos. P2) Light (pos. P2) Lighting for heating button, ready state indicator and power on control (pos. P2) for vehicle fan Combustion air fan Circulation pump Vehicle fan for heater pre-selection Immediate heating button on remote control in pos. A2 in pos. A2 in pos. A2 in pos. A2 in pos. A2 Diagnosis in pos. A2 (ST 2) in pos. P2 W-Bus diagnosis on Y1 Fuel pump for heater

ϑ

7,5 - 15 m < 7,5 m 0,75 mm 2 1,0 mm 2 1,0 mm 2 0,75 mm2 1,0 mm 2 1,5 mm 2 1,5 mm 2 2,5 mm 2 4,0 mm 2 2,5 mm 2 6,0 mm 2 4,0 mm 2

ϑ

COLOURS TABLE bl

Blue

sw Black

br

Brown

vi

ge Yellow gn Green or Orange

Violet

ws White Red rt

Fig. 161 - Wiring diagram with standard selector timer and separate external circulation pump control

10-176

Technical characteristics Table 107 1

Temperature setting (water outlet temperature):

2

Selector timer P2: with positive on connection 10 connection 10 open

3 4

Vehicle fuse Vehicle fan switch

see table “Supplementary heating - Webasto - Description of operation - Operating process of Thermo 90 S and ST” = continuous operation with immediate heating = user settable programmable heating period (from 10 min to 120 min); default setting 120 min

Table 108 Pos.

A1 A2 B1 B2 B3 B4 E F1 F2 F3 H1 H3 H6

Heater Control unit Flame sensor Temperature sensor Temperature limiter/overheat protection Ambient temperature thermostat Glow plug 20A fuse 5A fuse 20A fuse “Heating” symbol on display Symbol lighting Red LED

Designation

Note

K3 K5 M1 M2 M3 P2 S8 S9 X1 X2 X3 X4 X5 X6 X8 X9 X10 X11 Y1

Relay Relay Engine Engine Engine Standard selector timer Self resetting switch Switch Pin connector, 4 poles Pin connector, 2 poles Pin connector, 2 poles Pin connector, 2 poles Pin connector, 2 poles Pin connector, 2 poles Pin connector, 12 poles Pin connector, 12 poles Pin connector, 2 poles Pin connector, 2 poles Metering pump

Flat fuse SAE J 1284 Flat fuse SAE J 1284 Flat fuse SAE J 1284 Power-on indicator lamp (pos. P2) Light (pos. P2) Lighting for heating button, ready state indicator and power on control (pos. P2) for circulation pump with external control for vehicle fan Combustion air fan Circulation pump Vehicle fan for heater pre-selection Immediate heating button on remote control Heating/External control for circulation pump in pos. A2 in pos. A2 in pos. A2 in pos. A2 in pos. A2 Diagnosis in pos. A2 (ST 2) in pos. P2 W-Bus diagnosis on Y1 Fuel pump for heater

10-177

Technical characteristics 10.6 - Hydraulic system

1110 cm3

10.6.1 - Hydraulic system

17

C d

T b a LS

PO = B

A

B’1

Z

Z

N

R

B1 30

90 bar

B2 T’ B’2

TB

T

Fig. 162 - Hydraulic system diagram (1/2) Key 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.

Suction line filter (160 µm) Gear pump (16 cc/rev) Priority valve Power steering Steering cylinders Transmission oil cooler Return line filter (20 µm) Front axle suspension distributor Front axle suspension cylinder (2) Ancillary utility distributor N° 4 Ancillary utility distributor n°3 Trailer braking valve Hitch distributor Hitch Power Beyond connection Free drain Ancillary utility distributor n°5 Ancillary utility distributor n°2 Ancillary utility distributor n°1 Control for front hitch or front loader Control for front loader or front rams Variable displacement pump Hydraulic oil reservoir Suction line filter (160 µm) Rear right-hand braking device Rear left-hand braking device

10-178

D0079720

1110 cm3

Technical characteristics

17

C d

T b a LS

PO = B

A

B’1

Z

Z

N

R

B1 30

90 bar

B2 T’ B’2

TB

T

D0079720

Fig. 162 - Hydraulic system diagram (1/2) 27. 28. 29. 30. 31. 32. 33.

Valve for air trailer braking Master cylinder From 20 bar transmission circuit Brake accumulator unit Front axle servo-brake valve Front right hand braking device Front left hand braking device

10-179

Technical characteristics

Fig. 163 - Hydraulic system diagram (2/2) Key 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

Transmission oil cooler Hydrostatic transmission assembly Pressure regulator Clutch solenoid valves assembly Hydrostatic unit 4WD and Park Lock engagement control solenoid valves assembly Park Lock device 4WD engagement clutch Suction line filter (15 µm) Transmission pumps assembly Delivery line filter Cooler circuit pressure limiting valve Lubrication circuit pressure limiting valve Brakes cooling circuit pressure limiting valve Rear axle Brakes cooling Rear differential locking and PTO solenoid valves assembly Rear PTO clutch cooling control valve Rear PTO clutch Differential lock To brakes control circuit

10-180

Technical characteristics 10.6.2 - 45 cc variable displacement pump

Fig. 164 - Variable displacement pump components and connections Connections l l l l

a - Port L - To gearbox b - Port X - From auxiliary distributor or services c - Port B - To auxiliary distributor (Port P) or services d - Port S - From boost pump

Function l l l l

Port L: drain Port X: LS signal Port S: pick-up Port B: delivery

Components 1. 2.

Load Sensing valve Pressure cut-off valve

Specifications l l l

Nominal flow rate: 45 cc/rev Rated operating pressure: 210 bar Maximum operating pressure: 250 bar

10-181

Technical characteristics

Fig. 165 - Variable displacement pump - section A-A Components 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

Shaft Seal ring Swashplate return spring Swashplate Positioning rod Control piston Cylinder block Shim Cover Bearing Flat disc Piston (x 9) Drive plate Shoe Taper roller bearing Pump body

10-182

Technical characteristics

Fig. 166 - Variable displacement pump - section B-B Components 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Load Sensing valve shutter Choke Collar Load Sensing valve springs Spring cover Adjuster screw Adjuster screw Spring cover Pressure cut-off valve springs Collar Choke (Ø 0.6 mm) (0.024 in.) Pressure cut-off valve shutter

10.6.3 - 63 cc variable displacement pump

Fig. 166 - Variable displacement pump components and connections Connections l l l l

a - Port L - To gearbox b - Port X - From auxiliary distributor or services c - Port B - To auxiliary distributor (Port P) or services d - Port S - From boost pump

Function l l l l

Port L: drain Port X: LS signal Port S: pick-up Port B: delivery

Components 1.

Load Sensing valve 10-183

Technical characteristics 2.

Pressure cut-off valve

Specifications l l l

Nominal flow rate: 63 cc/rev Rated operating pressure: 210 bar Maximum operating pressure: 250 bar

Fig. 166 - Variable displacement pump - section A-A Components 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

Shaft Seal ring Swashplate return spring Swashplate Positioning rod Control piston Cylinder block Shim Cover Bearing Flat disc Piston (x 9) Drive plate Shoe Taper roller bearing Pump body

10-184

Technical characteristics

Fig. 166 - Variable displacement pump - section B-B Components 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Load Sensing valve shutter Choke Collar Load Sensing valve springs Spring cover Adjuster screw Adjuster screw Spring cover Pressure cut-off valve springs Collar Choke (Ø 0.6 mm) (0.024 in.) Pressure cut-off valve shutter

10.6.4 - Hydraulic pump Function l

l

The rotation and torque transmitted to the pump shaft are converted into hydraulic energy and the flow of pressurised oil is regulated in accordance with the demand from the various actuators. Pump displacement can be varied by altering the swash plate angle.

Description l l

l l l

Cylinder block (3) is held by and joined to shaft (1) by broaching B. Shaft (1) is supported by the front and rear bearings. The end of piston (4) is spherical; piston shoe (5) is staked to form a single assembly. Piston (4) and shoe (5) together form a ball joint. Swash plate (2) has a flat surface A against which shoe (5) is pressed. Shoe (5) performs a circular movement. Pistons (4) stroke axially inside the cylinder bores in cylinder block (3). Rotation of cylinder block (3) pressurises the oil in the cylinder bores; valve plate (6) determines the inlet and outlet ports. The oil in each of the cylinder bores is drawn in and discharged through the openings in valve plate (6).

10-185

Technical characteristics

Fig. 167 - Hydraulic pump components

Operation Pump operation 1. 2.

Cylinder block (3) rotates with shaft (1) and piston shoe (5) slides over flat surface A. Swash plate (2) moves over cylindrical surface B; angle «a» between the axis of shaft (1) and axis X of swash plate (2) changes, altering the axial position of the pistons with respect to the cylinder block. Angle «a» is called the «swash plate angle». When axis X of swash plate (2) is at angle «a» to shaft (1) and consequently also to cylinder block (3), flat surface “A” acts as cam for shoe (5). As a result, as the shaft rotates, piston (4) strokes inside cylinder block (3), thereby creating a difference between volumes C and D and drawing in and discharging oil in a quantity equal to this difference in volume (D -- C=delivery). In other terms, when cylinder block (3) rotates, the volume of cylinder D is reduced, thereby forcing out the oil, while the volume of cylinder C is increased, thereby drawing oil into the bore.

10-186

Technical characteristics

Fig. 168 - Condition of the pump on completion of the suction stage in chamber D and the delivery stage in chamber C 1.

When axis X of swash plate (2) is parallel to the axis of cylinder block (3) (swash plate angle «a»=0), the difference between volumes C and D inside cylinder block (5) is zero and no oil is pumped. (In reality, swash plate angle «a», is never exactly equal to zero).

Fig. 169 - Condition of the pump when the difference between volumes C and D is equal to zero 1.

The pump delivery is therefore directly proportional to swash plate angle «a»

Flow rate control

10-187

Technical characteristics l

l

l

When the pump runs at a given speed, the quantity of oil delivered to the work ports is regulated by angle «a» of swash plate (2). The swash plate is maintained in the maximum displacement position by spring (7) in contrast with the positioning piston, which defines angle «a». When the pump operates below maximum pressure, angle «a» is controlled in such a way that differential pressure between pump outlet pressure and LS signal pressure is set to a certain value (control differential pressure). When the pump operates at maximum pressure, angle «a» is set in such a way as to guarantee the flow rate without exceeding maximum pressure. This means that angle «a» is set to a slightly lower value than that requested by the LS signal.

Fig. 170 - Flow rate control

10-188

Technical characteristics 10.6.5 - Load sensing valve, pressure cut-off valve

Fig. 171 - Valve components and connection to variable displacement pump Components 1. 2. 3. 4. 5. 6. 7. 8.

Load Sensing valve spool Load sensing valve spring Pressure cut-off valve spool Pressure cut-off valve spring Swash plate return spring Control piston Directional control valve Load

Operating principle Controls the angle of the pump swash plate l

l

The swash plate angle (and thus pump delivery) is controlled in such a way that the pressure difference ?PR between the pump delivery pressure PP and the delivery pressure to the actuator PLS at the work port of the directional control valve is maintained at a constant value. (?PR = Pump delivery pressure PP – Delivery pressure to actuator PLS ). If the pressure difference ?PR decreases relative to the pressure setting of the LS valve, the swash plate angle will increase. If the pressure difference ?PR increases, the swash plate angle will decrease. m For more detailed information on this mechanism, see the description of the «HYDRAULIC PUMP»

10-189

Technical characteristics

Fig. 172 - Operating diagram Components 1. 2. 3. 4. 5.

Control piston Directional control valve Pump delivery Pressure cut-off valve Load Sensing valve

Load sensing valve (LS) Function l

l

The LS valve controls the pump delivery according to the stroke of the directional control valve lever, i.e., according to the demand for oil flow from the actuators. The LS valve determines the demand from the actuators by way of the pressure difference ?PR between the pump delivery pressure PP and the pressure PLS at the outlet of the directional control valve; this difference is then used to control the delivery Q of the hydraulic pump. (PP, PLS and ?PR, are respectively: the pump delivery pressure, the pressure of the Load Sensing signal and the pressure difference between these two values).

10-190

Technical characteristics l

In other terms, the LS valve determines the pressure difference ?PR, generated by the flow of oil through the passage opened up by the directional control valve spool and controls the pump delivery Q so as to maintain a constant pressure difference. This means that the pump delivery is proportional to the demand from the directional control valve.

Operation l

The operation of the pump can be described in four main stages: m a. When the directional control valve is in neutral position m b. When a control valve lever is operated m c. When the delivery stabilizes m d. When the system enters a state of “saturation”

When the directional control valve is in «NEUTRAL» l

l

l

l

l

l

The pressure PLS of the LS from the control valve outlet enters chamber a of the LS valve spring; the pump delivery pressure PP enters the chamber b on the opposite side of the spool. The movement of the spool (1) is determined by the combination of the force created by the pressure PLS plus the force exerted by the spring (2) and by the force exerted in the opposite direction by the pressure PP. Before the engine is started, the control piston (6) is pushed by the spring (5) to the right (corresponding to the maximum swash plate angle). When the engine is started, all the control valve spools are in «NEUTRAL», the pressure PLS of the LS remains at 0 bar (0 psi) as no fluid is delivered from the control valve outlets and the signal is connected to drain. At the same, pump delivery pressure PP increases as there is no demand from the users. When the force exerted by pressure PP in chamber b balances the force exerted by spring (2), spool (1) moves to the right and allows the fluid at pressure PP to flow into chamber X of piston (6) by connecting passages c and d. The force exerted by the fluid pressure on the piston (6) overcomes the force of the spring (5). The control piston is thus pushed to the left, i.e. towards the minimum swash plate angle position. The pump delivery pressure PP stabilizes around the value of 22 bar (319 psi), which corresponds to the standby pressure.

Fig. 173 - Operating diagram When a control valve lever is operated 10-191

Technical characteristics l

l

l

When a control valve lever is shifted from the NEUTRAL position, this generates an LS signal corresponding to the pressure PLS. The LS signal pressure in chamber a moves the spool to the left, thereby connecting passages d and e. Chamber X is thus depressurised and the swash plate is moved to the maximum delivery position by the action of spring (5). System balance is restored when the pressure difference ?PR acting on the spool (1) balances the force exerted by the spring (2) and thus re-opens the connection between passages c and d.

Fig. 174 - Operating diagram When the delivery stabilizes l

l

l l l

l

When the pump delivery matches the demand from the directional control valve, the pump delivery pressure PP present in chamber b of the LS valve balances the combination of the forces exerted by the pressure PLS of the LS in chamber a and by the spring (6). On reaching the state of balance, piston (1) stops in an intermediate position. In this condition, the passage from chamber c to chamber d remains partially open so that the pressure is maintained in chamber d. A sufficient flow of fluid to balance the force exerted by spring (5) enters control piston (6). This state of balance is maintained by a stabilized flow of fluid from the choke g. The force of spring (2) is adjusted in such a way that piston (1) is balanced when PP?–?PLS?=??PR?=?22 bar (319 psi). In practical terms, pump delivery is made proportional to the aperture of the control valve, maintaining the pressure difference ?PR?=?22 bar (319 psi). This state is maintained until there is a change in the operating conditions (for example, a change in the engine speed, an increase or reduction in the demand for fluid flow or pressure, etc.).

10-192

Technical characteristics

Fig. 175 - Operating diagram When the system enters a state of saturation l

l

l

l

l

If the engine speed is reduced while one or more hydraulic actuators are in operation, pump delivery will also be reduced. Consequently the swash plate angle is changed to increase pump delivery. When the pump reaches its maximum displacement, and therefore the delivery can no longer be increased, the difference between the pump pressure PP and the Load Sensing pressure PLS (pressure difference ?PR) is reduced (“saturation” condition”). The pressure PLS in chamber a of the LS valve becomes almost equal to the pump pressure PP and the control piston (1) shifts to the left under the combined action of the pressure PLS and the spring (2). The piston thus closes passage c and opens the connection between passages d and e. The pressurised oil in chamber X of the control piston (6) flows through passages d and e and into the drain chamber of the pump; consequently the pressure in chamber X of the control piston (6) becomes equal to the drain pressure. The control piston (6) is therefore shifted to the right by the action of the spring (5), to the position corresponding to the maximum swash plate angle.

10-193

Technical characteristics

Fig. 176 - Operating diagram

Pressure cut-off valve (TP) Function l

The pressure cut-off valve determines the pump displacement at maximum delivery pressure.

10-194

Technical characteristics

Fig. 177 - Operating diagram Operation l

l

The pressure control valve monitors the pump delivery pressure, and when this reaches the set pressure limit, it reduces the pump delivery to the minimum, by-passing the action of the LS valve. Pump delivery is then regulated at the minimum value to ensure internal lubrication of the main auxiliary services pump and maximum pressure in the hydraulic system.

10.6.6 - Priority valve

Fig. 178 - Priority valve connections Connection l l l l l

Port CF - Delivery to power steering Port P - Valve supply Port PP - Valve pilot flow Port EF - Delivery to services Port LS - Load Sensing signal 10-195

Technical characteristics 10.6.7 - Power steering

LS

L

T

L

P

R

R

LS

P

T D0019310

Fig. 179 - Power steering connections Connections l l l l l

Port P: delivery Port T: outlet Port R: RH steering Port L: LH steering Port LS: Load Sensing signal

Characteristics l

l

Displacement: m Normal steering: 180 cc/rev m Emergency steering: 90 cc/rev Relief valve: 170-175 bar

10-196

Technical characteristics 10.6.8 - Hydraulic front axle suspension Description

The function of the hydraulic front suspension system is to absorb impacts when travelling over rough terrain and to keep the tractor body on an even keel on the road. The system is composed of: l l l l l

swinging axle support arm (1) position sensor (2) 2 suspension cylinders (3) Front suspension control valve (4) electronic control unit (5)

Fig. 180 - Front axle hydraulic suspension system

Front suspension control valve Function l

In addition to the primary function of enabling front axle suspension by charging the hydraulic-pneumatic accumulators that constitute the elastic elements of the system, the front suspension control valve also serves to control the raising and lowering of the front axle.

10-197

Technical characteristics

Fig. 181 - Front suspension control valve components Key 1. 2. 3. 4. 5. 6. 7. 8.

Accumulator Accumulator Cylinder extension solenoid valve Cylinder retraction solenoid valve Axle suspension control lock solenoid valve Cylinder pressure discharge valve (base side) Cylinder pressure discharge valve (top side) Relief valve (setting 250±7 bar)

10-198

Technical characteristics 10.6.9 - Servo-brake valve for front axle

Fig. 182 - Servo-brake valve for front axle Connections l l l l l

Port R - Valve supply Port N - Drain Port T - To front axle brakes Port B1 - Pilot valve Port B2 - Pilot valve

Specifications l l

Maximum braking pressure: 180 bar Maximum braking pressure: 60 bar

10-199

Technical characteristics 10.6.10 - Hydraulic trailer braking system - Italy version

Fig. 183 - Operating diagram Valve control lever in position “1”. l

l

l l

When lever (1) is in position “1” (valve activated) and the brake pedals are not pressed, there is a pressure of 12.5 bar (181.3 psi) available at port B. This pressure is supplied constantly to the trailer to release the parking brake. When the operator applies the tractor brakes, the pressure in the circuit pilots the braking valve and the pressure at port B increases proportionally to the pressure in the tractor braking circuit. When the operator engages the parking brake, solenoid valve (2) is energised; this nullifies the pressure at port B. The pressure at port B is directly proportional to the pressure in the tractor braking circuit (Y).

Valve control lever in position “O”, l

When lever (1) is in position “O” (valve deactivated), there is no pressure at port B. As a result, the pressure switch (4) detects the lack of pressure and illuminates the indicator light (3 on the instrument panel. In this condition, the pressure at port B remains null regardless of the pressure in the tractor braking circuit.

10-200

Technical characteristics

Fig. 184 - Hydraulic trailer braking system connections Connections l l l l l l

Port P - Valve supply Port B - To trailer brake Port T- Drain Port Y - Connection to tractor braking system Port E -Low braking pressure sensor Port N -To cooler

Characteristics l l l l

Maximum operating pressure at port N: 210 bar (3046 psi) Minimum constant pressure at port B: 12.5±2 bar (181.3±29 psi) Maximum pressure at port B: 130-135 bar (1885-1957.5 psi) Oil supply flow rate: 20-80 l/min (5.3 – 21.14 US.gpm)

10-201

Technical characteristics 10.6.11 - Hydraulic trailer braking system - Export version

Fig. 185 - Operating diagram l l

When the brakes are not applied there is no pressure at port B. When the operator applies the tractor brakes, the pressure in the circuit pilots the braking valve and the pressure at port B increases proportionally to the pressure in the tractor braking circuit.

10-202

Technical characteristics

Fig. 186 - Hydraulic trailer braking system connections Connections l l l l l

Port P - Valve supply Port B - To trailer brake Port T- Drain Port Y - Connection to tractor braking system Port N -To cooler

Characteristics l l l l

Maximum operating pressure at port N: 200 bar (3046 psi) Minimum constant pressure at port B: 0 bar (0 psi) Maximum pressure at port B: 130-150 bar Oil supply flow rate: 20-80 l/min (5.3 – 21.14 US.gpm)

10-203

Technical characteristics 10.6.12 - Steering gear pump - Version without compressor P

L D0059550

Fig. 187 - Steering gear pump connections Connections l l

Port L - inlet Port P - pressure outlet to services

Specifications l l

Displacement: 22.5 cc/rev (61.2 l/min) Maximum pressure: 200 bar (2900 psi)

10-204

Technical characteristics 10.6.13 - Steering gear pump - Version with compressor L

P

D0035150

Fig. 188 - Steering gear pump connections Connections l l

Port L - inlet Port P - pressure outlet to services

Specifications l l

Displacement: 22.5 cc/rev (61.2 l/min) Maximum pressure: 200 bar (2900 psi)

10-205

Technical characteristics 10.6.14 - Braking system Description

The braking system is composed of 4 braking devices (1 for each wheel) operated by a double hydraulic master cylinder with mechanical control. When the brake pedals are latched together, all the braking systems are operated simultaneously on all 4 wheels (front and rear). When the brake pedals are operated separately (latch disengaged), only the front brakes are applied and a single rear brake corresponding to the pedal that has been pressed (right pedal - right brake, left pedal - left brake). The front braking devices are operated simultaneously and independently by the brake pedal pressed (only one or both) thanks to the pilot valve that intercepts the oil from both master cylinders selecting the circuit with the higher pressure value as the pilot circuit. The pilot valve thus directs oil from the hydraulic services circuit to the front brakes, modulating the pressure according to the pilot pressure from the brake master cylinders.

Fig. 189 - Braking system diagram 1. 2. 3. 4. 5.

Front axle Master cylinder Pilot valve for front brakes Rear axle Disc brake calipers

10-206

Technical characteristics 10.6.15 - Master cylinder

2

1 3

T

P

R

L

D0055860

Fig. 190 - Master cylinder Key l l l l

1. 2. 3.

P - Brake master cylinder oil feed T - Tank R - Brake RH circuit connection R - Brake LH circuit connection Pump body RH circuit control rod LH circuit control rod

Technical data l l

Pistons stroke: 39 mm Displacement: max. 20 cc per circuit

10-207

Technical characteristics 10.6.16 - Remote control valve - 8-way version 2

3

4

5

6

7

1 8

A1 B1

A2 B2

P

P

T T

R

A

A3 B3

A4 B4

F

F

F

F

2

2

2

2

0

0

0

0

1

1

1

1

b

b

b

b

a

a

a

a

H

S

LS

P Y R

P

1

2

3

T T

4

5

6

7

8 D0059520

Fig. 191 - Remote control valve - 8-way version Key 1. 2. 3. 4. 5. 6. 7. 8.

End plate with pilot valve for electrically operated valve sections Valve section 1 Valve section 2 Manifold section Lift control section Valve section 3 Valve section 4 End plate with LS signal output

10-208

Technical characteristics 10.6.17 - Ancillary utility distributor - 10-way version 2

3

4

5

6

7

8

1 9

A1 B1

A2 B2

P

P

T T

R

A

A3 B3

A4 B4

A5 B5

F

F

F

F

F

2

2

2

2

2

0

0

0

0

0

1

1

1

1

1

b

b

b

b

b

a

a

a

a

a

H

S

LS

P Y R

T T

P

1

2

3

4

5

6

7

8

9 D0067650

Fig. 192 - Ancillary utility distributor - 10-way version Legend 1. 2. 3. 4. 5. 6. 7. 8. 9.

End plate with pilot valve for electrically operated valve sections Distributor section 1 Distributor section 2 Manifold section Lift control section Distributor section 3 Distributor section 4 Distributor section 5 End plate with LS signal output

10-209

Technical characteristics 10.6.18 - Remote control valve - 12-way version 2

3

4

5

6

7

8

9

1 10

A6 B6

A1 B1

A2 B2

P

P

T T

R

A

A3 B3

A4 B4

A5 B5

F

F

F

F

F

F

2

2

2

2

2

2

0

0

0

0

0

0

1

1

1

1

1

1

b

b

b

b

b

b

a

a

a

a

a

a

H

S

LS

P Y R

T T

P

1

2

3

4

5

6

7

8

9

10 D0059530

Fig. 193 - Remote control valve - 12-way version Key 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

End plate with pilot valve for electrically operated valve sections Valve section 6 Valve section 1 Valve section 2 Manifold section Lift control section Valve section 3 Valve section 4 Valve section 5 End plate with LS signal output

10-210

Technical characteristics 10.6.19 - Remote control valve - 14-way version 2

3

4

5

6

7

8

9

10

1 11

A7 B7

A1 B1

A6 B6

A2 B2

P

P

T T

R

A

A3 B3

A4 B4

A5 B5

F

F

F

F

F

F

F

2

2

2

2

2

2

2

0

0

0

0

0

0

0

1

1

1

1

1

1

1

b

b

b

b

b

b

b

a

a

a

a

a

a

a

H

S

LS

P Y R

T T

P

1

2

3

4

5

6

7

8

9

10

11 D0059540

Fig. 194 - Remote control valve - 14-way version Key 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

End plate with pilot valve for electrically operated valve sections Valve section 7 Valve section 6 Valve section 1 Valve section 2 Manifold section Lift control section Valve section 3 Valve section 4 Valve section 5 End plate with LS signal output

10-211

Technical characteristics 10.6.20 - Air trailer braking system - Italy version 5 3

4

2

7 8 1

1

6

10

9

11

12

D0078800

Fig. 195 - Trailer air braking diagram Components 1. 2. 3. 4. 5. 6. 7. 8. 9.

Compressed air reservoir Air compressor Internal combustion engine Pressure limiting valve (7.8 bar (113 psi)) Trailer quick hitch coupler Trailer braking valve Trailer parking brake control solenoid valve Quick pressure release valve Circuit pressure sensor

10-212

Technical characteristics 5 3

4

2

7 8 1

1

6

10

9

11

12

D0078800

Fig. 195 - Trailer air braking diagram 10. 11. 12.

Circuit pressure indicator Brake master cylinder Brake device

10-213

Technical characteristics 10.6.21 - Air trailer braking system - DE Export version 5 3

4

2

A B

7 8 1

1

6

10

9

11

12

D0078810

Fig. 196 - Air trailer braking system diagram - DE Export version Components 1. 2. 3. 4. 5. 6. 7. 8. 9.

Compressed air reservoir Air compressor Internal combustion engine Pressure limiter valve (7.8 bar/113 psi) with filter Trailer quick hitch coupler Trailer braking valve (2-way) Trailer parking brake control solenoid valve Quick pressure release valve Circuit pressure sensor

10-214

Technical characteristics 5 3

4

2

A B

7 8 1

1

6

10

9

11

12

D0078810

Fig. 196 - Air trailer braking system diagram - DE Export version 10. 11. 12.

Circuit pressure indicator Brake master cylinder Brake device l l

A: Red connector B: Yellow connector

10-215

Technical characteristics 10.6.22 - Air trailer braking system - CH Export version 7 A B

3

5

4

2

6 A B

9 10 1

1

8

12

11

13

14

D0078820

Fig. 197 - Air trailer braking system diagram - CH Export version Components 1. 2. 3. 4. 5. 6. 7. 8. 9.

Compressed air reservoir Air compressor Internal combustion engine Pressure limiter valve (7.8 bar/113 psi) with filter Trailer braking valve (1-way) Trailer quick hitch coupler Quick hitch coupling for trailer (CH Export version) Trailer braking valve (2-way) Trailer parking brake control solenoid valve

10-216

Technical characteristics 7 A B

3

5

4

2

6 A B

9 10 1

1

8

12

11

13

14

D0078820

Fig. 197 - Air trailer braking system diagram - CH Export version 10. 11. 12. 13. 14.

Quick pressure release valve Circuit pressure sensor Circuit pressure indicator Brake master cylinder Brake device l l

A: Red connector B: Yellow connector

10-217

Technical characteristics 10.6.23 - Compressor

Fig. 198 - Compressor components and connections Connections l l l

1. 2. 3. 4.

a. Port 0.1 - Compressor lubrication b. Port 0 c. Port 2 - Compressed air delivery Head Cylinders Flange Control shaft

Specifications l l l l

Bore: 85 mm Stroke: 42 mm Displacement: 238 cm³ Max. pressure: 8,5 bar

10-218

Technical characteristics l

Drive shaft end float: 0.1 to 0.8 mm

10.6.24 - Pressure cut-off valve

1

a

b

2

3

1

c

21

3 0.017.0166.4

Fig. 199 - Pressure cut-off valve Legend l

l

Components 1. Filter 2. Silencer 3. Electrical connection for heater Connections a - Port 1 - From compressor b. Port 21 - To compressed air reservoir c - Port 3 - Compressed air pressure release vent

Specifications l l l

Cut-out pressure: 8.3 ± 0.4 Bar Operating pressure: 0-7 - 0.5 bar Relief valve setting: ≤ 14.5 bar (1a 100 l/min) 10-219

Technical characteristics l l

Heating on temperature: 7±6 °C Heating off temperature: 29.5±3 °C

10.6.25 - Quick pressure release valve

11

11

12

2

2

3

11

12 2

3

0.019.8598.4

Fig. 200 - Quick pressure release valve Connections l l l l

Port 2: To trailer brake quick coupling Port 3: Drain Port 11: From trailer parking brake solenoid valve Port 12: From trailer air brake valve

10-220

Technical characteristics 10.6.26 - Pressure limiting valve

21

1 1- 2

3

7,8±0,2 bar

1

21 0

12 + 2 bar

22

3

1- 2 D0004690

Fig. 201 l l l

Port 1 - From compressor Port 3 - Excess pressure vent Port 21 - To compressed air reservoir

Specifications l l l

Cut-out pressure: 7.8±0.2 bar (113±2.9 psi) Operating pressure: 0.6÷1 bar (8.7 - 14.5 psi) Relief valve setting: 12...14 bar (174...203 psi)

10-221

Technical characteristics 10.6.27 - Trailer air braking valve (2-way)

Fig. 202 - Trailer air braking valve (2-way) components and connections Components 1. 2.

Parking brake control lever Bleed screws

Connections l l l l

Port 1 - From compressed air reservoir Port 2 - To trailer brake Port 41 - From LH brake Port 42 - From RH brake

10-222

Technical characteristics 10.6.28 - Pneumatic trailer braking valve with unbraked front axle (2-way)

A

1

2 1

4

1

2

VIEW "A"

P2 (bar)

3

8

Delivery pressure

7 6

1

5

4

4 3 2

2

1 0

0

2

4

6

8

10

12

14

16

18

20 22

24

26

28

Hydraulic control pressure

30 P4 (bar)

0.019.7919.0

Fig. 203 - Pneumatic trailer braking valve with unbraked front axle (2-way) Components l l

1. Parking brake lever 2. Bleed screws

Functions l l l

Port 1 - From compressed air reservoir Port 2 - To trailer brake Port 4 - From braking device 10-223

Technical characteristics 10.6.29 - Trailer air braking valve (1-way)

Fig. 204 - Trailer air braking valve connections Connections l l l

Port 1 - From compressed air reservoir Port 2 - To trailer brake Port 4 - Pilot from delivery line to trailer (2-way braking)

10-224

Technical characteristics 10.6.30 - Trailer air brake boost solenoid valve

Fig. 205 - Trailer air brake boost solenoid valve connections Connections l l l

Port 1 - From compressed air reservoir Port 2 - To trailer braking valve Port 3 - Air release

10-225

Technical characteristics 10.6.31 - Trailer parking brake control solenoid valve

Fig. 206 - Trailer parking brake control solenoid valve connections Connections l l l

Port 1 - From compressed air reservoir Port 2 - To trailer braking valve Port 3 - Air release

10-226

20 - Calibrations and electronic diagnosis

20-1

Calibrations and electronic diagnosis 20.1 - ECU interrogation 20.1.1 - Diagnostics

Diagnostics is the set of analytical and reporting activities which, through the measurement of certain physical parameters characterising the machine monitored, provide significant information on the status of the machine itself and on how its status varies over time, to enable the evaluation and prediction of both short and long term reliability.

20.1.2 - How diagnostics works

When connected to the diagnostic sockets of tractors with specific cables, the All Round Tester (ART®) and SDF Analyser tools connect to and interrogate the different ECUs in the machine, and display the relative data acquired on screen.

20.1.3 - ECUs interrogated by the All Round Tester (ART®) and SDF Analyser

The All Round Tester (ART®) and SDF Analyser tools may acquire and analyse data from the following electronic control units. Rear hitch (EKR), front suspension, HPSA, HLHP1, HLHP2, PTO, Pre-heat, Hydraulic reverse shuttle (“Smart Lever”), Transmission, ZF transmissions (TCU/VDC, SGR/FMGR), SLH engines, CLUSTER on-board instrument, and INFOCENTER on-board instrument. WARNING The primary diagnostic functions of Deutz-AG ECUs are performed with the Serdia 2000/Serdia 2010 diagnostic tools. WARNING However, certain procedures are accessible and certain information viewable also with the All Round Tester (ART®) and SDF Analyser diagnostic tools.

20.1.4 - How to select the ECU interrogated All Round Tester (ART®)

1. Switch the tractor off and remove the ignition key; 2. Connect the ART® to the diagnostic socket; 3. Turn the ignition switch to “I” (ON); 4. When the ART® tool switches on, the battery charge level test screen is displayed. WARNING A voltage of less than 10V is insufficient for the ART® to connect to the ECUs, whereas voltages above 15V may damage the tool itself. 5. After a few seconds, the tester attempts to connect to the electronic system of the tractor, and displays a screen (which differs in relation to tractor model and the diagnostic connector used) in which the technician may select which ECU to connect to, and analyse functions of components. => The image aside shows an example of a selection screen visible when using the All Round Tester (ART®), in this case connected to the Agrofarm 115G tractor 1 - “Engine ECU” / SHL Tier3a engine ECU, 2 - “Smart Lever” / Hydraulic reverse shuttle ECU integrated in “Smart Lever” shuttle lever, 3 - “Cluster” / Digital on-board instrument cluster.

-

-

1 2 3 -

-

-

-

-

M E N U -

-

-

-

-

-

E N G I N E E C U S M A R T L E V E R C L U S T E R

[

E ]

E X I

T

Fig. 207

WARNING To change from one ECU to another, switch the tractor off, reconnect and select the new ECU. --20-2

Calibrations and electronic diagnosis SDF Analyser 1. Switch the tractor off and remove the ignition key; 2. Connect the SDF Analyser to the diagnostic socket; 3. Turn the ignition switch to “I” (ON); 4. Launch the diagnostic programme on your computer; 5. After scanning the channels, the tester attempts to connect to the electronic system of the tractor, and displays a screen (which differs in relation to tractor model and the diagnostic connector used) showing the technician a list of the ECUs recognised. Press “End”. => The image aside shows an example of a selection screen visible when using the SDF Analyser, in this case connected to the Dorado³ 100 tractor: ● “Cluster” / Digital on-board instrument cluster. ● “Smart Lever” / Hydraulic reverse shuttle ECU integrated in “Smart Lever” shuttle lever, ● “Engine ECU” / SHL Tier3a engine ECU, Fig. 208

WARNING To interrogate a different ECU, simply select the name of the desired ECU (the image aside shows an example of a selection screen visible when using the SDF Analyser in this case connected to the Dorado³ 100 tractor).

Fig. 209

20.1.5 - Menus available for each ECU

The number of ECUs listed varies in relation to the model of tractor the tool is connected to. After selecting an ECU, the list of options available usually consists of either 5 choices: 1.

2. 3.

4. 5.

“Monitors”/Monitor Menu: Analyses all sensors in monitor mode. View data received from the different electronic control units (e.g. sensor, button and potentiometer states etc.) managing the tractor systems. “Parameters”/Parameter Menu: For setting certain machine options. “Calibrations”/Calibration Menu: For calibrating the different subsystems of the machine, performing the operations necessary for commissioning the tractor, calibrating the hydraulic reverse shuttle and calibrating sensors. “Tests”/Test Menu: For testing actuators and testing the functions of the electric components installed on the tractor. (e.g. buttons, potentiometers, solenoid valves etc.) “Alarms”/Alarm list: Displays all active and passive alarms. Alarms may also be cancelled from this menu.

-

-

-

-

M E N U - - - - -

1 2 3 4 5

-

M P C T A

O A A E L

N R L S A

[

E ]

I A I T R

T M B S M

M E N U - - - - -

-

-

O R S E T R E S R A T I O N S S

E X I

T

Fig. 210

or

20-3

Calibrations and electronic diagnosis 4 choices: 1.

2.

3. 4.

“Monitors”/Monitor Menu: Analyses all sensors in monitor mode. View data received from the different electronic control units (e.g. sensor, button and potentiometer states etc.) managing the tractor systems. “Calibrations”/Calibration Menu: For calibrating the different subsystems of the machine, performing the operations necessary for commissioning the tractor, calibrating the hydraulic reverse shuttle and calibrating sensors. “Tests”/Test Menu: For testing actuators and testing the functions of the electric components installed on the tractor. (e.g. buttons, potentiometers, solenoid valves etc.) “Alarms”/Alarm list: Displays all active and passive alarms. Alarms may also be cancelled from this menu.

-

-

-

-

M A I - - -

1 2 3 4

-

M C T A

O A E L

N L S A

[

E ]

I I T R

N - -

M E N U - - - - -

T O R S B R A T I S M S

E X I

-

-

O N S

T

Fig. 211

--Hidden menus are also available for certain ECUs, which can only be accessed by entering a specific password.

-

-

-

-

M E N U - - - - -

1 2 3 4 5

-

M P C T A

O A A E L

N R L S A

I

N I

C -

[

I A I T R

T M B S M

T I

E ]

M E N U - - - - -

-

-

O R S E T R E S R A T I O N S S

A L I

T .

E X I

T

Fig. 212

20-4

Calibrations and electronic diagnosis 20.2 - Diagnostic sockets and connections 20.2.1 - Positioning of the diagnostic sockets

To access the diagnostics sockets (2) remove the cover (1) positioned on the front part of the right side console.

1

2

Fig. 213

The socket (3) allows you to conduct diagnostics on the engine control unit. The socket (4) allows you to conduct diagnostics on the HLHP2 control unit and the PLA2 Armrest.

3

4

Fig. 214

20-5

Calibrations and electronic diagnosis 20.2.2 - Serdia 2010 connection To carry out the correct connection to the engine control unit and to use the Serdia system, proceed as follows: 1. 2.

5

Connect the cable P/N 0.020.0441.4 (5) to the tractor diagnostics socket: m The “19 pin” end to the diagnostics socket (3). m The “14 pin” end to the diagnostics socket (4). Connect the Serdia interface (6) to the cable 0.020.441.4 (5) using the “E4” end.

E4 6

Fig. 215

20.2.3 - SDF Analyser/PC Tester connection To carry out the correct connection to the HLHP2 / PLA2 control unit and to use the SDF Analyser/PC Tester, proceed as follows: 1. 2.

9

Connect the cable P/N 5.9030.997.7 (9) to the diagnostics socket (4), Connect the cable P/N 5.9030.997.2 (8) to the cable P/N 5.9030.997.7 (9) and to the SDF Analyser (7).

8

7

Fig. 216

20.2.4 - SDF Analyser/CVT Diag connection To carry out the correct connection to the infocenter and to use the SDF Analyser/ CVT Diag system, proceed as follows: 1.

Connect the cable P/N 5.9030.997.4 (10) to the diagnostics socket (4) and to the SDF Analyser (7).

10

7

Fig. 217

20.2.5 - ART connection To carry out the correct connection to the HLHP2 / PLA2 control unit and to use the ART (All Round Tester) system, proceed as follows: 1. 2.

9

Connect the cable P/N 5.9030.997.7 (9) to the diagnostics socket (4), Connect the cable P/N 5.9030.681.4 (12) to the cable P/N 5.9030.997.7 (9) and to the ART (13).

12 13

Fig. 218

20-6

Calibrations and electronic diagnosis 20.3 - Diagnostic tools

20.3.1 - All Round Tester (ART® SAME) All Round Tester (ART®) Description To facilitate the operations of fault diagnosis, putting the vehicle into service and testing electrical components of the engine and lift, the technician is provided with a test instrument called All Round Tester (hereinafter ART®). Using the ART® the technician can: l l l

display errors (faults) that have occurred; calibrate the sensors; display data detected by the electronic control units (e.g. status of the sensors) managing the systems.

Data is exchanged between the ART® and the ECUs by way of a diagnostic socket incorporated in the combine wiring. The ART® is supplied with a number of different interface cables, which are to be selected in accordance with the type of vehicle and the methods described in the relative workshop manual or in the CD supplied with the tester. Description of the kit the ART® is supplied to authorised service centres in a case containing: l

Case, complete (P/N 5.9030.730.6/30) m 1 - All Round Tester (P/N 5.9030.730.0) m 2 - Diagnostic cable for BOSCH EHR4 rear hydraulic lift - Diagnosis and programming cable of electronic regulator, original type - Diagnostic cable for SBA system, original type (P/N 5.9030.681.3/10) m 3 - Adapter cable for radar connector (P/N 5.9030.681.7) m 4 - Adapter cable for wheel speed sensor connector (P/N 5.9030.681.5) m 5 - Cable for diagnostic socket (P/N 5.9030.681.4) (As from 01/01/06 the cable has been modified to allow the ART® to connect to all control units. Contact the Technical Assistance Service for further information) m 6 - Adapter cable for diagnosis socket on armrest (P/N 0.011.6178.4) m 7 - Cable for connection to diagnosis socket in engine, gearbox, and lift ECUs zone (P/N 0.011.5445.4) m 8 - EPROM port box (P/N 0.010.2154.2) m 9 - CD ROM (P/N 307.1056.8/60)

Fig. 219

* Notes on use The ART® is protected against battery polarity inversion and positive and negative over voltages of brief duration (1 msec). Do not attempt to connect the ART® to any sockets other than those specifically designed for use with the tester and do not use extension leads. The display is permanently backlit to ensure visibility on all light conditions. The knob on the side of the tester allows contrast adjustment. If the display appears blank, it is possible that the contrast knob is positioned in such a way that the data are not visible on the screen. The tester operates correctly at temperatures between 0 and 40°C; it is advisable to switch the tester off every 30 minutes to help prolong its service life. Before disconnecting the ART® from the diagnostic socket, turn the starter key to the “O” (OFF) position. Description of the tester

20-7

Calibrations and electronic diagnosis The ART® comprises: 1. 2. 3. 4. 5.

Liquid crystal display featuring permanent backlighting 16-key alphanumeric keypad Contrast adjustment knob. Serves to adjust the contrast of the display. If the display appears blank, it is possible that the contrast knob is positioned in such a way that the data are not visible on the screen. Parallel port (used to connect the ART® to systems with electronic control units that do not have microprocessors). Serial port (used to connect the ART® to systems with electronic control units incorporating microprocessors).

Fig. 220

General notes on connecting and powering up the Tester 1. 2. 3. 4. 5.

To connect the tester to the vehicle’s electronic system, proceed as follows: Switch off the engine and remove the key from the starter switch; Connect the ART® to a diagnostic; Insert the key in the starter switch and turn it to “I” (ON). On power up, the ART® will display the battery charge level test. If the voltage is below 10V, the ART® will not have sufficient voltage to connect to the ECUs, while voltages in excess of 15V could damage the ART®. After a few seconds, the tester will attempt to connect to the electronic system and will display a screen (which may vary according to the vehicle type or the connector to which it is connected) from which the technician can choose to connect to an ECU and test the operation of components.

Fig. 221

Selection of the display language 1. 2. 3. 4.

20-8

The ART® has the possibility to display information in a number of different languages (factory setting: ITALIAN). To change the display language, proceed as follows. Switch off the engine and remove the key from the starter switch Connect the ART® to a diagnostic socket While holding pressed key A on the keypad, turn the starter key to “I” (ON).

Calibrations and electronic diagnosis 5.

Enter the password 1 2 3 F.

Fig. 222

6.

Press “1 - Language SEL.”.

Fig. 223

7.

Press “C to change” and then the key corresponding to the desired language. In the example above, key “2 - ENGLISH” was pressed to select English. Press “E EXIT” twice to quit Turn the starter key to “O” (OFF) and disconnect the ART® from the diagnostic socket.

Fig. 224

20-9

Calibrations and electronic diagnosis Serial ports configuration 1.

2. 3. 4. 5.

The vehicle electronic systems to which the ART® can be connected differ from one another and utilize different pinouts at the diagnostic socket. For this reason, the serial ports must first be configured so as to guarantee full compatibility of the ART® with all SAME electronic systems. To change the configuration of the serial ports, proceed as follows. Switch off the engine and remove the key from the starter switch Connect the ART® to a diagnostic socket While holding pressed key A on the keypad, turn the starter key to “I” (ON) Enter the password 1 2 3 F.

Fig. 224

6.

Press “2 - Serial Ports”.

Fig. 225

7.

Enable all the serial ports by pressing “1 - Port Enable” seven times. Press “E EXIT” twice to quit. Turn the starter key to “O” (OFF) and disconnect the ART® from the diagnostic socket.

Fig. 226

20-10

Calibrations and electronic diagnosis 20.3.2 - SDF Analyser SDF Analyser Description The SDF Analyser instrument lets the technician troubleshoot and commission the tractor correctly, and test the functions of the electric components of the tractor’s on-board systems and engine. Data is exchanged between the instrument and the electronic control units on the tractor via a diagnostic socket installed on the tractor wiring harness. The SDF Analyser lets the technician perform the following: l

l l

l

View data received from the different electronic control units (e.g. sensor, button and potentiometer states etc.) managing the tractor systems. Test the functions of the electric components installed on the tractor. (e.g. buttons, potentiometers, solenoid valves etc.) Perform the operations necessary for commissioning the tractor, calibrating the hydraulic reverse shuttle and calibrating sensors. View errors (faults).

Advantages Using the SDF Analyser offers a number of significant advantages because: l l l

l

l

It has a screen refresh rate two time faster than previous diagnostic systems. It is compatible with all laptop operating systems in use today. It is faster than the ART® (All Round Tester). It functions as an active interface, with its own microprocessor and flash memory. New software updates are easily installable with a guided menu. It may be used on both old and new tractors, using the specific adapter cables included following the instructions given in the relative training and workshop manuals. May be connected to the laptop either with a USB cable or by Bluetooth connection within a 10 metre range.

Description of Kit The SDF Analyser is delivered to Authorised Service Centres in a case containing the following: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Complete SDF Analyser carrier case (P/N 5.9030.997.0) Analyser tool (P/N 5.9030.997.1) Base PC Tester diagnostic cable (P/N 5.9030.997.2) Base EDS diagnostic cable (P/N 5.9030.997.4) Bluetooth dongle (P/N 5.9030.997.5) EDS adapter cable, first type (P/N 5.9030.997.6) PC Tester adapter cable for Deutz (P/N 5.9030.997.7) PC Tester adapter cable for Rubin /Iron (P/N 5.9030.997.8) Case containing: m CD-Rom for installing software on laptop and m Multi-language handbook with installation instructions. USB connection cable

6

7 8

4

9

1

3

2

10 5

Fig. 227

Installing the software The minimum requisites for the laptop for installation of the SDF Analyser base software and the PC diagnostic software are indicated in the multi-language handbook included in the case. The installation procedure is also described in the handbook. Installing the SDF Analyser software is simple and only takes a few minutes. Once the software is installed, the icons for launching the 3 functions of the software will be displayed on the desktop of the host laptop.

Fig. 228

20-11

Calibrations and electronic diagnosis Functions The SDF Analyser software consists of 3 functions: PC Tester Generally used for connection to electronic control units on tractors with CANBUS network. There are certain exceptions, however, which are described in detail in the specific training courses. PCTester

CVT Diag For connection to “Infocenter” on-board instruments. CVT Diag

SDF Analyser For connection to ZF electronic control units on tractors without CANBUS network. SDF Analyser

Connecting tool and launching software Side: Tool-Tractor Connect the SDF Analyser to the electronic system of the tractor as follows: 1. 2.

Switch the tractor off and remove the ignition key, Connect the SDF Analyser interface to the correct adapter cable (in relation to tractor diagnosed), then connect the cable to the diagnostic socket on board the tractor, Turn the ignition switch to “On”.

3. -

Tool-Laptop side Connect the SDF Analyser to the laptop as follows: l l l

Use the Bluetooth dongle to connect via Bluetooth, or Enable Bluetooth on your laptop (if laptop has integrated Bluetooth module), or Connect the SDF Analyser interface to the laptop with the USB connector cable.

Launching functions To launch any of the functions, double-click the respective icon on the desktop. Basic settings in PC Tester The user may configure a number of basic settings (e.g. language, COM ports, screen layout etc.) for the PC Tester function before starting to use the function itself. Proceed as follows:

20-12

Calibrations and electronic diagnosis Double-click the relative icon on the desktop and wait for the start screen. Select “Tools” and then “Setup” from the option menu.

Fig. 229

Menus available: l l l

“Interface” / Interface, “Lines Selection” / Lines Selection, “Interface” / Interface.

“Interface” / Interface menu The following may be selected from this menu: l l

Interface and COM ports, and display language.

Fig. 230

“Visual Style” / Visual Style menu The following may be selected from this menu: l l l l

Background colour of screens, Font colour, Font type, and Enable “Microsoft Word” function (reproduces PC Tester screens in a Word document.)

Fig. 231

“Lines Selection” / Lines Selection menu The following may be selected from this menu: l

Tractor ECU pin mapping in manual mode.

Fig. 232

20-13

Calibrations and electronic diagnosis Base settings in SDF Analyser The user may configure a number of basic settings for (e.g. language, COM ports, screen layout etc.) for the SDF Analyser function before starting to use the function itself. Proceed as follows: Double-click the relative icon on the desktop and wait for the start screen. Select “Continue” / Continue from the options menu, then select “Configuration” / Configuration.

Fig. 233

“Configuration” / Configuration menu The following may be selected from this menu: l l l l l

Interface, Display language, COM ports, Font type, and Window layout.

Fig. 234

-

20.3.3 - Serdia 2010 Serdia

“Serdia 3.5 level III” software To enable correct analysis of faults, facilitate the procedure of putting the tractor into service and check correct operation of the engine electrical components, the Technician is provided with a software application called SERDIA (P/N 5.9030.740.4/10), for installation on a portable computer. With SERDIA, the technician can: l l l

display errors (faults) that have occurred; program the control unit; carry out sensor calibration or setting procedures.

Description of the kit The SERDIA software is supplied to Authorised Workshops in a carrying case with all the basic items needed for operation. The case contains:

20-14

Calibrations and electronic diagnosis

Fig. 235

Table 109 Pos.

1 2 3

P/N

5.9030.740.4/10 5.9030.740.0 5.9030.740.2 5.9030.741.0

Description

Case, complete . Installation disk . Level III interface General overhaul Adapter cable (not included in kit)

Qty

1 1 1 1

Data is exchanged between the SERDIA software and the control units by way of a diagnostic socket incorporated in the tractor wiring. Accordingly, the SERDIA package is supplied with an interface cable that must be used on the particular model and version of tractor being serviced.

DiagnosiS EMR 4 - Serdia 2010 General Informations l l l

Engines involved: DEUTZ AG type TCD 3.6 L4, TCD 4.1 L4, TCD 6.1 L6 Part Number: 10002785 Function group: B0

Description With the introduction of the new Tier 4i / Stage 3b engines, a new Serdia diagnostic software is required for use with the existing diagnostic interface. The new software is titled Serdia 2010 and is now available. This Software will be used in parallel to the existing Software Serdia 2000. This is necessary as Serdia 2010 at present only supports EMR 3 and 4, therefore Serdia 2000 will remain in service for use on previous EMR1, EMR2, EMR3 engines. The new Software will be released under a License agreement and an individual license will be required for each single SerdiaInterface (HS-Light II). This License is available through our parts departments using the part number 10002785.

20-15

Calibrations and electronic diagnosis License To order the License it is necessary to specify the Serial Number of the HS-Light II Interface in the order procedure as described below. Serial Number of the HS-Light II Interface identification.

Fig. 236

When placing the order, insert the Serial Number of the Serdia Interface HS-Light II wire in the input box “Order-No“.

000-130241

Fig. 237

The License is available within 5 days after placing the order and will require a License data file installation in your computer. Serdia 2010 Software installation procedure The Serdia 2010 Software is immediately available to download from the following web link. http://serdia.deutz.com After using the Link the following page appears: Serdia 2010 icon:

Fig. 238

- Click the Icon “Serdia 2010”. The download page for Serdia 2010 appears:

20-16

Calibrations and electronic diagnosis

7 2 3

1

4

6 5

Fig. 239 l l l

l l l l

1): Serdia 2010 User Manual - Download 2): Serdia 2010 Software - Download for Install 3): License data file - this is to be installed after the installation of Serdia 2010. With this file the Interface HS-Light II is activated in Serdia 2010 4): Error code list EMR 4 5): Software Update for Serdia 2010 (just needed if Serdia 2010 is already installed) 6): License Terms 7): Manual for Uninstall Serdia 2010

- Click the file “Serdia 2010 V...” to download it. (N.2) in the installation green box. - After the successful Download of the Software, refer to the document “Manual_Serdia2010:_EN_Level2_Version100_02052011. pdf” Chapter 3.3.4.” on how to install the software. License data file installation procedure - Go to weblink “http://serdia.deutz.com” to find out if your License has been activated - Click Serdia 2010 to enter the screen that shows the License box.

Fig. 240

- Click on the icon “Interface Lis.txt“ to open the document showing the list of Interface serial numbers activated.

20-17

Calibrations and electronic diagnosis

Fig. 241

Exemple of list:

Fig. 242

- Scroll the list until you find your Interface serial number. - If not present, you have to wait more time. - If present, close the document and click the file named: “Serdia 2010 License.exe” to download it in your computer. Serdia2010 Licence.

Fig. 243

- Follow the download guided sequence. 20-18

Calibrations and electronic diagnosis - Once completed the installation, the Serdia 2010 Software is ready to work. Intermediate Wire A new intermediate wire is also necessary to provide a connection between the Serdia Interface and the Electronic Engine Controller. The part number of the intermediate wire is 0.020.0441.4 which can also be used with the previous engines systems EMR1, EMR2 and EMR3, this making the old intermediate wire Part No 5.9030.741.0 redundant. Wire P.N. 0.020.0441.4.

8

9

10 11

Fig. 244

Layout of the wire: l l l l

8): Connection to 14 Pin Diagnostic Socket (is always to connect) 9): Connection to 19 Pin Can-Bus Socket (Only Maxi Vision Cabin) 10): Connection to Serdia Interface for Electronic Engine Control EMR1, EMR2, EMR3. 11): Connection to Serdia Interface for Electronic Engine Control EMR4

Please do not hesitate to contact your Technical Advisor for any help to install the new Serdia 2010 Software.

SerDia 2010 updating license file Document type Informative note for network General information Functional groups and subgroups B0 00 Description To ensure that the SerDia 2010 diagnostic software (P.N. 10002785) functions correctly, it must be updated at least twice every year. To do this, the new license file issued on the DEUTZ AG portal must be installed on the computer used for diagnostics before 01 February and 01 August of every calender year. This is necessary to ensure complete, trouble-free diagnostic and adjustment functionality. The new license file is available from the DEUTZ AG portal at the address: http://serdia.deutz.com/. Changing the date on the Windows system clock of the computer used will not prevent license deactivation.

Table 110 Updating the license file

Name Publication date Software download

License file: 1.8.xxx From 17/01/2014 http://serdia.deutz.com/

Procedure for installing SerDia 2010 license file update Install the license file update before the license expiry date, which is viewable in the SerDia 2010 main screen (Figure 1). If the update is not installed before this date, the software will stop working and request installation of the update.

20-19

Calibrations and electronic diagnosis Figure 1. 01.02.2014

Fig. 245

Access the website http://serdia.deutz.com/ and click SerDia 2010 (Figure 2). Figure 2.

Fig. 246

A link to the new SerDia2010 license file (License ... .exe) is visible in the window opened (Figure 3). Figure 3.

Fig. 247

Click the link to download the file, and follow the attached installation instructions. Click “Next” (Figure 4). Figure 4.

Fig. 248

Click “Next” (Figure 5).

20-20

Calibrations and electronic diagnosis Figure 5.

Fig. 249

Click “Install” (Figure 6). Figure 6.

Fig. 250

Click “Finish” (Figure 7). Figure 7.

Fig. 251

At the end of the installation procedure, the following table is displayed. Refer to this table to check if your license is listed and has been updated correctly. The license code matches the serial number of the interface in your possession (Figures 8 and 9). Figure 8 - Identifying interface.

Fig. 252

20-21

Calibrations and electronic diagnosis Figure 9 - Table of active licenses.

Fig. 253

Please contact your Area Technical Inspector for any queries on this subject.

We recommend visiting the “News Service” section of the technical documentation portal daily to check for new documents and view them as soon as they become available.

Introduction With the introduction of the new engine generation in the beginning of 2011, which fulfill the new emission standards EU stage III B, US Tier4i. Therefore Deutz releases a new Version of its diagnostics software SerDia2010 release 2.0.221. All engines fulfilling this emission standard are equipped with the EMR4 ECU, which allows many new diagnostic features, due to it’s new software concept and additional interfaces. SerDia2010 is a must for engine diagnostic purposes at engines according stage III B / Tier4i and higher. Important This manual was created for user with SerDia access level 1.

Important If you use a higher access level with SerDia2010 it is possible, that some functions, which are visible or useable for you, are not described in this script. DEUTZ AG Application Engineering

Safety instructions WARNING The use and the application of SerDia2010 can be dangerous! WARNING It is critical that you carefully read and follow the instructions and warnings below and in the associated installation manuals: WARNING Serdia2010 enables a user to influence or control the electronic system in a vehicle or machine. SerDia2010 is specially designed for the exclusive use by personnel, who have special experience and training. WARNING Improper use or unskilled application may alter the machine performance or system performance in a manner, that results in death, serious personal injury or property damage.

20-22

Calibrations and electronic diagnosis Important Do not use SerDia2010, if you do not have the proper experience and training.

Important It is recommended, that in-vehicle use of SerDia2010 shall be conducted on enclosed test tracks, or ensured machine surroundings. Important Use of SerDia2010 on a public road should not occur unless the specific calibration and settings have been preciously tested and verified as safe. Important When using SerDia2010 with machine systems, that influence vehicle behaviour and can affect the safe operation of the machine, you have to ensure, that the machine can be transitioned to a safe condition, if a hazardous incident should occur. Important All legal requirements, including regulations and statutes regarding vehicles and machines must be strictly followed when using this product. WARNING If you fail to follow these instructions, there might be a risk of death, serious injury or property destruction. Important Any data acquired through the use of SerDia2010 must be verified for reliability, quality and accuracy prior to use or distribution. This applies both to calibration and to measurements, that are used as a basis for calibration work. Important The DEUTZ AG and it’s representatives, agents and affiliated companies deny any liability for the functional impairment of DEUTZ products in terms of fitness, performance and safety, if non-DEUTZ software, parameter settings or model components are used with or deployed to access DEUTZ products. Important The DEUTZ AG and it’s representatives, agents and affiliated companies will never be liable for any damage or injury caused by improper use of SerDia2010. Important DEUTZ provides training regarding the proper use of SerDia2010.

Important Before using SerDia2010 it is required to verify, that the software is up to date and all updates are installed.

Important The DEUTZ AG and it’s representatives deny any liability for any injury caused by the use of a non up to date software version of SerDia2010. If necessary the software can be updated from serdia.deutz.com.

20-23

Calibrations and electronic diagnosis Important It is recommended to make an access to the ECU while engine is running only, if it is guaranteed, that a change of programming cannot lead to hazardous effects in engine behavior. If this is not ensured, a faulty programming can cause undefined engine reactions, that results in death,serious personal injury or property damage. Important A faulty programming of the ECU can activate a sleep mode of the ECU because of safety reasons. In this case the ECU is switched off, a communication to the ECU is not possible any more. A repair or reprogramming of the ECU is not possible. The ECU has to be replaced. Important If supply voltage of the ECU is switched off or the connection between the SerDia interface and the ECU is interrupted while changing parameters of the dataset, a sleep mode of the ECU, because of safety reasons, can be activated. In this case the ECU is switched off, a communication to the ECU is not possible any more. A repair or reprogramming of the ECU is not possible. The ECU has to be replaced. Important If you cannot agree with these limitations, you are excluded from using SerDia2010.

Important If you cannot agree with these limitations, you are excluded from using SerDia2010. In this case contact the supplier. The purchase price and the not used licence fee will be refunded within one month after receipt.

General preferences Subject of the present documentation is the use of SerDia2010 at DEUTZ engines with electronic injection equipment. Important This document shows the functionality of SerDia2010 and it’s use to communicate with and parameterize of DEUTZ ECU’s. The information contained herein only correspond to the state of the art at the time of setting and are not subject to an immediate revision service. Important In case of problems with SerDia2010 please contact the supplier.

Before contacting please collect information about the individual circumstances of the problem you have, as much as possible. The following information has to be given as a minimum: l l l l l l

PC-hardware Windows operating system SerDia2010 version Type of interface DEUTZ ECU part number Engine number WARNING To allow the access to the ECU it is recommended to install a diagnostic socket according DEUTZ wiring diagram for the respective engine. WARNING SerDia2010 will be delivered with access level 2 in general. The access level is not depending on the hardware interface level.

20-24

Calibrations and electronic diagnosis Important If a different access level is needed, it is necessary to make a request to the supplier. Within 5 working days you will get an email with a confirmation / negation to your request. If confirmed the licence update has to be downloaded from serdia.deutz.com and installed on the computer, in order to activate the new level. WARNING Following information has to be given in order to get a change of the access level.

l l l

Complete details as name and address of applicant (if different to the licence user). Complete details as name, address and qualification of the prospective licence user. Detailed description because of the reasons for changing the access level. WARNING It is not permitted to resell or transfer the licence and within also the interface for SerDia2010 without knowledge and agreement of DEUTZ AG! Is a transfer needed, please contact the supplier to get a confirmation. Without a written confirmation (email feedback) from DEUTZ a resell or transfer is strictly forbidden!

General preferences - Availability SerDia2010, documentation, updates and information is is available at the following locations: l l

Global SIS - portal Website: serdia.deutz.com

General preferences - Licence purchasing To use SerDia2010 it is recommended to purchase a software licence for each interface used. Not before successful registration and confirmation of the licence (by DEUTZ) for the individual interface serial number, a communication between software, interface and ECU is possible in order to have a diagnostic access to the new DEUTZ engines. Second dealer stage: Responsible for delivery, assistance, maintenance and service of the second dealer distribution net is the service partner or OEM, who is directly connected to the DEUTZ service network. He is also responsible for classification of his sub dealers regarding access level. If interfaces are sold via second dealer stage the final user has to be mentioned directly while ordering, respectively, if reselling is later, it has to be communicated to and confirmed to the supplier. Order procedure The licence can only be purchased through the official DEUTZ dealer net respectively the central OEM. Each licence is linked to one specific interface serial-no. To enable parallel diagnostics for e.g. 5 service technicians, five licence’s will be required. For ordering please use the DIWI-system only! It is currently not possible to place an order via SAP or file transfer. A physical dispatch of goods doesn’t take place if no interface hardware is ordered. If only the software SerDia2010 is ordered the registration / release of the interface serial no. is completed usually within 5 working days. After tis delay the software can be downloaded from serdia.deutz.com. You can check the registration easily: All registered serial no. are mentioned in the licence’s overview file licence.txt also available on the website. Procedure Important Allways enter the consignee (e.g.2nd dealer stage, OEM dealer, customer)!

20-25

Calibrations and electronic diagnosis

Fig. 254 - Ordering in DIWI Important Enter PN 1000 2785 (software-licence) and quantity.

Important Enter interface serial-no.in pop-up window.

Fig. 255 - Entering serial-no.(pop-up window) Important Release the order.

Important Download of actual SerDia2010 – software 5 days after release of the order. Install SerDia2010 on all required PC’s.

20-26

Calibrations and electronic diagnosis General preferences - Access and communication SerDia2010 (Service-Diagnosis) is a PC software which works together with notebook and interface to communicate with the engine control unit. For the use of SerDia2010 it is recommended to take a special software training at the training center. The training center cologne provides such EMR4 training courses. WARNING The data of the published and respectively valid technical documents, such as operating instructions, circuit diagrams, workshop manuals, repair and setting instructions, technical bulletins, service bulletins etc., are exclusively mandatory for operation, maintenance and repair. We refer especially to the valid edition of the “Installation Manual Electronic”, which is available from the Application Engineering Dept. Electronic engine control units (ECU) are state of the art in modern engine technology. Target for these controllers is at first to replace the functions of mechanical governors (like speed governor) and secondly to increase the ability of new functions. To communicate with the DEUTZ-ECU’s SerDia2010 is necessary. Furthermore 1. 2.

Interface (Dongle with wiring, diagnostic plug, serial number and authorization level). state of the art notebook or personal computer, optionally with printer are needed (see also Hardware).

Overwiev

Fig. 256 - Basic scheme of modern computer based diagnosis Introduction SerDia2010 is working with DEUTZ controller family EMR4. It is possible to use this software to communicate with different ECU’s. The software can be downloaded via the internet access serdia.deutz.com. If necessary,a new version of SerDia2010 is launched here. Also updates can be available, which have to be installed per hand by user. These updates will be included in the next SerDia2010 version, too. Changes in the ECU-software concerning adjustment, parameterization, calibration or deleting error memory are possible only with SerDia2010. The access to the several functions is depending on the access level of the user. SerDia2010 is running with operating systems MS-Windows XP SP2, Windows Vista and Windows 7. Functions are activated by clicking on command buttons on the screen. Minimal equipment To communicate with a DEUTZ engine controller the following equipment is necessary: l l

PC or Notebook DeCom or HS light II USB Interface 20-27

Calibrations and electronic diagnosis l

Diagnostic plug correctly connected with the controller

Hardware Software SerDia2010 is able to work with Interface l l

HS-Light DEUTZ Communicator DeCom

available from DEUTZ AG. Hs-Light Important SerDia2010 is executable with HS-Light II Interface.

WARNING Once SerDia2010 is compatible to EMR3 ECU’s the compatibility with HS-Light will not be enhanced any more. So HS-Light will not be provided in the far future any more! Important If a new interface is needed for communication with SerDia2010 it is recommended to order a Deutz Communicator DeCom as soon as available.

20-28

Calibrations and electronic diagnosis

Fig. 257 - HS-light Interface The licence for SerDia2010 has to be ordered separately via DIWI (see Licence purchasing). You can find the HS-Light serial number on the back side of the interface:

20-29

Calibrations and electronic diagnosis

Fig. 258 - Where to find the Seria number? DeCom Important SerDia2010 is executable with DEUTZ Communicator (DeCom).

20-30

Calibrations and electronic diagnosis WARNING Once SerDia2010 is compatible to EMR3 ECU’s the compatibility with HS-Light will not be enhanced any more. Beginning at this time, only the DEUTZ Communicator will show full functionality (including compatibility to EMR3 with SerDia2010)! Important If a new interface is needed for communication with SerDia2010, it is recommended to order a Deutz Communicator DeCom as soon as available.

Fig. 259 - Features 20-31

Calibrations and electronic diagnosis l l l l l l

K-Line and L-Line interface according ISO 9141-2 and ISO 14230-4. Baudrate up to 500 Kbaud 2 Full Can with max. 1 Mbit/s adjustable, according CAN-specification 2.0A and 2.0B USB 2.0 full-speed Galvanic isolation of inputs and to the PC Power supply from PC, current max. 250 mA LEDs for showing state of interface communication:

Table 111 LED

Green Green Green Green Green Green l l l l l l l l l l

USB/device status Ubat CAN communication 2 CAN communication 1 K-/L-Line communication SAE J1708/J1587 communication

working temperature range –20°C up to +60°C storing temperature range –40°C up to +85°C type of protection: IP50 Deutz standard diagnostic plug, 12 pole switchable termination resistor 1m wiring length: Interface <=> PC fixed on interface with bend protection and cord grip 2m wiring length: Interface <=> ECU fixed on interface with bend protection and cord grip power supply from PC voltage range: 8-32V EMC according DIN ISO 7637-2, DIN EN 61000-4-2, 61000-4-3, 61000-4-4, 61000-4-6, 61000-6-2, 61000-6-4

Pin assignment USB-Assignment

20-32

Status 2x CAN

Calibrations and electronic diagnosis

Fig. 260 - Pin assignment USB type A Pin assignment diagnostic plug

Table 112 PIN

1 2 3 4

Signal

VBUS DD+ GND

Description

+5VDC Data Data + Ground

20-33

Calibrations and electronic diagnosis

Fig. 261 - Standard Plug for Pin Contacts (ITT Cannon Part Number 192922-1270) Table 113 Pin

Signal (1x Can)

Signal (2x Can)

A

U_bat

U_bat

B C D E F G H J K L M

GND not connected J1708a J1708b not connected CANL CANH not connected K L not connected

GND not connected J1708a J1708b CANL2 CANL1 CANH1 not connected K L CANH2

Function (1x Can)

Norm

Supply Voltage (+8V ... +32V) Ground J1708a SAE J1708/J1587 J1708b SAE J1708/J1587 CAN Low ISO 11898 CAN High ISO 11898 K-Line ISO 9141 L-Line ISO 9141 -

Ordering DeCom The licence can only be purchased through the official DEUTZ dealer net respectively the central OEM. For ordering please use the DIWI-system only! It is currently not possible to place an order via SAP or file transfer. The registration / release of the interface serial no. is completed usually within 5 working days. After tis delay the software can be downloaded from serdia.deutz.com. You can check the registration easily: All registered serial no. are mentioned in the licences overview file licence.txt also available on the website. Procedere Important Allways enter the consignee (e.g.2nd dealer stage, OEM dealer, customer)!

20-34

Calibrations and electronic diagnosis

Fig. 262 - Ordering in DIWI Important Enter PN 1000 xxxx (Hardware incl. software-licence) and quantity of Interfaces.

Important Release the order.

Important Download of actual SerDia2010 – software 5 days after release of the order. Install SerDia2010 on all required PC’s.

PC/Notebook Minimum hardware l l l l l l l l l

Notebook or PC (IBM-AT compatible) USB interface graphic board VGA/SVGA with a resolution of 1024 x 768 Pixel frequency = 1,5 GHz main memory = 1 MB RAM hard disk = 500 MB (free memory) CD-driver internet access for SerDia2010 updates administrator status for installation

Minimum software, operating system l

operating system MS-Windows XP SP2, VISTA, Windows 7 (32bit or 64bit)

Diagnostic plug A connection plug has to be installed in the machine to connect the engine ECU with the SerDia2010 hardware interface. The plug has to be easily accessible (for example in cabin). While doing the wiring of the plug and connecting it to the control unit, please use 20-35

Calibrations and electronic diagnosis the right wiring diagram. The plug purchased via DEUTZ: l l

Diagnostic plug TN 0419 9615 Serial according to ISO 9141 and SAE J1587

Fig. 263 - Diagnostic plug Table 114 Signal

CANH CANL CANH CANL K L J1708a J1708b Ubat Gnd 20-36

Function

CAN High diagnostic CAN CAN Low diagnostic CAN CAN High customer CAN CAN Low customer CAN K-Line L-Line J1708a J1708b Power supply Ground reference

Norm

ISO-1941 ISO-1941 J1708/J1587 J1708/J1587 -

Assignment

H G F M K L D E A B

Calibrations and electronic diagnosis Software installation Newest SerDia2010 setup files are available at: serdia.deutz.com Before installation of the software, please download the new Setup data first. The new updates due to the change in control unit software, program extension and improvements, can always be found at above mentioned website. Important Please do not connect the SerDia2010 USB interface to the PC, until program installation is finished!

WARNING To use SerDia2010 you need a released licence (see chapter Order procedure and Ordering DeCom). Release is done for each interface separately. Installation of SerDia2010 Important For all following actions admin rights are necessary!

Chronological order of installation: l l l l l

Download SerDia2010 from serdia.deutz.com or start program-CD. Start installation of Setup.exe The installation process is running automatically. Additionally a JAVA-runtime-system is installed. Configuration of the HS-Light driver (if HS-Light interface shall be used). 1. connect HS-Light interfaces to USB 2. Start of “samPDU ConfigurationCenter” in Windows start menu at START => “Programs” => “samtec Diagnostic Tools” => “samPDU” 3. Search of the connected interface with activate “Find VCI”

20-37

Calibrations and electronic diagnosis

Fig. 264 - Start screen samPDU l

After installation SerDia2010 can be launched via SerDia2010 icon on the desktop.

Important For all administrators who configure the PC’s for other users: The path C:\Deutz\SerDia\*.* must be entirely accessible. Important Via internet serdia.deutz.com , the so called “Bugfixes” can be provided also. This bug fixes are files the user can manually copy to SerDia-directory. These data can solve problems as a short time solution in the actual SerDia program. In the next SerDia version this will be automatically included. Access level WARNING SerDia2010 will be delivered with access level 2 in general. The access level is not depending on the hardware interface level. 20-38

Calibrations and electronic diagnosis Important If a different access level is needed, it is necessary to make a request per email to the supplier. Within 5 working days you will get an email with confirmation / negation of the request. If confirmed the licence update has to be downloaded from serdia.deutz.com and installed on the computer, in order to activate the new level. l l

For installation the administrator mode is necessary. For all others PC-User modes, the path C:\Deutz\SerDia\*.*needs entirely full access.

Table 115 No.

Version

2

Interface Level II (2)

3

Interface Level III (3)

4

Interface Level IV (4)

1

Interface Level I (1)

Application

Control, regular maintenance work according to maintenance schedules Inspection, test and adjustment work, repair work also within the scope of the warranty, engine exchange (incl.EAT) working in the scope of the warranty, extensive diagnosis, test & adjustment work on whole engine, major overhaul, intermediate overhaul, mechanical reworking of engine components replacement program (only by DEUTZ)

Note

For end customer, only for respective engine in OEM machine Repair work within the scope of warranty only with worldwide service agreement. For OEM with regional For OEM without Selfservice mechanical reworking of engine components and major overhaul usually provided for OEM by the DEUTZ service organization only for DEUTZ-OEM- or Development-Engineer, Employees of DEUTZService organization

User level, competence level, interface access right

Table 116 EMR4

Operating software update the operating software (Flashen without password) supported control unit EMR4 (EDC17CV52, CV54, CV56) supported control unit EMR3 (EDC7, EDC16) supported control unit EMR2 Dataset read and write the dataset (without extra data) without access to parameter read and write of dataset (without extra data) with access to parameter overall programming without possibility of change the operation data overall programming with possibility of change the operation data Dataset access to all parameters according to the available competence level (UseCases) adjustment of service parameters in form of pre-defined tasks with running engine Measured Values showing the selected measured values showing the internal calculated values for Level IIIa and Level IIIaS CAN-Status

1

2

3

4

2

2

v

v

v

v

v

v

v v v v (L = Read / S = Write) 2 2

v v

v v

L/S

L/S

2

2

2

L/S

2

2

L/S

L/S

2

2

2

L/S

(L = Read / S = Write) 2 L/S

L/S

L/S

2

L/S

L/S

(L = Read / S = Write) 2 v 2 2

v v

v v

2

v

v

L/S

v

2) only allowed for hardware according to respective engine. Regardless of the level of competence exists all access for the hardware to the respective engine.

20-39

Calibrations and electronic diagnosis Table 117 EMR4

Error Memory show the errors in error memory 1 including the environment data delete all errors or single error in error memory 1 show the errors in error memory 2 including the environment data delete all errors or single error in error memory 2 Extras data (Logistic data, operating data and customer data) access to the logistic data read, reset the maintenance counter access to the load spectrum data read and reset the override memory Calibration and test functions drive pedal calibration low idle adjustment droop calibration Test the inputs and outputs Control Unit Functions reset activate and deactivate a test bench dataset engine shut off

1

2

3

4

v

v

v v

v v

2 2 (L = Read / S = Write)

v

v

2 L 2 2 2 2 2 2 (L = Read / S = Write) 2 v 2 v 2 v 2 v (L = Read / S = Write) 2 v

L L L/S 2 L

L/S L/S L/S L/S

v v v v

v v v v

v

v

2

v

v

(L = Read / S = Write) v v v 2

v v

v

2) only allowed for hardware according to respective engine. Regardless of the level of competence exists all access for the hardware to the respective engine.

Program handling - General communication access By the use of SerDia2010, in order to communicate with a DEUTZ control unit, the following instructions during connection, are recommended: l l l l l

Start the computer Connect the interface to the Computer via USB Interface Switch on power supply of the control unit Connect the interface to the diagnostic plug of control unit Start SerDia2010 on the Computer

Now the available interface for SerDia will be searched automatically and the connection will be created.The setting for the hard- and software of the ECU will be adjusted automatically. During program start the following information window is shown.

Fig. 265 - Information window

20-40

Calibrations and electronic diagnosis Program handling - Programstart and home screen After program start the start screen (home) is shown:

Fig. 266 - Start screen From all screens in program you can go back to home while pressing next icon in the button bar.

Using button “display for supported ECU software” a page with an overview regarding in SerDia2010 implemented software versions of ECU-software and assisted ECU hardware is shown.

20-41

Calibrations and electronic diagnosis

Fig. 267 - Overview SW-versions Information’s onto the start screen On the start screen many information’s give an overview about the system and the ECU. At “logistic data” you will find information about hard- and software of the ECU. Engine hours, counters, etc. is available at “ECU counters” On the lower body of the screen there is some information regarding communication ECU <-> User merged. In detail: l

Serial number of the interface.

This number is the basis for access level and licensing.

Fig. 268 l

20-42

Visualization of connection status.

Calibrations and electronic diagnosis If communication between Notebook and ECU is ok, indicator is green. If communication is not possible or interrupted, indicator is red. If communication is connected, indicator is green.

Fig. 269 l

ECU software.

The ECU software of the connected control unit is shown in the lower right window. Fig. 270 l

Engine number.

The engine number, stored in ECU, is shown.

Fig. 271

Program handling - Main menu For navigation in SerDia2010 a button bar is used called main menu. This main menu is shown at all screens in program.

Table 118

Fig. 272

Fig. 273

Home

Back to start screen

Error memory

Access to memory 1

Data set management

Download: new operating SW, com- Upload: complete data set plete data set, partial data set

Access to memory 2

Fig. 274

20-43

Calibrations and electronic diagnosis

Fig. 275

Fig. 276

Fig. 277

Fig. 278

Fig. 279

Fig. 280

Fig. 281

20-44

UseCases

Access to several measurement and parameterize functions in order to manage different

guided diagnostics

not finished yet

report documents

not finished yet

configuration

Adjust: language, access level elevation, setting folders for file storage

help

Information regarding SerDia2010

program exit

exit SerDia2010

rebuild connection

Updates a new connection

Calibrations and electronic diagnosis Program handling - Configuration Program settings like language, setting folders for file storage and access level elevation can be configured by pressing the CONFIGURATION icon.

Fig. 282 - configuration, setting The respective setting configuration can be saved by pressing the SAVE SETTING icon.

Program handling - Error memory By pressing the ERROR MEMORY icon the error memory 1 can be opened.

20-45

Calibrations and electronic diagnosis

Fig. 283 - Error memory 1 SerDia2010 is collecting all errors and it’s environment data out of the ECU. The errors will be shown together with KWP-code, DTCcode, number of occurrence and a short error description. Possible interactions: Button “Actualize error memory” reads out the error memory out of the ECU.

Button “Clear error memory” delete of all passive errors. Active errors can also be deleted but come up again directly.

Button “Save as CSV file” list of errors will be saved in a CSV file.

20-46

Calibrations and electronic diagnosis Button “Error details” shows some details about the chosen error and some hints to solve it (available with SW ...580..and higher).

Fig. 284 - Additional error information Button “Error environment” shows important measurements at time of error occurrence.

20-47

Calibrations and electronic diagnosis

Fig. 285 - Error environment

Program handling - Dataset management Important This function is only available with access level 2 or higher!

Program handling - Offline Viewer The Offline Viewer is available after installation of SerDia2010 with its own icon on the desktop Advantage: If only measurements have to be considered, it is not necessary to start SerDia2010 completely but the Offline Viewer can be loaded very fast.

20-48

Calibrations and electronic diagnosis

Fig. 286 - Start screen Offline Viewer Possible interactions Open measurement Click OPEN icon and select file from hard disk.

Zoom function If a measurement has been loaded, the screen can be zoomed in and out with the highlighted slider.

Fig. 287 - Slider Change of background color

20-49

Calibrations and electronic diagnosis Decouple measurement window.

Change of background color. Fig. 288

Color palette.

Fig. 289

Program handling - Usecases EMR4 Button USECASES starts screen with the overview of the available use cases. Depending on the actual access level different use cases can be started here.

For all changes of parameters while using the use cases, the following is obligatory: WARNING The user has to check all changes and make plausible all influence and risk of the changes. WARNING The user is bearing the responsibility for all expected and unexpected effects because of the parameter changes. WARNING After changing parameters the effects regarding functionality of the engine / machine hast to be checked under ensured machine surroundings. Assembly Inspection and Initialisation Tests After installation and commissioning of a plant inspections of warning lights and simulations of warning limits can be performed on this site. Parameters can be set to the window for the given values.

20-50

Calibrations and electronic diagnosis

Fig. 290 - Assembly Inspection and Initialization Tests (1/3) Important Please note the order of entry!

Important First enter the relevant value then set the hook otherwise exists danger of uncontrolled engine switch off!

In the input field several values can be entered to check the warning limits. After entering the values the hook will be set next to the description to confirm the respective value. This value will be shown next to the input field.

20-51

Calibrations and electronic diagnosis

Fig. 291 - Assembly Inspection and Initialization Tests (2/3) In the lower part of the screen checks for cooling water level switch and water in fuel switch are possible. By setting the hook for the respective inspection the warning systems can be checked. The engine will be specified in such border states.

20-52

Calibrations and electronic diagnosis

Fig. 292 - Assembly Inspection and Initialization Tests (3/3) Graphic dipslay The summary page gives an overview about the available measurements. Several predefined measurements or graphical displays can be chosen by the user.

20-53

Calibrations and electronic diagnosis

Fig. 293 - Summary page graphic display

Fig. 294 - Running graphic display Possible interactions

20-54

Calibrations and electronic diagnosis Scaling y-axis: double click onto the values of the axis. In the shown window will pop up and a new value can be given.

Fig. 295

Table 119

Fig. 296

Start of measurement record (before starting measurement a file name for storing data has to be defined).

Fig. 297

Fig. 298

Start of measurement.

Stop of measurement.

Fig. 299

20-55

Calibrations and electronic diagnosis Interrupt measurement (pause).

Fig. 300

Fig. 301

Fig. 302

Fig. 303

20-56

Delete measurement.

Spreadsheet window separating / docking for placing on the screen

Switch to bosch acronyms instead of normal parameter labels.

Calibrations and electronic diagnosis

Fig. 304 - Spreadsheet window Measured values:

Fig. 305 - List of values Next icon include/delete values for measurements

Fig. 306

Change of background color:

20-57

Calibrations and electronic diagnosis Click at chosen color. Fig. 307

Color palette.

Fig. 308

BACK BUTTON back to overview screen.

Similarly is the setting for measurements of engine start, measurement configuration of EAT and applications. Dynamic Reading-Gauge Using the Dynamic Reading-Gauge in the Use-Case graphic display, allows you to create individual Experiments, regarding your engine. The possibility of recording up to 20 different engine controller parameters at the same time, SerDia 2010 allows a simple but effective diagnosis. For example to monitor the fuel injected output, air-mass flow and engine speed, diagnosing wether plausible values are caused.

20-58

Calibrations and electronic diagnosis

Fig. 309 - Startscreen Use-Case graphic Display Mouse clicking the Dynamic Reading-Gauge Button (marked green) starts the diagnosis configuration.

Fig. 310 - Startscreen dynamic reading-gauge The picture above shows which parameters can be recorded (left column) with SerDia 2010. Mouse clicking the green marked button 20-59

Calibrations and electronic diagnosis selects a single parameter and copies it to the right column (measurement selection).

Fig. 311 - Parameter Selection dynamic reading-gauge Besides the possibility of creating and configuring individual adapted experiments, SerDia 2010 allows the user to load pre configured experiments created by the Deutz Service with the *.mwa file-ending. By mouse clicking the blue marked button in the picture shown above, *.mwa files can be searched on the computer and loaded in to SerDia 2010. Clicking either the red marked or green button, all parameters of the *.mwa file or an singular parameter of the *.mwa file is copied to the measurement selection.

Fig. 312 - Selected Parameters - creating and saving *.mwa files Are all parameters loaded in the measurement selection the experiment can be started by clicking the green button on the lower right 20-60

Calibrations and electronic diagnosis side. By clicking either the red or blue marked button the selected parameters are deleted or saved to HDD as a *.mwa file.

Fig. 313 - Dynamic reading-Gauge in action Output test Important This function is only available with access level 2 or higher!

20-61

Calibrations and electronic diagnosis Input test

Fig. 314 - Screen: input test The actual switching status of the ECU inputs are shown as a lamp. The active switching status (depending on the input configuration high or low) is shown as a switched on lamp (yellow). So it is easy to check, if inputs are wired correct and change their state if hardware switch is actuated. Analogue speed setpoint Important This function is only available with access level 2 or higher!

Constant Speed setpoint Important This function is only available with access level 2 or higher!

Low Idle adjustment Important This function is only available with access level 2 or higher!

20-62

Calibrations and electronic diagnosis Droop adjustment Important This function is only available with access level 3 or higher!

Set limp home RPM In case of failure of the accelerator pedal or the CAN-Bus the emergency speed intervene to be in a constant condition.

Fig. 315 - Screen Set limp home RPM The emergency speed can be pretended in the right text box: Possible interactions: l

Store emergency speed in ECU by entering:

l

Read emergency speed out of the ECU:

20-63

Calibrations and electronic diagnosis Important The emergency speed range is limited from low idle up to 1200 rpm!

Trip Recorder Important This function is only available with access level 2 or higher!

Sensors The UseCase sensors provides an overview of various measurements. For 4 of these measurements the upper and lower limits are displayed in the bar graph with corresponding measured value.

Fig. 316 - Screen sensors Following values can be viewed if they are sent by ECU: l l l l l l l l l

Boost pressure Ambient pressure Fuel delivery pressure Engine oil pressure Boost temperature Ambient temperature Cooling temperature Battery voltage Vehicle velocity

EGR, Throttle The UseCase for analyze and diagnose exhaust gas recirculation and throttle is only available with engines, who are equipped with this features. 20-64

Calibrations and electronic diagnosis Important This function is only available with access level 2 or higher!

Calibration of injectors (IQA-Code) Compression test Important This function is not available with a level lower than access level 2!

Engine hours Important This function is only available with access level 2 or higher!

SCR-Overview Important Provided for a correct use of the UseCases is an engine, equipped with a system of SCR exhaust after treatment.

Fig. 317 - SCR-overview This overview page provides a quick overview about values of different sensors and the whole EAT system.

20-65

Calibrations and electronic diagnosis Pressing next icon opens the page of measurements for the SCR-System. (see also Measurements).

Fig. 318 - Page of measurement SCR By pressing the next iconthe user gets to the SCR-test functions (Access only with Level 2 or higher).

Mouse clicking the next icon starts the SCR-End Of Line Test (see description SCR-EOL).

20-66

Calibrations and electronic diagnosis The arrow Button guides back to the SCR overview.

SCR Test function Important This function is only available with access level 3 or higher!

SCR End Of Line test Main page diesel particulate filter DPF On the DPF main page, the whole DPF-system is shown graphically in an exemplary situation at the engine.

Fig. 319 - DPF-main page Besides the entire overview of the DPF-system on the left side, the most important values of the DPF equipment is shown on the right side. The user switches over to a component specific page by selecting the individual relevant diagnostic components of the DPF-system using the PC-mouse.

20-67

Calibrations and electronic diagnosis Turn to page diesel particulate filter and burner then click on the filter.

Fig. 320

Turn to page supply-module then click on the module.

Fig. 321

Turn to page diesel particulate filter and burner then click on the burner.

Fig. 322

20-68

Calibrations and electronic diagnosis Turn to page air pump then click on the pump.

Fig. 323

Fig. 324 - Activate spark plug then click on the plug For each single summary page the possibility to turn back to the main page exists. Burner testing is the only exception. Button “measuring data acquisition”:

20-69

Calibrations and electronic diagnosis Pushing the button “Measuring Data Acquisition “, the user will be skipped back to the diagnostic page “Measuring Data Acquisition”, that will allow to record and trace the measurements of the main page. To verify, that the engine is running, so that the DPF-System is able to work, therefore the engine speed will be checked. If the engine doesn’t run, the user is asked to start the engine with the following message:

Fig. 325

Important values of the DPF-burner system are shown in various labels in the upper half of the functional area. For example the “combustion chamber temperature“ at the top, the “burner air mass flow reference value“, the “burner air mass flow actual value“ in the left labels, such as the secondary fuel injection mass of the burner in the right label. In the middle the status display of the burner is placed. Next image shows functional area upper half.

Fig. 326

In the lower half of the functional area important values of the DPF in various labels are shown. These are: the “exhaust gas temperature“ at the entry of the diesel oxidation catalyst (DOC) in the left label l the “exhaust gas temperature reference value“ and the actual value in the right label l In the middle the status display of the DPF is placed Next image shows functional area lower half. l

Fig. 327

In the picture on the upper left hand side the time since last successful regeneration is shown.

Fig. 328

Values DPF The overview page for the measurement “Measuring Data Acquisition“ shows the indicated values from the DPF main page as a graphical tool.

20-70

Calibrations and electronic diagnosis

Fig. 329 - Screen: measurement Demo modus Within the diagnostic application of the Deutz DPF-system, there is a DEMO-mode integrated, that can be activated, by mouse clicking the DEMO button in the upper right corner of the system overview, on the DPF main page. In the DEMO-mode a real DPFburner system will be simulated. It basically only shows what plausible values of a DPF-burner will be shown.

20-71

Calibrations and electronic diagnosis

Fig. 330 - Screen DPF DEMO-mode Diesel particulate filter (DPF) and burner Here the system component “Diesel Particulate Filter (DPF) and burner“ will be shown.

20-72

Calibrations and electronic diagnosis

Fig. 331 - Burner top view With pushing the button “switch burner on/off” the burner can be switched on and by pushing it again, it will be switched off.

The button “Measuring Data Acquisition” traces the indicated values from the DPF main page for measurement into a graphical tool.

20-73

Calibrations and electronic diagnosis

Fig. 332 - Screen: measurement By pushing the button “request regeneration” a regeneration can be started on demand.

The actual status of the burner is shown during regeneration at the status display. Fig. 333

Click on the symbol to change the burner conditions:

Table 120 Possible burner conditions

state 1 of burner initialization: stand by

Fig. 334

20-74

Calibrations and electronic diagnosis Possible burner conditions

state 4 of burner: preheating

Fig. 335

Fig. 336

Fig. 337

Fig. 338

state 8 of burner: ignition

state 16 of burner: ramping

state 32 of burner: on

state 64 of burner: glowing off

Fig. 339

20-75

Calibrations and electronic diagnosis Table 121 For changing DPF-conditions, press onto the symbol:

state 1 DPF: initialization / state 2 DPF: charging/loading

Fig. 340

Fig. 341

state 4 DPF: cat-warm up (start burner) / state 8 DPF: warm up phase (HC-injection)

state 16 DPF: regeneration

Fig. 342

At the same time the temperatures before and after DPF (or DOC), and the DPF differential pressure, can be checked in the lower half of the screen.

Fig. 343 - Check temperatures before and after DPF (or DOC) DPF End of Line Test

20-76

Calibrations and electronic diagnosis By pressing EOL Button an EOL-test of the DPF burner system can be started.(only level access 2 or higher!)

WARNING The EOL (End of line) Test is available with software P_802_592_XXX or higher. Important The tests are running fully automatic. At the end a result for the complete test is shown (Test successful / not successful). WARNING The individual test functions can be activated only above a minimum coolant temperature of 70°C.

Fig. 344 - DPF EOL-Test By clicking on End of line (EOL) Test the test will be started. Depending on the engine temperature this test will take about 15 minutes. For a successful EOL-test two conditions must be guaranteed, on the hand the coolant-temperature needs to be at least 75 °C and the engine needs to running, else the test will fail. The button named burner test will start the burner, afterwards SerDia feeds back wether the burner has started successfully. Clicking on the button named deflate pipes will vent the pipes concerning the entire DPF-Burner system. It is recommended to vent the pipes before operating the DPF-burner system for the first time as well as after draining the fuel pipes. 20-77

Calibrations and electronic diagnosis Clicking on the button named Reset ash Load, will reset the maintenance intervals for the ash-load within the ECU. Analogously the buttons reset soot load and reset ash & soot load. Important This is a service function, which is required after each exchange of DPF-filter.

If a filter regeneration was not possible for an extended period, a service regeneration is required. A click on this button will start the service regeneration. Fig. 345

If a filter regeneration was not possible for an extended period, a service regeneration is required. A click on this button will start the service regeneration. By pressing the shown button the window “Measuring Data Acquisition DPF” will open (see Values DPF).

By pressing next button the screen of the supply module will be opened.

By pressing next button the results of the individual EOL-tests will be stored (with added information about engine type, machine type, etc.).For documenting the EOL-test results either a unencrypted as well as a encrypted file will be generated.

20-78

Calibrations and electronic diagnosis

Fig. 346 - Additional information for documentation of DPF EOL-test Supply Module DPF, burner The overview page allows to control each valve for fuel injection of the burner and for HC-injection.

20-79

Calibrations and electronic diagnosis

Fig. 347 - Supply Module On the left side the component view of the supply module is placed, on the right side a simplified representation of the circuit is shown. Above a functional area is available. It contains control elements, which, if activated, indicate actual values like pressure or temperatures directly into the simplified representation circuit. Additionally the position of each component will be shown by a color labeling in the component view. Important Further function is only available with access level 3 or higher!

Air pump The system component air pump is described on the overview page as well.

20-80

Calibrations and electronic diagnosis

Fig. 348 - Air pump For the air pump functional test, a setpoint can be given manually. Important The manual air pump functional test is only available for some versions of the ECU-software.

With the linear regulator an air mass flow can be chosen for setpoint of the air pump. The label above the linear regulator shows the actual setpoint. After that the setpoint has to be confirmed by pressing the button “ok”.

For finishing the test the “Stop Button” can be used.

Following values will be shown in the left picture above the air pump:

20-81

Calibrations and electronic diagnosis Table 122 At the top on the left: At the top in the middle: In the middle: At the bottom on the right:

Air pump rotation speed Air mass flow(reference value) Air mass flow (actual value) Air pump pressure

Spark plug

Fig. 349 - Setting the spark plug in ignition-mode via SerDia Pressing the small spark plug picture next to the red 4, shown in the System Overview in Use-Case mainpage DPF, will let the picture shown above pop up. Placing the hook in the little Check-Box “activate spark plug” will start the ignition process. Analogously, unhooking the check box will deactivate the ignition process. Please notice the trailing time of the system! WARNING Be aware of the high Voltages during the ignition process, which can seriously harm human beings as well damage either Equipment or Engine periphery. Important All safety precautions must be checked prior to start functioning!

WARNING Keep ready to use the emergency stop of the machine!

20-82

Calibrations and electronic diagnosis Program handling - Usecases EMR3 Important Further function is only available with access level 2 or higher!

Graphic display EMR3 On the following summary page are information displayed to possible experiments or UseCases. Here the user can select pre-configured experiments.On the right side is a favorites list shown, which allows to choose experiments directly. Adjacently tree structure contains all experiments. By selection of a branch and confirm the “ok-button” the respective experiment will be opened.

Fig. 350 - Graphic display By pushing following button next to the tree structure the favorites list on the right side can be edited.

Following window opens for editing the favorites list:

20-83

Calibrations and electronic diagnosis

Fig. 351 - Editing the favorites list Important The favorites list can consist of only 10 favorites!

20-84

Calibrations and electronic diagnosis Favorites can be removed or added to the list by using following arrows:

Fig. 352

20-85

Calibrations and electronic diagnosis The vertical arrows are used to sort within the favorites list.

Fig. 353

Leaving the settings is possible by pushing button:

Possible interactions for all following experiments Select readings: In this dialogue the user can choose a selection of displayed signals. By default, all signals are activated. Depending on the respective experiment the measured values of the measurement vary.

Fig. 354

Scaling y-axis: double click onto the values of the axis. Above shown window will pop up and a new value can be given.

Fig. 355

20-86

Calibrations and electronic diagnosis Change of background color. By default is set black. Fig. 356

Functions of diagrams

Table 123 Button

Function

Start of measurement

Fig. 357

Fig. 358

Fig. 359

Fig. 360

Fig. 361

Description

Measurements will be displayed in a diagram. After stopping the measurement temporary data can be saved.

Start of measurement record (before start- Before starting recording the data name of the recording must ing measurement a file name for storing be entered. data has to be defined).

Interrupt measurement (Pause)

The measurement will be interrupted until renewed entering the button.

Stop of measurement

After stopping the measurement, the displayed data can be stored, pressing “Save measurement” button.

Open measurement

This button opens a saved measurement.

Delete measurement

With this button the measurement can be discarded.

Fig. 362

20-87

Calibrations and electronic diagnosis Button

Function

Fig. 363

Fig. 364

Fig. 365

Description

Save measurement

This buttons stores the measurements data in a measurement file.If the data name is not entered yet,the dialogue appears to save the measurement file. The directory can be selected and the filename has to entered.

Correlation / Adjust Trigger

Hereby a correlation can be created between measured values and trigger.

spreadsheet window separating / docking The table of measurement names and the actual measurements for placing on the screen can be separated or renewed docked.

Switch to Bosch acronyms instead of nor- By default measurement names will be shown in the selected mal parameter labels language. By pushing this button the Bosch acronyms will be displayed. By renewed entering the button the selected language will be displayed renewed.

Fig. 366

Analogue speed setpoint EMR3 To use this UseCase, the engine has to run in allspeed-governor mode or min-/max-governor mode. Speed set point has to be activated via analogue signal (foot pedal, hand throttle, e.g.).

20-88

Calibrations and electronic diagnosis

Fig. 367 - Screen analog speed setpoint SerDia is identifying the configuration of the analog speed set point facilities and shows, depending on the setting in the ECU, the values for foot pedal and / or handgas. Additional the measured values of the signals (in %) are shown on the screen. The resulting speed setpoint, depending on functional scope (mostly maximum of pedal, handgas wins), is shown, too. Process of automatic calibration

20-89

Calibrations and electronic diagnosis

Fig. 368 - Chosen “automatic mode” When pressing button “auto” the automatic mode for calibration is started, Button on the screen is marked yellow. On the left side of the page the values for minimum, maximum and the actual measured values are shown.

20-90

Calibrations and electronic diagnosis

Fig. 369 - End “automatic mode” A second click onto the button “auto” stops the automatic mode. The values for pedal, low and high limit are calculated. After starting the automatic mode SerDia learns the new values for the limits while pushing the pedal several times. The threshold values and the pedal characteristic is calculated and shown on the screen. After calculation a validation is done. The values for 0% and 100% pedal have to differ 1V in minimum. The low and high limit have to have a gap of min. 200mV to the values 0V and 5V. If one of this checks is hurt, the respective value is marked red and the user is informed about the violation of the limit. Process of automatic calibration: By repeatedly up and down moving the pedals SerDia learns the actual pedal limits and calculates the necessary pedal curves and error limits. The user has to make sure, that the mechanical limits are reached while pushing the pedal or throttle. After finishing calibration the new values can be stored into the ECU or rejected. WARNING The user is responsible for plausibility and check of the new values. The liability for parameter changes is taken by the user. Process of hand mode calibration Important The manual mode should be used only by experienced users!

20-91

Calibrations and electronic diagnosis

Fig. 370 - Chosen “hand mode” When pressing button “hand mode” the actual values from dataset are collected and shown at the tables and text fields on the screen. The user is able to make changes by hand. The “hand mode” button has changed color to yellow.

20-92

Calibrations and electronic diagnosis

Fig. 371 - End “hand mode” Second click on “hand mode” starts the check and validation procedure in SerDia. The values for 0% and 100% pedal have to differ 1V in minimum. The low and high limit must have a gap of min. 200mV to the values 0V and 5V. If one of this checks is hurt, the respective value is red marked and the user is informed about the violation of the limit. WARNING It is recommended to use the hand mode function only if experienced. WARNING The user is responsible for plausibility and check of the new values. The liability for parameter changes is taken by the user. Storing data Pressing button “read data from ECU” all new values are rejected and deleted.

20-93

Calibrations and electronic diagnosis Pressing button “store in ECU” the new values are transfered to the ECU and stored. Old values are gone.

Important It is recommended to use the automatic mode for calibration of the foot pedal. If the hand mode is used by the experienced user, the values for the throttle have to be prepared by user himself. Constant speed adjustment EMR3 To use this function, the engine has to be in fixspeed mode or the setting allows to activate the fixspeed mode.

Fig. 372 - Screen change constant speed The actual setting for the fixspeed values are shown on the left upper part of the screen. The setting of the switch is marked, too. Left hand placed is the status for the constant speed position switch as marking point. Additionally the actual engine speed and the speed setpoint is shown as value and tachometer on the right side inclusive hysteresis to have a qualitative feedback. Pressing button “read from ECU” the original stored values of the ECU were refreshed on the screen. Changes of the values are deleted

20-94

Calibrations and electronic diagnosis Pressing button “write values to ECU” values shown on the screen for fixspeed 2 (first intermediate speed) and fixspeed 3 (2. intermediate speed) are flashed to the ECU. If the engine is still running while activation of this procedure, SerDia will ask to stop engine automatically.

Important The values for fixspeed 1 (low idle) and fixspeed 4 (high idle) cannot be changed free because they are linked to low, respectively high idle. Text box “Constant Speed 2”,”Constant Speed 3”. Changes in these text boxes have to be confirmed with ENTER. After confirmation the new value will get active, if switched on (see marking point at fixspeed). It is not possible to install a speed below fixspeed one or above fixspeed four. The fixspeed 1 and 4 are not changeable in this screen (see hints above).

Fig. 373

Limp home adjustment EMR3 In case of failure of the accelerator pedal or the CAN-Bus the emergency speed intervene to be in a constant condition.

Fig. 374 - Screen Set emergency speed The emergency speed can be pretended in the right text box. Possible interactions:

20-95

Calibrations and electronic diagnosis l

Store emergency speed in ECU by entering.

l

Read emergency speed out of the ECU.

Important The emergency speed range is limited from low idle up to 1200 rpm!

EEPROM error reset EMR3

Fig. 375 - Screen EEPROM error reset EMR3

20-96

Calibrations and electronic diagnosis The EEPROM errors can be stored by entering following button, the lamp besides the button indicates whether the system is ready or not.

Fan control EMR3 The UseCase of the fan control basically consists of the adjustment values: 1. 2. 3.

Parameters Characteristics Maps

These consist again of several sub items.

Fig. 376 - Screen fan control Left side shows an overview about the possible adjustment values. On the right side is a graphical display placed, which shows various fan parameters, possible to take a look at. Below the graphic display there is button located for storing data in the ECU.

20-97

Calibrations and electronic diagnosis Below the graphic display there is button located to reset to default values.

If a parameter is selected, either default and current parameter value is displayed below the graphical display. Actual measurements and initial values can be confirmed by entering following button.

By default the settings, as described in chapter measurements, are possible to adjust except adjusting the background color. Scaling y-axis: double click onto the values of the axis. Above shown window will pop up and a new value can be given.

Fig. 377

Functions of diagrams

Table 124 Button

Function

Start of measurement

Fig. 378

Fig. 379

Fig. 380

20-98

Description

Measurements will be displayed in a diagram. After stopping the measurement temporary data can be saved.

Start of measurement record (before start- Before starting recording the data name of the recording must ing measurement a file name for storing be entered. data has to be defined).

Interrupt measurement (Pause)

The measurement will be interrupted until renewed entering the button.

Calibrations and electronic diagnosis Button

Function

Fig. 381

Fig. 382

Fig. 383

Fig. 384

Fig. 385

Fig. 386

Description

Stop of measurement

After stopping the measurement, the displayed data can be stored, pressing “Save measurement” button.

Open measurement

This button opens a saved measurement.

Delete measurement

With this button the measurement can be discarded.

Save measurement

This buttons stores the measurements data in a measurement file.If the data name is not entered yet,the dialogue appears to save the measurement file. The directory can be selected and the filename has to entered.

Correlation / Adjust Trigger

Hereby a correlation can be created between measured values and trigger.

spreadsheet window separating / docking The table of measurement names and the actual measurements for placing on the screen can be separated or renewed docked.

Switch to Bosch acronyms instead of nor- By default measurement names will be shown in the selected mal parameter labels language. By pushing this button the Bosch acronyms will be displayed. By renewed entering the button the selected language will be displayed renewed.

Fig. 387

20-99

Calibrations and electronic diagnosis Parameters Actual measurements and initial values can be changed directly in following text bar:

Fig. 388 - Screen actual and default values Actual measurements and initial values can be confirmed by entering following button and stored into RAM.

Following parameters can be changed: l l l l l l l l

D-component of the amplitude ratio of fan speed Extended coolant temperature slope Fan speed I-component within range I-component fan speed for signals below limit I-component fan speed for signals above limit P-component fan speed for signals below limit Expansion of the coolant temperature P-component P-component fan speed for signals above limit

Characteristics Actual measurements are shown below the graphical display in tabular form with the x-value and the respective FNC.

20-100

Calibrations and electronic diagnosis

Fig. 389 - Screen actual and initial values Actual measurements and initial values can be confirmed by entering following button and stored into RAM.

Following characteristics can be changed: l l l l l l l l l l l l l l l l l

Group characteristics of the fan speed addicted P-component in range P-component group characteristics of the fan speed below the limit P-component group characteristics of the fan speed above the limit Actual P-component of the PID-controller coolant temperature Group characteristics of the fan speed addicted I-component in range I-component group characteristics of the fan speed below the limit I-component group characteristics of the fan speed above the limit Actual I-component of the PID-controller coolant temperature Group characteristics of the fan speed addicted D-component in range Group characteristics of the fan speed addicted to waiting time Group characteristics D-component of the coolant temperature Group characteristics D-component of the engine speed Actual D-component of the PID-controller coolant temperature Group characteristics of the coolant temperature addicted I-component in range Group characteristics of the engine speed addicted I-component in range I-component of the group characteristics of the coolant temperature below limit I-component of the group characteristics of the engine speed below limit 20-101

Calibrations and electronic diagnosis l l l l l l l l l l

I-component of the group characteristics of the coolant temperature above limit I-component of the group characteristics of the engine speed above limit Group characteristics of the coolant temperature addicted P-component in range P-component of the group characteristics of the engine speed above limit P-component of the group characteristics of the coolant temperature below limit P-component of the group characteristics of the engine speed below limit P-component of the group characteristics of the coolant temperature above limit ID ‘P-component of the group characteristics of the engine speed above limit not found Actual relation of CAN adaptation Actual value of output fan speed adaptation

Maps Current and initial values of the map for fan speed are shown below graphical display and can be changed directly in the map.

Fig. 390 - Screen actual and initial values The fan speed is divided into 5 steps. X (horizontal axis) represents engine speed [rpm]. Y (vertical axis) represents the fan speed [rpm]. By double clicking on the FNC-value the respective speed can be changed. Current and initial values can be confirmed by entering button. These values will be stored in the RAM.

20-102

Calibrations and electronic diagnosis Input test EMR3 With the UseCase “Input test” security systems such as switches, warning lamps can be checked in the left third of the window. The central part of input test contains current motor values. On the right side of the window are shown the engine speed, injection volume and rail pressure.

Fig. 391 - Screen input test Low idle adjustment EMR3 It is provided for using this function, that the engine is operating in min-/max-governor or allspeed-governor mode (f.e. not fixspeed).

20-103

Calibrations and electronic diagnosis

Fig. 392 - Screen: idling control SerDia reads out the actual values of idle run and copies them into the labels in the sub array on the left hand side. This values will be saved further, too. In parallel a tachometer operates on the right hand. The actual setpoint value and the actual rotating speed are shown, each as a decimal value below the tachometer and also with indicator and hysteresis region. Button “read data from ECU” went back to previous value of idling speed, which was acquired at the start of the UseCase.

Button”store in ECU” writes all variables for idle speed back into the ECU. If the engine is still running, SerDia will offer to stop the engine automatically, so that the programming of the ECU can take place.

Text box “new value”, an input into this text box has to be confirmed by ENTER. After that, SerDia changes all variables for idle speed and switches over to working page, so all changes will be activated in realtime.

Fig. 393

20-104

Calibrations and electronic diagnosis Important The input is limited for a speed range of 600 – 1200 1/min.

Fault location The most frequent reasons for problems in SerDia2010 are: l l l l

Dead file bodies of previous SerDia-installations Power management of computer long low cost USB-cable (> 2m) Intermittent electrical contact in the diagnostic electric line

FAQ 1. Error l

SerDia won’t start, after installing.

Action l

Go to the Folder C:\DEUTZ\SerDia\lic\... and execute workaround2.reg by double-clicking it. Follow the systems-instruction and restart SerDia2010

2. Error message l

Java Virtual Machine Launcher.

Fig. 394

Action l

To install the workarounds you unpack the ZIP archive (from Z_ into ZIP):C: \DEUTZ\SerDia\Lic and rename the R_data in .REG. By double clicking on the REG file the workaround will be installed.

3. Error message l

Program for executing could not be found

Action l

Open the .reg file, which can only runs on the target system. This can be seen in: C:\ \Windows\SysWOW64\

4. Error message l

Missing link to DAPS-file

Action l

Start registry-program for workaround (See error message 1).

5. Error message l

Serdia2010.daps and default .daps find no ECU or no SW-Version. Data speed (baud-rate) error is shown.

Action l

Check termination resistors. CAN-High and CAN-Low exchange. With different baud rates on the Bus take an ECU with 250 KBaud-DS or repair the bus.

6. Error message l

No valid license not found.

Fig. 395

Action 20-105

Calibrations and electronic diagnosis l

Will be displayed when a new license file is replaced by an older one. Use newer license file!

7. Error message ZIP-installation problem.

l

Fig. 396

Action l l

(Firewall problem) Solve the problem: 1. By IT-department which “untreated” takes or 2. new FTP-Link with the same file but “harmless” file ending adjust

8. Error message l

Device manager.

Fig. 397

Action l

See next image.

Fig. 398

9. Error message l

Not a valid password.

Fig. 399

20-106

Calibrations and electronic diagnosis Action l

Install newest SerDia-Version (1.8.750) with newest licence file, because older databases contain old passwords.

20-107

Calibrations and electronic diagnosis 20.4 - Commissioning and calibrating the tractor

20.4.1 - Putting in service - Introduction (Software HLHP versione SC134AE) The procedures described in the following chapters apply to version SC134AE of the HLHP control unit software.

These procedures must be performed in the event of replacing an HLHP con unit in an Agrotron TTV 72-10-7230-7250 models or in the event of a software update.

Table 125 PROCEDURE

Basic procedure for startup End of line settings Transmission PTO ASM Lift

Suspension System Distributors

Engine

Air conditioner Park brake Agrosky MR-D Cabin Delete alarms

HEADING

. Configuration . Calibration

. Options . Calibration . Calibration of potentiometer . Type . 4WD . System . PLA configuration Parameters CAN program Curves Flow control JoyNeut. Calibration Step +- Analog Throttle pedal Hand gas Engine speed Valve Recirculation

Enable Cabin suspension calibration

20.4.2 - Putting in service - Basic procedure for startup 1. 2.

Turn off the engine . Connect to the diagnostics socket A. R.T.

20-108

20-108 20-112 20-113 20-122 20-123 20-125

20-129 20-131 20-138

20-147

20-150 20-154 20-155 20-155 20-158

Calibrations and electronic diagnosis 3.

Turn the ignition key in the second position. m m m m m m m m m m m m m

2. Tractor model 3. Software version 4. Software date 5. Type of transmission 6. Maximum set velocity 7. Selected tyres 8. Type of front suspension 9. Front PTO presence 10. Radar Presence 11. Automatic air clima presence 12. Type of el. Distributors 13. Front lift assignment 14. Semiactive Cabine suspension presence

- - A g r

T S T S A F R A D F C

- o t D 0 5 N S E D E P .

L n r 4 R A : P E : Y R : U S : S M : . P T O : A D A R : / C : I S T R . : . L I F T : A B . M R D : [

r F M

H o _ 0 .

E ]

H P T 2 5 - 2 E C 4 0 2 0 3 V Y e Y e N o Y e 7 C N o N o

T 5 0 C . I s s

- V 1 O k 8

-

-

-

3 M 1 . 5 m / h R 3 8 “

s A N

E X I

T

Fig. 400

EEPROM memory reset 1.

Press two times button [0] in order to insert the password

-

-

-

-

-

-

M E N U -

P a s s w o r

d :

-

-

-

-

-

C 1 B 0 9 0

Fig. 401

2.

Enter password: C1B090 After digit the password presentation screen is shown. Press [E] to enter main menu. It is activated the hide function “EEPROM init.”

-

-

-

-

M A I - - -

1 2 3 4

-

M C T A

o a e l

n l s l

A -

i i t a

N - -

t o r s b r a t i s r m s

E E P R O M

[

E ]

M E N U - - - - - -

I

o n s

n i

E X I

-

t

.

T

Fig. 402

20-109

Calibrations and electronic diagnosis 3.

Press [A] to start initializing procedure and reset the EEPROM.

E E P R O M

E E b e e n w i t p a

I

P R O i n i h d r a m

N I

M t i e f e t

h a a e

T .

a l u r

s i s e d l t s

= = = = = = = = = = = = = = = = [

E ]

E X I

T

Fig. 403

4.

In order to end correctly the initialization turn off and then turn on ignition key.

Tractor model selection 1.

Reconnect SAME ART. The tractor model is undefined.

-

T S T S A F R A D F C

- - ? ?

R P Y U S . A / I . A

? D F 0 5 A N S M E E D R E S P . M P T O D A R C S T R . L I F T B . M R [

-

H L ? _ r 0 4 . : : : : : : : : : : D :

E ]

H P ? 2 5 - 2 N o 2 0 1 8 N o N o N o N o N o N o C 1 N o

-

- - - ? ?

-

5 0 1 3 C o n f i g k m / h . 4 R 3 8 “

-

E X I

> D 1 T

Fig. 404

2.

Press [E] to start the configuration procedure. Press [5].

-

-

5 -

-

-

M A I - - -

C o n f

[

E ]

i

N - -

M E N U - - - - - -

g u r

a t

E X I

i

-

o n s

T

Fig. 405

20-110

Calibrations and electronic diagnosis 3.

Press [F] if your model is not shown and you want to look next page. -

-

T R A C T O R - - - - - - - -

M O D E L - T 7 1 0 0

1 2 3 4 5 6 7 8

-

K I R X K I R X

i L r v

R O 6 . M P R O 6 . M

N

r o f N H H i H i -

i i L

L P e

n i o e

[

F ]

P a g e

[

E ]

E X I

e n e f i l l

e

+

T

Fig. 406

4.

In this page it could be configured the transmissions ECCOM1.5 e ECCOM1.3

-

-

1 2 3 -

[ [

T R A C T O R - - - - - - - -

A g r o t S A M E L a m b .

D ] F ]

M O D E L - E C C O M

r o n C o n t R 7 .

P a g e P a g e E ]

[

T T V i n u o V R T

+

E X I

T

Fig. 407

5.

In this page it could be configured the transmissions SMATIC S180 e SMATIC S240.

-

-

1 2 3 -

[ [

T R A C T O R - - - - - - - -

M O D E L - E C C O M

D e u t z T T V S A M E T T V L a m . b T T V

D ] F ]

P a g e P a g e E ]

[

E X I

+ T

Fig. 408

6.

Select the right model, e.g. Agrotron TTV.

20-111

Calibrations and electronic diagnosis 7.

Switch off and then switch on the ignition key to complete the configuration .

S s c c

w w o o

i i m n

t t p f

c c l i

h h e t g u

O F F O N t e t h r a t i

a n d o e o n

Fig. 409

20.4.3 - Putting in service - End of line settings 1.

Reconnect the SAME All Round Tester. Now in presentation screen you can see the model of the tractor.

- - A g r

T S T S A F R A D F C

- o t D 0 5 N S E D E P .

L n r 4 R A : P E : Y R : U S : S M : . P T O : A D A R : / C : I S T R . : . L I F T : A B . M R D : [

r F M

H o _ 0 .

E ]

H P T 2 5 - 2 N o 0 0 1 8 3 V Y e N o N o N o N o N o N o

T 5 0 C . I s

E X I

- V 1 o k 4

-

-

-

3 n f m / h R 3 8

T

Fig. 410

2.

Press [E]. Enter main menu and press [2] to enter in calibration menu.

C = 1 2 3 4 5 6 7 8 9 A B C D

A = -

L I = = T r P T A S L i S u S y C A Di E n A i P a A g M R [

B = a O M f s s N s g r r r -

R A T I O N M E N U = = = = = = = = = = = n s m i s s i o n

t p e n s i t e m t i C k o D

E ]

r n o B s

i e n r k C

o n

b u t

o r

s

d i t . a k e y P S a b E X I

T

Fig. 411

20-112

Calibrations and electronic diagnosis 20.4.4 - Putting in service - Transmission Configuration 1.

Press [1] to enter in transmission menu.

T R = = = = 1 - C o 2 - C a

[

A = n l

N = f i

E ]

S = i b

M = g r

I = u a

S = r t

S = a i

E X I

I = t o

O N = = = = i o n n

T

Fig. 412

2.

Press [1] to enter in configuration.

C O N = = = = 1 - T r 2 - W h 3 4 5 -

G U R A T = = = = = s m i s s B a s l W h e e l C i r S p e e d R e v . L e v e

[

F = a e

I = n e

E ]

E X I

I O N = = = = = i o n e c u m f

.

r

T

Fig. 413

3.

Press [1] to set the type of transmission. In particular: TTV 7210 TTV 7210 Heavy Duty m TTV 7230-7250 m TTV 7230-7250 Heavy Duty Select right transmission pressing [1],[2],[3] or [4]. m m

= 1 2 3 4 5

= -

T = S S S S S

R = 1 1 1 2 2

A = 8 8 8 4 4

[ [

A ] C ]

N S M I S S I O N = = = = = = = = = = = 0 S T D N e w 0 S T D O l d 0 H D 0 S T D 0 H D

A b o r S t o r

t e

Fig. 414

20-113

Calibrations and electronic diagnosis 4.

Wait until configuration is successfully finished. = = = = = = = = = = = = = = = =

W a i t c o m m u n i

f o r c a t

i

o n

= = = = = = = = = = = = = = = = [

E ]

E X I

T

Fig. 415

5.

Switch off and switch on the tractor and then connect again the SAME ART. = = = = = = = = = = = = = = = =

c o n f i g u r a t i s u c c e s s f u l

o n l

= = = = = = = = = = = = = = = = [

E ]

E X I

T

Fig. 416

6.

An error can occur during the configuration. The errors have the following code:

Table 126 VALUE

7.

0D 0E 2A 3F 48

DESCRIPTION

configuration prog. idle wait for configuration confirmation configuration prog. variant error configuration prog. variant and customer error configuration prog. customer error

Return in transmission configuration menu and press [2] to set the wheel type.

T T V W H E E L B A S E = = = = = = = = = = = = = = = =

1 2 3 -

1 8 . 2 0 . 2 0 .

[ [

A ] C ]

4 8 8

R 3 8 R 3 8 R 4 2

A b o r S t o r

t e

Fig. 417

20-114

Calibrations and electronic diagnosis 8.

From configuration menu, pressing [3] you can modify the preset value for the wheel circumference. Enter the new value and then press [E] to save it.

Fig. 418

9.

From configuration menu, press [4] and set the maximum speed for the tractor according with the law of the appropriate country.

V E L O C I T Y = = = = = = = = = = = = = = = =

0 1 2 3 4 5

-

2 3 4 5 6

[ [

6 0 0 0 0 0

A ] C ]

k k k k k k

m m m m m m

/ / / / / /

h h h h h h

A b o r S t o r

t e

Fig. 419

10.

From configuration menu, press [5] and indicate if reverser lever on the steering wheel is present or not.

R E V E R S E R L E V E R = = = = = = = = = = = = = = = =

0 1 -

N o t P r e s e n t P r e s e n t

[ [

A ] C ]

A b o r S t o r

t e

Fig. 420

20-115

Calibrations and electronic diagnosis Calibration 1.

Come back on Transmission menu, push [2] to enter in Calibration menu.

C A L I B R A T I O N = = = = = = = = = = = = = = = = 1 2 -

C l u t H y s t

c h a t .

4 5 -

P T O P r F r o n t

P e d a l U n i t

o p . W h e e l

s

= = = = = = = = = = = = = = = = [

E ]

E X I

T

Fig. 421

Clutch pedal calibration 1.

Press [1] in order to calibrate the minimum and maximum stroke of the pedal position.

= = = = = = = = = = = = = = = = P p e t p b t p

r e n h e r h o

e d d e d i e s

[ [

C ] E ]

s s a l o n a l n g s i t

f r

t i

t h e s l o t r e l e s l o i t a r t o n

S t a r E x i t

w a a w b i

t

c l v s l a n

l u t y t e l , e t y a c k g

C a l

i

c h o h e n d t o

b .

Fig. 422

2.

Press [C] to start the calibration. = = = = = = = = = = = = = = = =

c a l i n

i b r a t p r o g r

i o n e s s

= = = = = = = = = = = = = = = = [

E ]

E X I

T

Fig. 423

20-116

Calibrations and electronic diagnosis 3.

When calibration is finished, the following message is shown on the screen. = = = = = = = = = = = = = = = =

c a l i b r a t s u c c e s s f

i o n u l l

= = = = = = = = = = = = = = = = [

E ]

E X I

T

Fig. 424

4.

Table 127 VALUE

0x0A 0x0B 0x0C 0x46 0x55 0x56 0x57

DESCRIPTION

Operation not possible Operation is running Operation aborted Operation completed successfully Wheel circumference OK Wheel circumference below limit Wheel circumference above limit

Hydrostatic unit calibration 1.

From calibration menu press [2] to calibrate TCU (hydrostatic unit). On the screen it is possible to read the condition that it has to be reached. Engine has to run at least at 800 RPM, EPB has to be activated, brake and clutch have to be released.

Fig. 425

2.

Press [C] to start the automatic calibration. = = = = = = = = = = = = = = = =

c a l i n

i b r a t p r o g r

i o n e s s

= = = = = = = = = = = = = = = = [

E ]

E X I

T

Fig. 425

20-117

Calibrations and electronic diagnosis 3.

If something goes wrong, an error message appears on the screen. Look at the code error in order to get information on the error in the following table.

Table 128 VALUE

0x0A=11 0x0B=11 0x0C=12 0x0D=13 0x0F=31 0x20=32 0x46=70 00 01 02 03 06 07 08 09 0B 4. 5.

DESCRIPTION

Action not permitted, check enviroment condition; TCU change to shutdown, restart of TCU via ignition necessary Action running Action aborted, read enviroment information Waiting for engine running stable Calibration data valid (transition only) Calibration data invalid (transition only) Operation completed successfully Enviroment conditions OK Engine stop request Engine speed to low Engine speed to high Clutch K1 not engaged Transmission temperature to low Transmission temperature to high Minimum system pressure required Calibration tolerance exceeded

After an error turn off and turn on the machine. If the calibration is successful, the following screen appears on the display. Switch off and switch on the tractor and then reconnect SAME All Round Tester.

Fig. 426

= = = = = = = = = = = = = = = =

c a l i b r a t s u c c e s s f

i o n u l l

= = = = = = = = = = = = = = = = [

E ]

E X I

T

Fig. 426

20-118

Calibrations and electronic diagnosis Proportional PTOs calibration 1. 2.

The vehicle is equipped on the basic configuration with the rear proportional PTO. In optional, the front proportional PTO is available. Each PTO has to be calibrated, in order to assure a proper behaviour of the clutch modulation. From “Calibration” menu press [4] in order to start the PTO calibration. Before start the calibration the following conditions must be satisyed: m m m m m m m m

Engine must run at 800 rpm; EPB activated; PTO shaft locked; Direction command in neutral position; Direction command in neutral position; Clutch released; PTO command in 1000N position; Oil temperature must be greater than 30°C. Fig. 427

3.

After reaching the conditions; press [C] to continue.

Fig. 428

4.

When “ACTIVATE PTO” message appears on the screen activate rear PTO with the corresponding button. Calibration process will start automatically.

Fig. 429

5.

If something goes wrong, an error message appears on the screen with the corresponding error code.

Fig. 430

20-119

Calibrations and electronic diagnosis 6.

Look at the code error in order to get information on the error in the following table.

Table 129 VALUE

0x0A=10

7.

0x0B=11 0x0C=12 0x0D=13 0x0F=31 0x20=32 0x46=70 00 02 03 07 0E 19 21 28 64

DESCRIPTION

Action not permitted, check enviroment condition; TCU change to shutdown, restart of TCU via ignition necessary Action running Action aborted, read enviroment information Waiting for ePTO-ON signal Calibration data valid (transition only) Calibration data invalid (transition only) Operation completed successfully Enviroment conditions OK Delay limit of activating of PTO exceeded Park brake not engaged PTO speed above limit Calibration value range exceeded Engine speed deceleration range exceeded Engine load exceeded limit Oil temperature limits exceeded Calibration time limit exceeded

When the calibration process for the PTO is finished, the “TCU calibration successuful” message will be shown on the sreen.

Fig. 431

20-120

Calibrations and electronic diagnosis Front wheels calibration 1.

From calibration menu push [5] in order to start “Front wheels” calibration.

Fig. 432

2.

In order to do a correct calibration the following conditions have to be satisfy: Drive with a constant velocity (8 km/h); 4wd has to be disengaged. After reached these conditions press [C] to star calibration. m m

Fig. 432

3.

When calibration is finished the following screen appears on the display.

Fig. 433

20-121

Calibrations and electronic diagnosis 4.

If something goes wrong, e.g. velocity less than 5 km/h, an error message appears on the display.

Fig. 434

20.4.5 - Putting in service - PTO 1.

From “Calibration menu” press [2] to enter PTO menu.

C = 1 2 3 4 5 6 7 8 9 A B C D

A = -

L I = = T r P T A S L i S u S y C A Di E n A i P a A g M R [

B = a O M f s s N s g r r r -

R A T I O N M E N U = = = = = = = = = = = n s m i s s i o n

t p e n s i t e m t i C k o D

E ]

r n o B s

i e n r k C

o n

b u t

o r

s

d i t . a k e y P S a b E X I

T

Fig. 434

2.

The following points explain the meaning of each row on the screen: m m m m m

Number of teeth for the encoder on the rear PTO; Transmission ratio (x1000) of front PTO; Automatic PTO limit [% related to max height setting]; Maximum time in “stand-by” mode for PTO-Auto [s]; Time to activate rear PTO brake after PTO off (only when PTO brake is present) [s].

Fig. 435

20-122

Calibrations and electronic diagnosis 3.

Press [1] to set if is it present or not the front PTO. Options from 2 to 6 are tuneable parameters. Option “Present auto” means that the front PTO works in auto mode related to the position of rear lift.

Fig. 436

20.4.6 - Putting in service - ASM 1.

From “Calibration menu” press [3] to enter ASM menu.

C = 1 2 3 4 5 6 7 8 9 A B C D

A = -

L I = = T r P T A S L i S u S y C A Di E n A i P a A g M R [

B = a O M f s s N s g r r r -

R A T I O N M E N U = = = = = = = = = = = n s m i s s i o n

t p e n s i t e m t i C k o D

E ]

r n o B s

i e n r k C

o n

b u t

o r

s

d i t . a k e y P S a b E X I

T

Fig. 436

2.

The following points explain the meaning of each row on the screen: m m m m

Steering angle for deactivation of DT (4WD) [°]; Steering angle for deactivation of DiffLock [°]; Speed for deactivation of DT (4WD) [km/h]; Speed for deactivation of DiffLock [km/h];

Fig. 437

20-123

Calibrations and electronic diagnosis 3.

Press [2] to set if ASM is present or not.

Fig. 438

4.

From ASM menu press [7] in order to calibrate the steering sensor. Move the steering wheel until the wheels are straight, than press [E] to confirm and [C] to store the new value.

Fig. 439

5.

From ASM menu, press [8] to set the front speed sensor. The sensor can be present or not [0]; if it is present, it can be active[1] or not [2]. When active, all the warnings are displayed otherwise the warnings are not displayed .

Fig. 440

20-124

Calibrations and electronic diagnosis 6.

From ASM menu, press [9] to set if the hitch link is disabled [0] or enabled [1]. With hitch link enabled, when rear lift reached the “PTO auto threshold”, differential lock will be deactivated. This support user to change direction during work with tools.

Fig. 441

20.4.7 - Putting in service - Lift 1.

From “Calibration menu” press [4] to enter “Lift” menu.

C = 1 2 3 4 5 6 7 8 9 A B C D

A = -

L I = = T r P T A S L i S u S y C A Di E n A i P a A g M R [

B = a O M f s s N s g r r r -

R A T I O N M E N U = = = = = = = = = = = n s m i s s i o n

t p e n s i t e m t i C k o D

E ]

r n o B s

i e n r k C

o n

b u t

o r

s

d i t . a k e y P S a b E X I

T

Fig. 441

Options 1.

Press [1] to enter in “Options” menu.

Fig. 442

20-125

Calibrations and electronic diagnosis 2.

The following list describe the meaning of each row of the screen: m m m

m m

m m

m

m

1. Autodrop: control of lowering speed. 2. Sensitiv.: sensitivity of the sensor. 4. MIX mode: enable or disable Mix mode control of the lift using a mixed position/draft control. 6. 100mm Cyl.: set the presence of a bigger cylinder. 8. RadarEnable: set the presence of the radar sensor to measure the actual speed of the tractor. 9. Radar K: set the value of the radar speed sensor costant. A. A.D. Speed: below this value of velocity [x0.1 km/h] of the tractor, the speed for lower the lift is blocked to the minimum. B. Buzzer: set how the system inform the user about the lockage of the lift. C. LockButt: set the presence of the additional button to lock/unlock the lift.

Fig. 443

Auto drop 1.

From previous screen press [1] to set the “Auto drop” functionality. MANUAL: The lowering of the rear lift is commanded with the same parameters of the rear lift control algorithms m AUTOMATIC: The lowering of the rear lift is commanded with a controller velocity up to the memorized rear lift postion, then the lowering is done with the same parameters of the rear lift control algorithms m SEMI-AUTOMATIC: The lowering of the rear lift is commanded with a controller velocity Based on the type of “Auto drop” push [0],[1] or [2] button. Press [C] to store the mode and exit. m

Fig. 444

Mix mode 1.

From previous screen press [4] to set the “Mix mode” functionality. Operator can enable [1] or disable [0] Mix mode control of the lift using a mixed position/draft control. When MixMode is enabled, the MIX potentiometer work in a way to mix the position control mode and the draft control mode according to the position of the potentiometer itself. When MixMode is not enabled, the MIX potentiometer work in draft control mode, moving the potentiometer in the direction of the “position control” the rear lift works in draft control with progressive reducing of max depth. Close to the “control position” position of the potentiometer, the rear lift work in position control.

Fig. 445

20-126

Calibrations and electronic diagnosis 100mm lift cylinder 1.

From previous screen press [6]to set the “100mm lift cylinder” functionality. Press [0] if the bigger cylinder is absent or [1] if it is present.

Fig. 446

Radar 1.

From previous screen press [8]to set the “Radar” function. Press [0] if the radar is not present or [1] if the radar is present.

Fig. 447

Buzzer 1.

From previous screen press [B]to set how the system inform the user about the lockage of the lift. Press the number for the corresponding option and than [C] to store the configuration.

Fig. 448

20-127

Calibrations and electronic diagnosis Lock/unlock 1.

From previous screen press [C]to set the “Lock/unlock” function.

Fig. 449

Calibration 1.

Press [2] to enter in “Calibration” menu.

Fig. 449

2.

m

m

m

m

m

m

m

m

20-128

1 - MinHeight is the calibration of the lowest rear lift position (harms completely down). 2 - MaxHeight is the calibration of highest rear lift position (harm completely up then slow down some degree). 3 - Lockspeed over this velocity [km/h] of the tractor, lift will be blocked. For the manual control with the fender pushbuttons there are 2 different ramp, first a soft ramp (4-low speed), then a strong ramp (5-high speed). The shift from low speed to high speed is done in time. 4 - Low speed is the setpoint of the rear lift velocity in the from the start of the activity on the external button up to “6-L.S.Time”. 5 - High speed is the setpoint of the rear lift velocity from the “L.S.Time” on. 6 - L.S.Time is the time expressed in second to switch between slow speed and fast speed. 7 - Step 1 is the agressivity of the adjustment when the low speed is active in order to keep the setpoint. 8 - Step 2 is the agressivity of the adjustment when the high speed is active in order to keep the setpoint.

Fig. 450

Calibrations and electronic diagnosis Calibration of potentiometer 1.

Press [3] to enter in “Calibration of potentiometer” menu.

Fig. 450

2.

Press the corresponding option to set the minimum or maximum value of the potentiometer. Minimum value is releated to minimum voltage, maximum value is releated to maximum voltage.

Fig. 451

20.4.8 - Putting in service - Suspension 1.

From “Calibration menu” press [5] to enter Suspension menu.

C = 1 2 3 4 5 6 7 8 9 A B C D

A = -

L I = = T r P T A S L i S u S y C A Di E n A i P a A g M R [

B = a O M f s s N s g r r r -

R A T I O N M E N U = = = = = = = = = = = n s m i s s i o n

t p e n s i t e m t i C k o D

E ]

r n o B s

i e n r k C

o n

b u t

o r

s

d i t . a k e y P S a b E X I

T

Fig. 451

20-129

Calibrations and electronic diagnosis 2.

Option [2] is the velocity limit below which the front suspension will be blocked ([km/h]).

Fig. 452

3.

Press [1] to set if the front suspension is present or not.

Fig. 453

Type 1.

From “Suspension” menu, press [3] to set the type of suspension: m m m m

0- 3 VALVES: Old 3 valves configuration. 1- 3 VALVES: Old 2 valves configuration. 2- 3 VALVES INT: New 3 valve INTEGRAL configuration. 3- 3 VALVES INT: New 3 valve INTEGRAL configuration with unlock system.

Fig. 454

20-130

Calibrations and electronic diagnosis 4WD 1.

From “Suspension” menu, press [4] to if the 4WD check is on or off. This function disable the lockage of the front suspension because of 4WD activation.

Fig. 455

20.4.9 - Putting in service - System 1.

From “Calibration menu” press [6] to enter “System” menu.

C = 1 2 3 4 5 6 7 8 9 A B C D

A = -

L I = = T r P T A S L i S u S y C A Di E n A i P a A g M R [

B = a O M f s s N s g r r r -

R A T I O N M E N U = = = = = = = = = = = n s m i s s i o n

t p e n s i t e m t i C k o D

E ]

r n o B s

i e n r k C

o n

b u t

o r

s

d i t . a k e y P S a b E X I

T

Fig. 455

System 1.

Press [1] to enter in the second “System” menu.

Fig. 456

20-131

Calibrations and electronic diagnosis 2.

m m m m m m m m m m

1. Language: set the system language. 2. Airbrake: airbrake system. 3. AirCond.: automatic clima system 5. TC Filt.: reset interval maintenance transmission oil filter 6. TC Oil: reset interval maintenance transmission oil 7. Rape Oil: set if it is used rape oil as fuel 8. iMONITOR: set presence of iMonitor/ISObus 9. Aux Tank: set presence of auxiliary fuel tank A. EngineBrake: set presence of engine exhaust brake B. Hydr Oil: reset interval maintenance for hydrauilc oil

Fig. 457

Language 1.

Choose a language from the list, then press the corresponding button ([0]… [7]).

Fig. 458

Air brake 1.

From “System” menu, press [2] to set if the air brake system is present or not.

Fig. 458

20-132

Calibrations and electronic diagnosis 2.

If it is present set the value to 1, if it is not present set the value to 0.

Fig. 459

Air conditioner 1.

From “System” menu, press [3] to set if the automatic air conditioner system is present or not.

Fig. 460

TC filter 1.

From “System” menu, press [5] to reset interval maintenance transmission oil filter.

Fig. 460

20-133

Calibrations and electronic diagnosis 2.

“Actual” is the last time when the filter has been changed. “New” is the actual value, in hours, of the filter. Press [E].

Fig. 461

3.

Press [C] to update and store the actual value of hours for the filter.

Fig. 462

TC oil 1.

From “System” menu, press [6] to reset interval maintenance transmission oil.

Fig. 462

20-134

Calibrations and electronic diagnosis 2.

“Actual” is the last time when the oil has been changed. “New” is the actual value, in hours, of the transmission oil. Press [E].

Fig. 463

3.

Press [C] to update and store the actual value of hours for the transmission oil.

Fig. 464

Rape oil 1.

From “System” menu, press [7] to set if the Rape oil is present or not.

Fig. 465

20-135

Calibrations and electronic diagnosis iMonitor 1.

From “System” menu, press [8] to set the actual instrumentation mounted on the tractor.

Fig. 465

2.

m m m m m

0 = No iMo0nitor 1 = Only iMonitor 2 = Only TECU ISOBUS 11783 3 = Imonitor + TECU ISO 11783 4 = Imonitor + TECU + Auxiliary Input/output ISO11783

Fig. 466

Aux tank 1.

From “System” menu, press [9] to set if the aux tank is present or not. If it is present set the value to 1, if it is not present set the value to 0.

Fig. 467

20-136

Calibrations and electronic diagnosis Engine brake 1.

From “System” menu, press [A] to set if the engine brake is present or not. If it is present set the value to 1, if it is not present set the value to 0.

Fig. 468

Hydraulic Oil 1.

From “System” menu, press [B] to reset interval maintenance hydraulic oil.

Fig. 468

2.

“Actual” is the last time when the oil has been changed. “New” is the actual value, in hours, of the hydraulic oil. Press [E].

Fig. 469

20-137

Calibrations and electronic diagnosis 3.

Press [C] to update and store the actual value of hours for the hydraulic oil.

Fig. 470

PLA configuration 1.

From the first “System menu” press [2] to start PLA automatic configuration.

Fig. 471

2.

Press [1] to start automatic detection of the optionals on the armrest. If an optional is present an [X] will be displayed near it. Press [C] to confirm. Press [E] to exit.

Fig. 472

20-138

Calibrations and electronic diagnosis 20.4.10 - Putting in service - Distributors 1.

From “Calibration menu” press [8] to enter “Distributors configuration” menu.

C = 1 2 3 4 5 6 7 8 9 A B C D

A = -

L I = = T r P T A S L i S u S y C A Di E n A i P a A g M R [

B = a O M f s s N s g r r r -

R A T I O N M E N U = = = = = = = = = = = n s m i s s i o n

t p e n s i t e m t i C k o D

E ]

r n o B s

i e n r k C

o n

b u t

o r

s

d i t . a k e y P S a b E X I

T

Fig. 472

2.

m m m

m m m

1. Parameters: set the parameters of the distributors. 2. CAN ID progr.: program CAN ID manually or sequentially. 3. Curves: set the relationship between command position and flow in the distributors. 5. Flow Control: set the type of the control for the oil flow. 9. JoyNeut. Calib.: automatic calibration for the joystick. A. Step +- Analog: set the ballistic/analog mode for the joystick.

Fig. 473

20-139

Calibrations and electronic diagnosis Parameters 1.

From previous menu, press [1] to set the parameters of the distributors. m m

m

m

m m

m m m

1. Configuration: set the number of distributors. 2. TimeMax: in the time mode this is the time after which the distributor will stopped. 3. Command: assign different configurations (swap) to the distributors. 4. Type: set how the distributor are commanded (by PWM signal or CAN message). 5. Ext.Butt.: set which distributor use the external pushbutton. 6. FrontLift: set if there is a the front lift and set which distributor it corresponds. 7. Switch 8. Virt.Dist. 9. F.Lift Kmh: over this velocity [km/h] the front lift will be blocked. Fig. 474

Configuration 1.

Press [1] to enter in configuration and set the number of distributors present on the tractor.

Fig. 475

Commands 1.

Press [3] to enter in “commands” menu. It is possible to assign different configurations (swap) to the distributors.

Fig. 476

20-140

Calibrations and electronic diagnosis Type 1.

Press [4] to enter in “type” menu and set the correct type of regulation for the distributors. Press [0] if there aren’t distributors. Press [1] if distributors are commanded with PWM signal. Press [2] if distributors are commanded with CAN message.

Fig. 477

External pushbutton 1.

Press [5] to enter in “External pushbutton” menu and set if it is present or not. If there is an external pushbutton set which distributor it corresponds.

Fig. 478

Front lift 1.

Press [6] to enter in “Front lift” menu and set if it is present or not. If there is a the front lift, set which distributor it corresponds.

Fig. 479

20-141

Calibrations and electronic diagnosis CAN program Manual 1.

From previous menu, press [1] to set manually the CAN distributors configuration.

Fig. 480

2.

Connect only one distributors and than press [1] to set distributors 1, [2] to set distributors 2 and so on. When a configuration for one distributor is complete, disconnect it in order to configure the next distributor.

Fig. 481

3.

After connect one at time all the distributors the configuration is complete.

Fig. 482

4.

This procedure is useful to set manually the configuration, e.g. when the operator has to replace a particular distributors. Mount all the distributors.

20-142

Calibrations and electronic diagnosis Sequential 1.

From previous menu, press [2] to set sequentially the CAN configuration for all the distributors. All the distributors have to be disconnected. Connect one at time the distributors when requested.

Fig. 482

2.

Press [C] to start sequential programming for distributors.

Fig. 483

3.

Connect first distributor and then press [C].

Fig. 484

4.

Continue with this procedure without disconnect the previous distributor until the operator will connect all the distributors. At the end the operator will find all the distributors already connected.

20-143

Calibrations and electronic diagnosis Curves 1.

From “Distributors” menu, press [3] to set the type of curves for the distributors that correlate the joystick position to the commanded oil flow.

Fig. 485

2.

For each distributors it is possible 3 types of curves: linear [1], quadratic [2] or cubic [3].

Fig. 486

Flow control 1.

From “Distributors” menu, press [5] to set the configuration for the flow control.

Fig. 487

20-144

Calibrations and electronic diagnosis Oil pump 1.

From previous menu, press [1] to set the dimension of the oil pump mounted on the tractor.

Fig. 488

Priority distributor 1.

From previous menu, press [2] to set the priority distributor.

Fig. 489

Mode 1.

From previous menu, press [3] to set the advanced oil flow management. m m m

m

1. no advanced management; 2. the available flow is shared between the el.valves; 3. the engine is raised up to 1800 rpm in order to provide more oil flow. The tractor velocity is kept; 4. Mix of 1 and 2.

Fig. 490

20-145

Calibrations and electronic diagnosis JoyNeut. Calibration 1.

From “Distributors” menu, press [9] to calibrate the neutral position for the joysticks.

Fig. 491

2.

Be sure that all the joysticks are in neutral position.

Fig. 492

3.

Press [C] to start the automatic calibration. Press [A] to cancel, [B] to repeat the procedure and [C] to continue.

Fig. 493

20-146

Calibrations and electronic diagnosis Step +- Analog 1.

From “Distributors” menu, press [A] to set the type of control for the joystick. Joystick can control the distributor in ballistic mode or analog mode. m

m

Balistic mode: with the joystick the operator just command “more” or “less”. Analog mode: the position of the joystick is related the value.

Fig. 494

2.

Press [0],[1],[2],[3] to set the range inside which the value reach the corresponding set point with time [4],[5],[6],[7]. Press [A] to insert a decimal number that enable or disable the ballistic mode on distributor. To determinate the number use the following table:

Table 130

Distributor

3.

Value

1 1 2 2 3 4 4 8 5 16 6 32 7 64 Insert in “A-Enable bm” the sum of the value of the distributors that are controlled in ballistic mode. Example If you want to enable balistic mode for distributor 1,4 and 5 you have to insert: 1 +8 + 16 = 25

20.4.11 - Putting in service - Engine 1.

From “Calibration menu” press [9] to enter “Engine calibrations” menu.

C = 1 2 3 4 5 6 7 8 9 A B C D

A = -

L I = = T r P T A S L i S u S y C A Di E n A i P a A g M R [

B = a O M f s s N s g r r r -

R A T I O N M E N U = = = = = = = = = = = n s m i s s i o n

t p e n s i t e m t i C k o D

E ]

r n o B s

i e n r k C

o n

b u t

o r

s

d i t . a k e y P S a b E X I

T

Fig. 494

20-147

Calibrations and electronic diagnosis Throttle pedal 1.

From “Engine calibrations” menu, press [1] in order to calibrate the throttle pedal. Follow the instructions shown on the screen.

Fig. 495

2.

Pedal to min.

Fig. 496

3.

Pedal to max.

Fig. 497

20-148

Calibrations and electronic diagnosis 4.

Pedal calibration OK

Fig. 498

Hand gas 1.

From “Engine calibrations” menu, press [2] in order to calibrate the hand gas command. Follow the instructions shown on the screen.

Fig. 498

2.

Handgas at min .

Fig. 499

20-149

Calibrations and electronic diagnosis 3.

Handgas at max .

Fig. 500

4.

Handgas calibration OK

Fig. 501

Engine speed 1.

From “Engine calibrations” menu, press [3] in order to set minimum and maximum speed of the engine.

Fig. 502

20-150

Calibrations and electronic diagnosis 20.4.12 - Putting in service - Air conditioner 1.

From “Calibration menu” press [A] to enter “Air conditioner” menu.

C = 1 2 3 4 5 6 7 8 9 A B C D

A = -

L I = = T r P T A S L i S u S y C A Di E n A i P a A g M R [

B = a O M f s s N s g r r r -

R A T I O N M E N U = = = = = = = = = = = n s m i s s i o n

t p e n s i t e m t i C k o D

E ]

r n o B s

i e n r k C

o n

b u t

o r

s

d i t . a k e y P S a b E X I

T

Fig. 502

2.

If air conditioner is not present, the “Air conditioner not installed” message appears on the display.

Fig. 503

3.

If the air conditioner is present the following screen appears on the screen.

Fig. 504

20-151

Calibrations and electronic diagnosis Valve 1.

From “Air conditioner” menu, press [1] to calibrate the water valve.

Fig. 505

2.

If the calibration procedure failure the following screen appears on the display:

Fig. 506

3.

If the calibration procedure is successful the following screen appears on the display:

Fig. 507

20-152

Calibrations and electronic diagnosis Recirculation 1.

From “Air conditioner” menu, press [1] to calibrate the recirculation valve.

Fig. 508

2.

If the calibration procedure failure the following screen appears on the display:

Fig. 509

3.

If the calibration procedure is successful the following screen appears on the display:

Fig. 510

20-153

Calibrations and electronic diagnosis 20.4.13 - Putting in service - Park brake 1.

From “Calibration menu” press [B] to enter “Park brake” menu.

Fig. 511

Slope sensor calibration The vehicle is equipped with a slope sensor, mounted inside the Electronic Park Brake. This sensor is able to detect if the vehicle is working in slope condition or not. In order to use correctly the slope measured by this sensor, it has to be calibrated. The calibration must be done: l l l l

after the substitution of the Park Brake (EPB) after mechanical operations which required a disassemble and reassemble of EPB after the tire replacement after the replacemente of the transmission ECU

The necessary condition to execute the calibration are the following: l l l

engine off tractor not in slope and without trailer, implements or ballasts tires inflated at the right pressure CAUTION The vehicle must not have any ballast on the front or on the rear and any implement.

Calibration 1.

Form “Park brake” menu, press “[2], the following page will be shown.

Fig. 512

2.

The items in the page have the following meaning: m Sensor: slope value read by the sensor (if greater than 254 the sensor could not be calibrated) m Calib. Val: calibration value stored in EEPROM Furthermore is present an indication about the calibration status. The possible values are: m NOT CALIBRATED: the sensore is not calibrated m CALIBRATED: the sensor is calibrated

20-154

Calibrations and electronic diagnosis 3.

In order to calibrate the sensor press “[B]Memo”. The indication NOT CALIBRATED became CALIBRATED and the procedure is finished. In order to restore the factory calibration press “[D]Reset” (the status became NOT CALIBRATED). If “[B]Memo” is pressed and the calibration conditions are not satisfied (the engine is running or the slope signal is not available), the calibration could not be done. Verify the calibration conditions before go on.

Fig. 513

20.4.14 - Putting in service - Agrosky

In order to calibrate this system refer to the proper document.

20.4.15 - Putting in service - MR-D Cabin 1.

From “Calibration menu” press [D] to enter “Cabin suspension” menu.

Fig. 514

Enable 1.

From “Cabin suspension” menu, press [1] to enter in “Enable” menu.

Fig. 515

20-155

Calibrations and electronic diagnosis 2.

Press [1] and set if the cabin suspension is installed [1] or not installed [0].

Fig. 516

Cabin suspension calibration 1.

From “Cabin suspension” menu, press [2] in order to start the calibration of the cabin suspension. If the suspension is not installed, the following screen appears on the display. If the cabin suspension is installed, it is possible to start calibration.

Fig. 517

2.

Position the cabin at the lower mechanical end and store the position with [C].

Fig. 518

20-156

Calibrations and electronic diagnosis 3.

Position the cabin at the higher mechanical end and store the position with [C].

Fig. 519

4.

Move the levelling mechanical lever until the “Position” indication shown OK.

Fig. 520

5.

Fix the mechanical levelling lever in that position. Press [C] to store the new value.

Fig. 521

20-157

Calibrations and electronic diagnosis 20.4.16 - Putting in service - Delete alarms 1.

When the entire procedure it is done, then all the passive error must be deleted. Go to Main menu.

Fig. 522

2.

Press [4] to enter in “Alarm list” menu.

Fig. 523

3.

Press [D] to go in the Erase Alarm Page.

Fig. 524

20-158

Calibrations and electronic diagnosis 4.

Erase, one after the other, all the passive errors of the different ECUs pressing the corresponding number.

Fig. 525

20-159

Calibrations and electronic diagnosis 20.5 - ECU alarms

20.5.1 - Engine alarms

Engine control unit alarms - From SPN 29 to SPN 132 Table 131

Cod. ART Spn Fmi

29

3

29

3

29

4

29

4

51

3

51

3

51

3

51

3

51

4

51

4

20-160

Severity Instrument panel display error

Engine alarm SPN 29 FMI 3 Engine alarm SPN 29 FMI 3 Engine alarm SPN 29 FMI 4 Engine alarm SPN 29 FMI 4 Engine alarm SPN 51 FMI 3 Engine alarm SPN 51 FMI 3 Engine alarm SPN 51 FMI 3 Engine alarm SPN 51 FMI 3 Engine alarm SPN 51 FMI 4 Engine alarm SPN 51 FMI 4

Component

Fault

Sensor error handthrottle; signal range check high Handthrottle idle validation switch; short circuit to battery Sensor error handthrottle sensor; signal range check low Handthrottle idle validation switch; short circuit to ground Position sensor error of actuator EGR-Valve (2.9;3.6) or ThrottleValve (6.1,7.8); signal range check high EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to battery (A02) EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to battery EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to battery (A67) EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to ground EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to ground (A67)

Controls

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

Severity Instrument panel display error

51

4

Engine alarm SPN 51 FMI 4

51

4

51

5

51

5

51

5

51

5

51

6

51

6

51

6

51

7

51

12

51

12

Engine alarm SPN 51 FMI 4 Engine alarm SPN 51 FMI 5 Engine alarm SPN 51 FMI 5 Engine alarm SPN 51 FMI 5 Engine alarm SPN 51 FMI 5 Engine alarm SPN 51 FMI 6 Engine alarm SPN 51 FMI 6 Engine alarm SPN 51 FMI 6 Engine alarm SPN 51 FMI 7 Engine alarm SPN 51 FMI 12 Engine alarm SPN 51 FMI 12

Component

Fault

Controls

Link to system

Position sensor error actuator EGR-Valve (2.9;3.6) or ThrottleValve (6.1,7.8); signal range check low EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); short circuit to ground (A02) Actuator error EGRValve (2.9;3.6) or Throttle-Valve (6.1,7.8); signal range check low Actuator error EGRValve (2.9;3.6) or Throttle-Valve (6.1,7.8); signal range check low Actuator EGR-Valve (2.9;3.6) or ThrottleValve (6.1,7.8); open load Actuator EGR-Valve (2.9;3.6) or ThrottleValve (6.1,7.8); open load Actuator error EGRValve (2.9;3.6) or Throttle-Valve (6.1,7.8); signal range check high Actuator EGR-Valve (2.9;3.6) or ThrottleValve (6.1,7.8); over current Actuator error EGRValve (2.9;3.6) or Throttle-Valve (6.1,7.8); signal range check high Actuator position for EGR-Valve (2.9,3.6) or Throttle-Valve (6.1,7.8) not plausible Actuator EGR-Valve (2.9;3.6) or ThrottleValve (6.1,7.8); powerstage over temperature Mechanical actuator defect EGR-Valve (2.9,3.6) or Throttle-Valve (6.1,7.8)

20-161

Calibrations and electronic diagnosis Cod. ART Spn Fmi

51

12

Severity Instrument panel display error

Component

Severity Instrument panel display error

Component

Engine alarm SPN 51 FMI 12

Fault

Controls

Link to system

Controls

Link to system

Actuator EGR-Valve (2.9;3.6) or ThrottleValve (6.1,7.8); over temperature

Table 132 Cod. ART Spn Fmi

84

2

91

3

91

4

91

8

91

8

91

8

91

8

91

11

94

1

20-162

Engine alarm SPN 84 FMI 2 Engine alarm SPN 91 FMI 3 Engine alarm SPN 91 FMI 4 Engine alarm SPN 91 FMI 8 Engine alarm SPN 91 FMI 8 Engine alarm SPN 91 FMI 8 Engine alarm SPN 91 FMI 8 Engine alarm SPN 91 FMI 11 Engine alarm SPN 94 FMI 1

Fault

Sensor vehicle speed; plausibility error Sensor error accelerator pedal; signal range check high Sensor error accelerator pedal; signal range check low Accelerator pedal duty cycle PWM signal; signal range check high Accelerator pedal dutycycle PWM signal; signal range check low Acceleration pedal cycle duration PWM signal; signal range check low Acceleration pedal cycle duration PWM signal; signal range check high Plausibility error between APP1 and APP2 or APP1 and idle switch Low fuel pressure; shut off threshold exceeded

Calibrations and electronic diagnosis Cod. ART Spn Fmi

94

1

94

3

94

4

97

3

97

4

97

12

100

0

100

0

100

1

100

1

100

3

Severity Instrument panel display error

Engine alarm SPN 94 FMI 1 Engine alarm SPN 94 FMI 3 Engine alarm SPN 94 FMI 4 Engine alarm SPN 97 FMI 3 Engine alarm SPN 97 FMI 4 Engine alarm SPN 97 FMI 12 Engine alarm SPN 100 FMI 0 Engine alarm SPN 100 FMI 0 Engine alarm SPN 100 FMI 1 Engine alarm SPN 100 FMI 1 Engine alarm SPN 100 FMI 3

Component

Fault

Controls

Link to system

Low fuel pressure; warning threshold exceeded Sensor error low fuel pressure; signal range check high Sensor error low fuel pressure; signal range check low Sensor error water in fuel; signal range check high Sensor error water in fuel; signal range check low Water in fuel level prefilter; maximum value exceeded High oil pressure; warning threshold exceeded

High oil pressure; shut off threshold exceeded

Low oil pressure; warning threshold exceeded

Low oil pressure; shut off threshold exceeded

Sensor error oil pressure; signal range check high

20-163

Calibrations and electronic diagnosis Cod. ART Spn Fmi

100

4

Severity Instrument panel display error

Component

Severity Instrument panel display error

Component

Engine alarm SPN 100 FMI 4

Fault

Controls

Link to system

Controls

Link to system

Sensor error oil pressure sensor; signal range check low

Table 133 Cod. ART Spn Fmi

102

2

102

2

102

3

102

4

105

0

105

0

105

3

20-164

Engine alarm SPN 102 FMI 2 Engine alarm SPN 102 FMI 2 Engine alarm SPN 102 FMI 3 Engine alarm SPN 102 FMI 4 Engine alarm SPN 105 FMI 0 Engine alarm SPN 105 FMI 0 Engine alarm SPN 105 FMI 3

Fault

Charged air pressure above warning threshold

Charged air pressure above shut off threshold

Sensor error charged air pressure; signal range check high Sensor error charged air pressure; signal range check low High charged air cooler temperature; warning threshold exceeded High charged air cooler temperature; shut off threshold exceeded Sensor error charged air temperature; signal range check high

Calibrations and electronic diagnosis Cod. ART Spn Fmi

105

4

107

0

107

0

107

3

108

3

108

4

110

0

110

0

110

3

110

4

Severity Instrument panel display error

Engine alarm SPN 105 FMI 4 Engine alarm SPN 107 FMI 0 Engine alarm SPN 107 FMI 0 Engine alarm SPN 107 FMI 3 Engine alarm SPN 108 FMI 3 Engine alarm SPN 108 FMI 4 Engine alarm SPN 110 FMI 0 Engine alarm SPN 110 FMI 0 Engine alarm SPN 110 FMI 3 Engine alarm SPN 110 FMI 4

Component

Fault

Controls

Link to system

Sensor error charged air temperature; signal range check low High air filter differential pressure; warning threshold exceeded Sensor error airfilter differential pressure; short circuit to ground Sensor error airfilter differential pressure; short circuit to battery Sensor error ambient air pressure; signal range check high Sensor error ambient air pressure; signal range check low High coolant temperature; shut off threshold exceeded High coolant temperature; warning threshold exceeded Sensor error coolant temperature; signal range check high Sensor error coolant temperature; signal range check low

20-165

Calibrations and electronic diagnosis Cod. ART Spn Fmi

111

1

132

11

132

11

132

11

132

11

20-166

Severity Instrument panel display error

Engine alarm SPN 111 FMI 1 Engine alarm SPN 132 FMI 11 Engine alarm SPN 132 FMI 11 Engine alarm SPN 132 FMI 11 Engine alarm SPN 132 FMI 11

Component

Fault

Coolant level too low

Air flow sensor load correction factor exceeding drift limit; plausibility error Air flow sensor load correction factor exceeding the maximum drift limit Air flow sensor low idle correction factor exceeding the maximum drift limit Air flow sensor load correction factor exceeding the maximum drift limit; plausibility error

Controls

Link to system

Calibrations and electronic diagnosis Engine control unit alarms - From SPN 157 to SPN 677 Table 134

Cod. ART Spn Fmi

157

3

157

4

164

2

168

0

168

1

168

2

168

2

168

3

168

4

Severity Instrument panel display error

Engine alarm SPN 157 FMI 3 Engine alarm SPN 157 FMI 4 Engine alarm SPN 164 FMI 2 Engine alarm SPN 168 FMI 0 Engine alarm SPN 168 FMI 1 Engine alarm SPN 168 FMI 2 Engine alarm SPN 168 FMI 2 Engine alarm SPN 168 FMI 3 Engine alarm SPN 168 FMI 4

Component

Fault

Controls

Link to system

Sensor error rail pressure; signal range check high Sensor error rail pressure; signal range check low Rail pressure safety function is not executed correctly Physikal range check high for battery voltage

Physikal range check low for battery voltage

Low battery voltage; warning threshold exceeded High battery voltage; warning threshold exceeded Sensor error battery voltage; signal range check high Sensor error battery voltage; signal range check low

20-167

Calibrations and electronic diagnosis Cod. ART Spn Fmi

171

3

171

4

172

2

172

3

172

4

174

0

174

0

175

0

175

0

175

0

20-168

Severity Instrument panel display error

Engine alarm SPN 171 FMI 3 Engine alarm SPN 171 FMI 4 Engine alarm SPN 172 FMI 2 Engine alarm SPN 172 FMI 3 Engine alarm SPN 172 FMI 4 Engine alarm SPN 174 FMI 0 Engine alarm SPN 174 FMI 0 Engine alarm SPN 175 FMI 0 Engine alarm SPN 175 FMI 0 Engine alarm SPN 175 FMI 0

Component

Fault

Sensor error environment temperature; signal range check high Sensor error environment temperature; signal range check low Sensor ambient air temperature; plausibility error Sensor error intake air; signal range check high

Sensor error intake air sensor; signal range check low High low fuel temperature; warning threshold exceeded High Low fuel temperature; shut off threshold exceeded Physical range check high for oil temperature

High customer oil temperature; shut off threshold exceeded High oil temperature; shut off threshold exceeded

Controls

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

175

0

175

0

175

1

175

2

175

2

175

2

175

3

175

4

Severity Instrument panel display error

Engine alarm SPN 175 FMI 0 Engine alarm SPN 175 FMI 0 Engine alarm SPN 175 FMI 1 Engine alarm SPN 175 FMI 2 Engine alarm SPN 175 FMI 2 Engine alarm SPN 175 FMI 2 Engine alarm SPN 175 FMI 3 Engine alarm SPN 175 FMI 4

Component

Fault

Controls

Link to system

High customer oil temperature; warning threshold exceeded High oil temperature; warning threshold exceeded Physical range check low for oil temperature

Customer oiltemperature: signal unplausible

Sensor oil temperature; plausibility error

Sensor oil temperature; plausibility error oil temperature too high Sensor error oil temperature; signal range check high Sensor error oil temperature; signal range check low

20-169

Calibrations and electronic diagnosis Table 135 Cod. ART Spn Fmi

190

0

190

2

190

8

190

8

190

11

190

12

190

12

190

14

190

14

20-170

Severity Instrument panel display error

Engine alarm SPN 190 FMI 0 Engine alarm SPN 190 FMI 2 Engine alarm SPN 190 FMI 8 Engine alarm SPN 190 FMI 8 Engine alarm SPN 190 FMI 11 Engine alarm SPN 190 FMI 12 Engine alarm SPN 190 FMI 12 Engine alarm SPN 190 FMI 14 Engine alarm SPN 190 FMI 14

Component

Fault

Engine speed above warning threshold (FOCLevel 1) Offset angle between crank- and camshaft sensor is too large Sensor camshaft speed; disturbed signal

Sensor crankshaft speed; disturbed signal

Engine speed above warning threshold (FOCLevel 2) Sensor camshaft speed; no signal

Sensor crankshaft speed; no signal

Engine speed above warning threshold (Overrun Mode) Camshaft- and Crankshaft speed sensor signal not available on CAN

Controls

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

411

0

411

1

411

3

411

4

412

3

412

4

520

9

597

2

624

3

624

4

Severity Instrument panel display error

Engine alarm SPN 411 FMI 0 Engine alarm SPN 411 FMI 1 Engine alarm SPN 411 FMI 3 Engine alarm SPN 411 FMI 4 Engine alarm SPN 412 FMI 3 Engine alarm SPN 412 FMI 4 Engine alarm SPN 520 FMI 9 Engine alarm SPN 597 FMI 2 Engine alarm SPN 624 FMI 3 Engine alarm SPN 624 FMI 4

Component

Fault

Controls

Link to system

Physical range check high for differential pressure Venturiunit (EGR) Physical range check low for differential pressure Venturiunit (EGR) Sensor error differential pressure Venturiunit (EGR); signal range check high Sensor error differential pressure Venturiunit (EGR); signal range check low Sensor error EGR cooler downstream temperature; signal range check high Sensor error EGR cooler downstream temperature; signal range check low Timeout Error of CANReceive-Frame TSC1TR; Setpoint Break lever mainswitch and break lever redundancyswitch status not plausible SVS lamp; short circuit to battery

SVS lamp; short circuit to ground

20-171

Calibrations and electronic diagnosis Cod. ART Spn Fmi

624

5

624

12

630

12

630

12

630

12

20-172

Severity Instrument panel display error

Engine alarm SPN 624 FMI 5 Engine alarm SPN 624 FMI 12 Engine alarm SPN 630 FMI 12 Engine alarm SPN 630 FMI 12 Engine alarm SPN 630 FMI 12

Component

Fault

SVS lamp; open load

SVS lamp; powerstage over temperature

Access error EEPROM memory (write)

Access error EEPROM memory (delete)

Access error EEPROM memory (read)

Controls

Link to system

Calibrations and electronic diagnosis Table 136 Cod. ART Spn Fmi

639

14

651

3

651

4

651

5

652

3

652

4

652

5

653

3

653

4

Severity Instrument panel display error

Engine alarm SPN 639 FMI 14 Engine alarm SPN 651 FMI 3 Engine alarm SPN 651 FMI 4 Engine alarm SPN 651 FMI 5 Engine alarm SPN 652 FMI 3 Engine alarm SPN 652 FMI 4 Engine alarm SPN 652 FMI 5 Engine alarm SPN 653 FMI 3 Engine alarm SPN 653 FMI 4

Component

Fault

Controls

Link to system

CAN-Bus 0 “BusOff-Status”

Injector 1 (in firing order); short circuit

High side to low side short circuit in the injector 1 (in firing order) Injector 1 (in firing order); interruption of electric connection Injector 2 (in firing order); short circuit

High side to low side short circuit in the injector 2 (in firing order) Injector 2 (in firing order); interruption of electric connection Injector 3 (in firing order); short circuit

High side to low side short circuit in the injector 3 (in firing order)

20-173

Calibrations and electronic diagnosis Cod. ART Spn Fmi

653

5

654

3

654

4

654

5

655

3

655

4

655

5

656

3

656

4

656

5

20-174

Severity Instrument panel display error

Engine alarm SPN 653 FMI 5 Engine alarm SPN 654 FMI 3 Engine alarm SPN 654 FMI 4 Engine alarm SPN 654 FMI 5 Engine alarm SPN 655 FMI 3 Engine alarm SPN 655 FMI 4 Engine alarm SPN 655 FMI 5 Engine alarm SPN 656 FMI 3 Engine alarm SPN 656 FMI 4 Engine alarm SPN 656 FMI 5

Component

Fault

Injector 3 (in firing order); interruption of electric connection Injector 4 (in firing order); short circuit

High side to low side short circuit in the injector 4 (in firing order) Injector 4 (in firing order); interruption of electric connection Injector 5 (in firing order); short circuit

High side to low side short circuit in the injector 5 (in firing order) Injector 5 (in firing order); interruption of electric connection Injector 6 (in firing order); short circuit

High side to low side short circuit in the injector 6 (in firing order) Injector 6 (in firing order); interruption of electric connection

Controls

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

676

11

676

11

677

3

677

3

677

4

677

4

677

5

677

12

Severity Instrument panel display error

Engine alarm SPN 676 FMI 11 Engine alarm SPN 676 FMI 11 Engine alarm SPN 677 FMI 3 Engine alarm SPN 677 FMI 3 Engine alarm SPN 677 FMI 4 Engine alarm SPN 677 FMI 4 Engine alarm SPN 677 FMI 5 Engine alarm SPN 677 FMI 12

Component

Fault

Controls

Link to system

Cold start aid relay error.

Cold start aid relay open load

Starter relay low side; short circuit to battery

Starter relay high side; short circuit to battery

Starter relay high side; short circuit to ground

Starter relay low side; short circuit to ground

Starter relay; no load error

Starter relay; powerstage over temperature

20-175

Calibrations and electronic diagnosis Engine control unit alarms - From SPN 703 to SPN 3234 Table 137

Cod. ART Spn Fmi

703

3

703

4

703

5

703

12

729

5

898

9

975

3

975

3

975

4

20-176

Severity Instrument panel display error

Engine alarm SPN 703 FMI 3 Engine alarm SPN 703 FMI 4 Engine alarm SPN 703 FMI 5 Engine alarm SPN 703 FMI 12 Engine alarm SPN 729 FMI 5 Engine alarm SPN 898 FMI 9 Engine alarm SPN 975 FMI 3 Engine alarm SPN 975 FMI 3 Engine alarm SPN 975 FMI 4

Component

Fault

Engine running lamp; short circuit to battery

Engine running lamp; short circuit to ground

Engine running lamp; open load

Engine running lamp; powerstage over temperature Cold start aid relay open load

Timeout Error of CANReceive-Frame TSC1TE; Setpoint Fan actuator (PWM output); short circuit to battery Digital fan control; short circuit to battery

Fan actuator (PWM output); short circuit to ground

Controls

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

975

4

975

5

975

5

975

12

975

12

1079

13

1080

13

1109

2

1136

0

1136

1

Severity Instrument panel display error

Engine alarm SPN 975 FMI 4 Engine alarm SPN 975 FMI 5 Engine alarm SPN 975 FMI 5 Engine alarm SPN 975 FMI 12 Engine alarm SPN 975 FMI 12 Engine alarm SPN 1079 FMI 13 Engine alarm SPN 1080 FMI 13 Engine alarm SPN 1109 FMI 2 Engine alarm SPN 1136 FMI 0 Engine alarm SPN 1136 FMI 1

Component

Fault

Controls

Link to system

Digital fan control; short circuit to ground

Digital fan control; open load

Fan actuator (PWM output); open load

Fan actuator (PWM output); powerstage over temperature Digital fan control; powerstage over temperature

Sensor supply voltage monitor 1 error (ECU)

Sensor supply voltage monitor 2 error (ECU)

Engine shut off demand ignored

Physikal range check high for ECU temperature Physikal range check low for ECU temperature

20-177

Calibrations and electronic diagnosis Cod. ART Spn Fmi

1136

3

1136

4

Severity Instrument panel display error

Component

Engine alarm SPN 1136 FMI 3 Engine alarm SPN 1136 FMI 4

Fault

Controls

Link to system

Controls

Link to system

Sensor error ECU temperature; signal range check high Sensor error ECU temperature; signal range check low

Table 138 Cod. ART Spn Fmi

1180

0

1180

0

1180

0

1180

1

1180

1

1180

1

20-178

Severity Instrument panel display error

Engine alarm SPN 1180 FMI 0 Engine alarm SPN 1180 FMI 0 Engine alarm SPN 1180 FMI 0 Engine alarm SPN 1180 FMI 1 Engine alarm SPN 1180 FMI 1 Engine alarm SPN 1180 FMI 1

Component

Fault

Exhaust gas temperature upstream turbine; warning threshold exceeded Exhaust gas temperature upstream turbine; warning threshold exceeded Physical range check high for exhaust gas temperature upstream turbine Exhaust gas temperature upstream turbine; shut off threshold exceeded Exhaust gas temperature upstream turbine; shut off threshold exceeded Physical range check low for exhaust gas temperature upstream turbine

Calibrations and electronic diagnosis Cod. ART Spn Fmi

1180

3

1180

4

1180

11

1188

2

1188

7

1188

11

1188

11

1188

11

1188

11

1188

11

Severity Instrument panel display error

Engine alarm SPN 1180 FMI 3 Engine alarm SPN 1180 FMI 4 Engine alarm SPN 1180 FMI 11 Engine alarm SPN 1188 FMI 2 Engine alarm SPN 1188 FMI 7 Engine alarm SPN 1188 FMI 11 Engine alarm SPN 1188 FMI 11 Engine alarm SPN 1188 FMI 11 Engine alarm SPN 1188 FMI 11 Engine alarm SPN 1188 FMI 11

Component

Fault

Controls

Link to system

Sensor error exhaust gas temperature upstream turbine; signal range check high Sensor error exhaust gas temperature upstream turbine; signal range check low Sensor exhaust gas temperature upstream turbine; plausibility error Wastegate; status message from ECU missing

Wastegate blocked

actuator;

Wastegate actuator; EOL calibration not performed correctly Wastegate actuator; operating voltage error

Wastegate actuator; over temperature (> 135°C)

Wastegate actuator; internal error

Wastegate actuator; over temperature (> 145°C)

20-179

Calibrations and electronic diagnosis Cod. ART Spn Fmi

1188

13

1231

14

1235

14

1237

2

1322

12

1323

12

1324

12

1325

12

20-180

Severity Instrument panel display error

Engine alarm SPN 1188 FMI 13 Engine alarm SPN 1231 FMI 14 Engine alarm SPN 1235 FMI 14 Engine alarm SPN 1237 FMI 2 Engine alarm SPN 1322 FMI 12 Engine alarm SPN 1323 FMI 12 Engine alarm SPN 1324 FMI 12 Engine alarm SPN 1325 FMI 12

Component

Fault

Wastegate actuator calibration deviation too large, recalibration required CAN-Bus 1 “BusOff-Status”

CAN-Bus 2 “BusOff-Status”

Override switch; plausibility error

Too many recognized misfires in more than one cylinder Too many recognized misfires in cylinder 1 (in firing order) Too many recognized misfires in cylinder 2 (in firing order) Too many recognized misfires in cylinder 3 (in firing order)

Controls

Link to system

Calibrations and electronic diagnosis Table 139 Cod. ART Spn Fmi

1326

12

1327

12

1328

12

1639

0

1639

1

1761

14

2621

3

2621

4

2621

5

Severity Instrument panel display error

Engine alarm SPN 1326 FMI 12 Engine alarm SPN 1327 FMI 12 Engine alarm SPN 1328 FMI 12 Engine alarm SPN 1639 FMI 0 Engine alarm SPN 1639 FMI 1 Engine alarm SPN 1761 FMI 14 Engine alarm SPN 2621 FMI 3 Engine alarm SPN 2621 FMI 4 Engine alarm SPN 2621 FMI 5

Component

Fault

Controls

Link to system

Too many recognized misfires in cylinder 4 (in firing order) Too many recognized misfires in cylinder 5 (in firing order) Too many recognized misfires in cylinder 6 (in firing order) Sensor error fan speed; signal range check high

Sensor error fan speed; signal range check low

Urea tank level; warning threshold exceeded

Flush valve burner (EPV DPF-System); short circuit to battery Flush valve burner (EPV DPF-System); short circuit to ground Flush valve burner (EPV DPF-System); open load

20-181

Calibrations and electronic diagnosis Cod. ART Spn Fmi

2621

12

2797

4

2798

4

2798

4

2798

4

3031

0

3031

1

3031

3

3031

4

3224

1

20-182

Severity Instrument panel display error

Engine alarm SPN 2621 FMI 12 Engine alarm SPN 2797 FMI 4 Engine alarm SPN 2798 FMI 4 Engine alarm SPN 2798 FMI 4 Engine alarm SPN 2798 FMI 4 Engine alarm SPN 3031 FMI 0 Engine alarm SPN 3031 FMI 1 Engine alarm SPN 3031 FMI 3 Engine alarm SPN 3031 FMI 4 Engine alarm SPN 3224 FMI 1

Component

Fault

Flush valve burner (EPV DPF-System); powerstage over temperature Injector diagnostics; timeout error of short circuit to ground measurement cyl. Bank 0 Injector diagnostics; timeout error of short circuit to ground measurement cyl. Bank 1 Injector diagnostics; short circuit to ground monitoring Test in Cyl. Bank 1 Injector diagnostics; short circuit to ground monitoring Test in Cyl. Bank 0 AdBlue-Tank temperature: maximum exceeded

DEF-Tank temperature: below minimum

Sensor error urea tank temperature; short circuit to battery Sensor error urea tank temperature; short circuit to ground Nox sensor upstream of SCR Catalysator; low signal not plausible

Controls

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

Severity Instrument panel display error

3224

2

Engine alarm SPN 3224 FMI 2

3224

9

3224

9

Engine alarm SPN 3224 FMI 9 Engine alarm SPN 3224 FMI 9

3234

2

Engine alarm SPN 3234 FMI 2

3234

9

Engine alarm SPN 3234 FMI 9

3234

9

Engine alarm SPN 3234 FMI 9

3234

11

Engine alarm SPN 3234 FMI 11

Component

Fault

Controls

Link to system

DLC Error of CAN-Receive-Frame AT1IG1Vol NOX Sensor (SCR-system upstream cat; DPF­ system downstream cat); length of frame incorrect Timeout Error of CANReceive-Frame AT1IG1; NOX sensor upstream Timeout Error of CAN-Receive-Frame AT1IG1Vol; NOX sensor (SCR-system upstream cat; DPF­system downstream cat) DLC Error of CAN-Receive-Frame AT1O1Vol NOX Sensor (SCRsystem downstream cat; DPF­system downstream cat); length of frame incorrect Timeout Error of CAN-Receive-Frame AT1OG1Vol; NOX sensor (SCR-system downstream cat; DPF-system downstream cat) Timeout Error of CANReceive-Frame AT1OG1; NOX sensor (SCR-system downstream cat; DPF­system downstream cat) Nox Sensor downstream of SCR Catalysator; plausibility error “stuk in range”

20-183

Calibrations and electronic diagnosis Engine control unit alarms - From SPN 3241 to SPN 4765 Table 140

Cod. ART Spn Fmi

3241

0

3241

1

3248

0

3248

0

3248

0

3248

1

3248

1

3248

1

3248

2

20-184

Severity Instrument panel display error

Engine alarm SPN 3241 FMI 0 Engine alarm SPN 3241 FMI 1 Engine alarm SPN 3248 FMI 0 Engine alarm SPN 3248 FMI 0 Engine alarm SPN 3248 FMI 0 Engine alarm SPN 3248 FMI 1 Engine alarm SPN 3248 FMI 1 Engine alarm SPN 3248 FMI 1 Engine alarm SPN 3248 FMI 2

Component

Fault

Sensor SCR catalyst upstream temperature too high; plausibility error Sensor SCR catalyst upstream temperature too low; plausibility error Physical range check high for exhaust gas temperature particulate filter downstream Physical range check high for exhaust gas temperature particulate filter downstream; shut off regeneration Physical range check high for exhaust gas temperature particulate filter downstream; warning Physical range check low for exhaust gas temperature particulate filter downstream; warning Physikal range check low for exhaust gas temperature particulate filter downstream; shut off regeneration Physical range check low for exhaust gas temperature particulate filter downstream Sensor exhaust gas temperature downstream DPF; plausibility error

Controls

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

3248

4

3251

0

3251

1

3253

2

3253

2

3253

3

3253

4

3361

3

3361

3

3361

4

Severity Instrument panel display error

Engine alarm SPN 3248 FMI 4 Engine alarm SPN 3251 FMI 0 Engine alarm SPN 3251 FMI 1 Engine alarm SPN 3253 FMI 2 Engine alarm SPN 3253 FMI 2 Engine alarm SPN 3253 FMI 3 Engine alarm SPN 3253 FMI 4 Engine alarm SPN 3361 FMI 3 Engine alarm SPN 3361 FMI 3 Engine alarm SPN 3361 FMI 4

Component

Fault

Controls

Link to system

Sensor error particle filter downstream temperature; signal range check low Physical range check high for differential pressure (DPF); shut off regeneration Physical range check low for differential pressure (DPF); shut off regeneration Sensor differential pressure (DPF); plausibility error Sensor differential pressure (DPF); plausibility error regarding signal offset Sensor error differential pressure (DPF); signal range check high Sensor error differential pressure (DPF); signal range check low Urea dosing valve high side; short circuit to battery Urea dosing valve; short circuit to battery

Urea dosing valve low side; short circuit to ground

20-185

Calibrations and electronic diagnosis Cod. ART Spn Fmi

3361

4

3361

7

3532

3

3532

4

Severity Instrument panel display error

Component

Engine alarm SPN 3361 FMI 4 Engine alarm SPN 3361 FMI 7 Engine alarm SPN 3532 FMI 3 Engine alarm SPN 3532 FMI 4

Fault

Controls

Link to system

Controls

Link to system

Urea dosing valve high side; short circuit

AdBlue dosing blocked (SCR)

valve

Sensor error urea tank level; signal range check high Sensor error urea tank level; signal range check low

Table 141 Cod. ART Spn Fmi

3711

12

4243

11

4334

0

4334

0

20-186

Severity Instrument panel display error

Engine alarm SPN 3711 FMI 12 Engine alarm SPN 4243 FMI 11 Engine alarm SPN 4334 FMI 0 Engine alarm SPN 4334 FMI 0

Component

Fault

Regeneration temperature (PFltRgn LigtOff) not reached; regeneration aborted Urea pressureline heating procedure not successful; shut off SCRsystem Physical range check high for Urea Pump Pressure Sensor error urea pump pressure; signal range check high before pressure build up

Calibrations and electronic diagnosis Cod. ART Spn Fmi

4334

1

4334

1

4334

3

4334

4

4341

3

4341

4

4341

5

4341

5

4343

3

4343

4

Severity Instrument panel display error

Engine alarm SPN 4334 FMI 1 Engine alarm SPN 4334 FMI 1 Engine alarm SPN 4334 FMI 3 Engine alarm SPN 4334 FMI 4 Engine alarm SPN 4341 FMI 3 Engine alarm SPN 4341 FMI 4 Engine alarm SPN 4341 FMI 5 Engine alarm SPN 4341 FMI 5 Engine alarm SPN 4343 FMI 3 Engine alarm SPN 4343 FMI 4

Component

Fault

Controls

Link to system

AdBlue pump pressure: signal range before pressure build up is below minimum Physical range check low for Urea Pump Pressure

Sensor error urea pump pressure; signal range check high Sensor error urea pump pressure; signal range check low SCR-heater urea supplyline; short circuit to battery SCR-heater urea supplyline; short circuit to ground SCR-heater relay urea supplyline; open load

SCR-heater urea supplyline; open load

SCR-heater urea pressureline; short circuit to battery SCR-heater urea pressureline; short circuit to ground

20-187

Calibrations and electronic diagnosis Cod. ART Spn Fmi

4343

5

4343

5

4343

11

4345

3

4345

4

4345

5

4345

5

4345

11

4360

0

20-188

Severity Instrument panel display error

Engine alarm SPN 4343 FMI 5 Engine alarm SPN 4343 FMI 5 Engine alarm SPN 4343 FMI 11 Engine alarm SPN 4345 FMI 3 Engine alarm SPN 4345 FMI 4 Engine alarm SPN 4345 FMI 5 Engine alarm SPN 4345 FMI 5 Engine alarm SPN 4345 FMI 11 Engine alarm SPN 4360 FMI 0

Component

Fault

SCR heater relay urea pressureline; open load

SCR-heater urea pressureline; open load

General pressure check error (SCR)

SCR-heater urea returnline; short circuit to battery SCR-heater urea returnline; short circuit to ground SCR heater relay urea returnline; open load

SCR-heater urea returnline; open load

Sensor backflow line pressure (SCR); plausibility error Physical range check high for urea catalyst upstream temperature

Controls

Link to system

Calibrations and electronic diagnosis Table 142 Cod. ART Spn Fmi

4360

1

4360

3

4360

4

4365

0

4366

3

4366

4

4366

5

4366

5

4366

5

Severity Instrument panel display error

Engine alarm SPN 4360 FMI 1 Engine alarm SPN 4360 FMI 3 Engine alarm SPN 4360 FMI 4 Engine alarm SPN 4365 FMI 0 Engine alarm SPN 4366 FMI 3 Engine alarm SPN 4366 FMI 4 Engine alarm SPN 4366 FMI 5 Engine alarm SPN 4366 FMI 5 Engine alarm SPN 4366 FMI 5

Component

Fault

Controls

Link to system

Physical range low for urea catalyst upstream temperature Sensor error urea catalyst exhaust gas temperature upstream; signal range check high Sensor error urea catalyst exhaust gas temperature upstream; signal range check low Urea tank temperature too high

SCR-heater urea tank; short circuit to battery

SCR-heater urea tank; short circuit to ground

SCR-heater urea tank; open load

Tank heating valve: open load

SCR main relay: shortcut to ground

20-189

Calibrations and electronic diagnosis Cod. ART Spn Fmi

4366

5

4366

12

4374

13

4375

3

4375

4

4375

5

4376

3

4376

4

4376

4

4376

5

20-190

Severity Instrument panel display error

Engine alarm SPN 4366 FMI 5 Engine alarm SPN 4366 FMI 12 Engine alarm SPN 4374 FMI 13 Engine alarm SPN 4375 FMI 3 Engine alarm SPN 4375 FMI 4 Engine alarm SPN 4375 FMI 5 Engine alarm SPN 4376 FMI 3 Engine alarm SPN 4376 FMI 4 Engine alarm SPN 4376 FMI 4 Engine alarm SPN 4376 FMI 5

Component

Fault

SCR main relay: shortcut to battery

SCR-heater relay urea tank powerstage output; over temperature Pressure stabilisation error dosing valve (SCR)

Urea pump motor; short circuit to battery

Urea pump motor; short circuit to ground

Urea pump motor; open load

SCR reversing valve; short circuit to battery

SCR reversing valve; short circuit to ground

SCR reversing valve; short circuit to ground

SCR reversing valve; open load

Controls

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

4376

5

4376

12

4376

12

4765

0

4765

1

Severity Instrument panel display error

Engine alarm SPN 4376 FMI 5 Engine alarm SPN 4376 FMI 12 Engine alarm SPN 4376 FMI 12 Engine alarm SPN 4765 FMI 0 Engine alarm SPN 4765 FMI 1

Component

Fault

Controls

Link to system

SCR reversing valve; open load

SCR reversing valve; over temperature

SCR reversing valve; over temperature

Physical range check high for exhaust gas temperature upstream (DOC) Physical range check low for exhaust gas temperature upstream (DOC)

20-191

Calibrations and electronic diagnosis Engine control unit alarms - From SPN 4766 to SPN 523612 Table 143

Cod. ART Spn Fmi

4766

0

4766

1

4768

2

4768

3

4768

4

4769

2

4769

2

4769

2

4769

3

20-192

Severity Instrument panel display error

Engine alarm SPN 4766 FMI 0 Engine alarm SPN 4766 FMI 1 Engine alarm SPN 4768 FMI 2 Engine alarm SPN 4768 FMI 3 Engine alarm SPN 4768 FMI 4 Engine alarm SPN 4769 FMI 2 Engine alarm SPN 4769 FMI 2 Engine alarm SPN 4769 FMI 2 Engine alarm SPN 4769 FMI 3

Component

Fault

Physical range check high for exhaust gas temperature downstream (DOC) Physical range check low for exhaust gas temperature downstream (DOC) Sensor exhaust gas temperature upstream (DOC); plausibility error Sensor error exhaust gas temperature upstream (DOC); signal range check high Sensor error exhaust gas temperature upstream (DOC); signal range check low Sensor exhaust gas temperature OxiCat downstream (regeneration); plausibility error Sensor exhaust gas temperature OxiCat downstream (normal operation); plausibility error Sensor exhaust gas temperature downstream (DOC); plausibility error Sensor error exhaust gas temperature downstream (DOC); signal range check high

Controls

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

4769

4

523006 3

523006 4

523008 1

523008 2

523009 9

523009 10

523212 9

523216 9

523240 9

Severity Instrument panel display error

Engine alarm SPN 4769 FMI 4 Engine alarm SPN 523006 FMI 3 Engine alarm SPN 523006 FMI 4 Engine alarm SPN 523008 FMI 1 Engine alarm SPN 523008 FMI 2 Engine alarm SPN 523009 FMI 9 Engine alarm SPN 523009 FMI 10 Engine alarm SPN 523212 FMI 9 Engine alarm SPN 523216 FMI 9 Engine alarm SPN 523240 FMI 9

Component

Fault

Controls

Link to system

Sensor error exhaust gas temperature downstream (DOC); signal range check low Controller mode switch; short circuit to battery

Controller mode switch; short circuit to ground

Manipulation control was triggered

Timeout error in Manipulation control

Pressure Relief Valve (PRV) reached maximun allowed opening count Pressure relief valve (PRV) reached maximun allowed open time Timeout Error of CANReceive-Frame ComEngPrt; Engine Protection Timeout Error of CANReceive-Frame PrHtEnCmd; pre-heat command, engine command Timeout CAN-message FunModCtl; Function Mode Control

20-193

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523330 14

523350 4

523352 4

523354 12

Severity Instrument panel display error

Component

Engine alarm SPN 523330 FMI 14 Engine alarm SPN 523350 FMI 4 Engine alarm SPN 523352 FMI 4 Engine alarm SPN 523354 FMI 12

Fault

Controls

Link to system

Controls

Link to system

Immobilizer status; fuel blocked

Injector cylinder-bank 1; short circuit

Injector cylinder-bank 2; short circuit

Injector powerstage output defect

Table 144 Cod. ART Spn Fmi

523450 2

523450 3

523450 4

523451 2

20-194

Severity Instrument panel display error

Engine alarm SPN 523450 FMI 2 Engine alarm SPN 523450 FMI 3 Engine alarm SPN 523450 FMI 4 Engine alarm SPN 523451 FMI 2

Component

Fault

Multiple Stage Switch constant speed; plausibility error Multiple Stage Switch constant speed; short circuit to battery Multiple Stage Switch constant speed; short circuit to ground Multiple Stage Switch engine speed control parameter; plausibility error

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523451 3

523451 4

523452 2

523452 3

523452 4

523470 2

523470 2

523470 7

523470 11

523470 12

Severity Instrument panel display error

Engine alarm SPN 523451 FMI 3 Engine alarm SPN 523451 FMI 4 Engine alarm SPN 523452 FMI 2 Engine alarm SPN 523452 FMI 3 Engine alarm SPN 523452 FMI 4 Engine alarm SPN 523470 FMI 2 Engine alarm SPN 523470 FMI 2 Engine alarm SPN 523470 FMI 7 Engine alarm SPN 523470 FMI 11 Engine alarm SPN 523470 FMI 12

Component

Fault

Controls

Link to system

Multiple Stage Switch engine speed control parameter; short circuit to battery Multiple Stage Switch engine speed control parameter; short circuit to ground Multiple Stage Switch engine torque limitation curve; plausibility error Multiple Stage Switch engine torque limitation curve; short circuit to battery Multiple Stage Switch engine torque limitation curve; short circuit to ground Pressure Relief Valve (PRV) forced to open; performed by pressure shock Pressure Relief Valve (PRV) forced to open; performed by pressure increase Maximum rail pressure in limp home mode exceeded (PRV) Rail pressure out of tolerance range

Open Pressure Relief Valve (PRV); shut off condition

20-195

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523470 12

523470 14

523550 12

523601 13

523602 0

523602 0

523603 9

523605 9

523606 9

20-196

Severity Instrument panel display error

Engine alarm SPN 523470 FMI 12 Engine alarm SPN 523470 FMI 14 Engine alarm SPN 523550 FMI 12 Engine alarm SPN 523601 FMI 13 Engine alarm SPN 523602 FMI 0 Engine alarm SPN 523602 FMI 0 Engine alarm SPN 523603 FMI 9 Engine alarm SPN 523605 FMI 9 Engine alarm SPN 523606 FMI 9

Component

Fault

Open Pressure Relief Valve (PRV); warning condition Pressure Relief Valve (PRV) is open

T50 start switch active for too long

Sensor supply voltage monitor 3 error (ECU)

High fan speed; warning threshold exceeded

High fan speed; shut off threshold exceeded

Timeout Error of CANReceive-Frame AMB; Ambient Temperature Sensor Timeout Error of CANReceive-Frame TSC1AE; Traction Control Timeout Error of CANReceive-Frame TSC1AR; Retarder

Controls

Link to system

Calibrations and electronic diagnosis Table 145 Cod. ART Spn Fmi

523612 12

523612 12

523612 12

523612 12

523612 12

523612 12

523612 12

523612 12

523612 12

Severity Instrument panel display error

Engine alarm SPN 523612 FMI 12 Engine alarm SPN 523612 FMI 12 Engine alarm SPN 523612 FMI 12 Engine alarm SPN 523612 FMI 12 Engine alarm SPN 523612 FMI 12 Engine alarm SPN 523612 FMI 12 Engine alarm SPN 523612 FMI 12 Engine alarm SPN 523612 FMI 12 Engine alarm SPN 523612 FMI 12

Component

Fault

Controls

Link to system

Internal ECU monitoring detection reported error

Internal ECU monitoring detection reported error

Internal ECU monitoring detection reported error

Internal ECU monitoring detection reported error

Internal ECU monitoring detection reported error

Internal ECU monitoring detection reported error

Internal ECU monitoring detection reported error

Internal ECU monitoring detection reported error

Internal ECU monitoring detection reported error

20-197

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523612 12

523612 12

523612 12

523612 12

523612 12

523612 12

523612 12

523612 12

523612 12

523612 14

20-198

Severity Instrument panel display error

Engine alarm SPN 523612 FMI 12 Engine alarm SPN 523612 FMI 12 Engine alarm SPN 523612 FMI 12 Engine alarm SPN 523612 FMI 12 Engine alarm SPN 523612 FMI 12 Engine alarm SPN 523612 FMI 12 Engine alarm SPN 523612 FMI 12 Engine alarm SPN 523612 FMI 12 Engine alarm SPN 523612 FMI 12 Engine alarm SPN 523612 FMI 14

Component

Fault

Controls

Internal ECU monitoring detection reported error

Internal ECU monitoring detection reported error

Internal software error ECU

Internal software error ECU; injection cut off

Internal ECU monitoring detection reported error

Internal ECU monitoring detection reported error

Internal ECU monitoring detection reported error

Internal ECU monitoring detection reported error

Internal ECU monitoring detection reported error

Softwarereset SWReset_0

CPU

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523612 14

523612 14

Severity Instrument panel display error

Component

Engine alarm SPN 523612 FMI 14 Engine alarm SPN 523612 FMI 14

Fault

Softwarereset SWReset_1

CPU

Softwarereset SWReset_2

CPU

Controls

Link to system

Controls

Link to system

Engine control unit alarms - From SPN 523613 to SPN 523910 Table 146

Cod. ART Spn Fmi

523613 0

523613 0

523613 0

523613 0

523613 0

523613 0

Severity Instrument panel display error

Engine alarm SPN 523613 FMI 0 Engine alarm SPN 523613 FMI 0 Engine alarm SPN 523613 FMI 0 Engine alarm SPN 523613 FMI 0 Engine alarm SPN 523613 FMI 0 Engine alarm SPN 523613 FMI 0

Component

Fault

Maximum positive deviation of rail pressure exceeded (RailMeUn0) Maximum rail pressure exceeded (RailMeUn4)

Maximum positive deviation of rail pressure in metering unit exceeded (RailMeUn1) Negative deviation of rail pressure second stage (RailMeUn22) Maximum negative deviation of rail pressure in metering unit exceeded (RailMeUn2) Railsystem leakage detected (RailMeUn10)

20-199

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523613 1

523613 2

523615 3

523615 3

523615 4

523615 4

523615 5

523615 12

523632 0

523632 1

20-200

Severity Instrument panel display error

Engine alarm SPN 523613 FMI 1 Engine alarm SPN 523613 FMI 2 Engine alarm SPN 523615 FMI 3 Engine alarm SPN 523615 FMI 3 Engine alarm SPN 523615 FMI 4 Engine alarm SPN 523615 FMI 4 Engine alarm SPN 523615 FMI 5 Engine alarm SPN 523615 FMI 12 Engine alarm SPN 523632 FMI 0 Engine alarm SPN 523632 FMI 1

Component

Fault

Controls

Minimum rail pressure exceeded (RailMeUn3)

Setpoint of metering unit in overrun mode not plausible Metering unit (Fuel-System); short circuit to battery highside Metering unit (Fuel-System); short circuit to battery low side Metering unit (FuelSystem); short circuit to ground high side Metering Unit (FuelSystem); short circuit to ground low side Metering unit (Fuel-System); open load

Metering unit (Fuel-System); powerstage over temperature Pressure overload SCR-System

of

Pressure build-up error SCR-System

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523632 2

523632 16

523632 18

523633 11

523633 11

523633 11

523698 11

Severity Instrument panel display error

Engine alarm SPN 523632 FMI 2 Engine alarm SPN 523632 FMI 16 Engine alarm SPN 523632 FMI 18 Engine alarm SPN 523633 FMI 11 Engine alarm SPN 523633 FMI 11 Engine alarm SPN 523633 FMI 11 Engine alarm SPN 523698 FMI 11

Component

Fault

Controls

Link to system

Metering control is not performed in time error

Pump pressure SCR metering unit too high

Pump pressure SCR metering unit too low

Nox conversion rate insufficient (SCR-Cat defect, bad AdBule quality) Nox conversion rate insufficient (SCR-Cat defect, bad AdBule quality); temperature range 1 Nox conversion rate insufficient (SCR-Cat defect, bad AdBule quality); temperature range 2 Shut off request from supervisory monitoring function

20-201

Calibrations and electronic diagnosis Table 147 Cod. ART Spn Fmi

523718 3

523718 4

523718 5

523719 3

523719 4

523719 5

523719 5

523720 2

523720 2

20-202

Severity Instrument panel display error

Engine alarm SPN 523718 FMI 3 Engine alarm SPN 523718 FMI 4 Engine alarm SPN 523718 FMI 5 Engine alarm SPN 523719 FMI 3 Engine alarm SPN 523719 FMI 4 Engine alarm SPN 523719 FMI 5 Engine alarm SPN 523719 FMI 5 Engine alarm SPN 523720 FMI 2 Engine alarm SPN 523720 FMI 2

Component

Fault

SCR-heater external relay; short circuit to battery SCR-heater external relay; short circuit to ground SCR-heater external relay; open load

SCR-heater urea supply modul; short circuit to battery SCR-heater urea supply modul; short circuit to ground SCR heater relay urea supply modul; open load

SCR-heater urea supplyline; open load

Sensor urea supply module heater temperature; plausibility error (normal condition) Sensor urea supply module heater temperature; plausibility error (cold start condition)

Controls

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523720 8

523720 8

523721 2

523721 2

523721 8

523721 8

523721 11

523722 8

523722 8

523723 11

Severity Instrument panel display error

Engine alarm SPN 523720 FMI 8 Engine alarm SPN 523720 FMI 8 Engine alarm SPN 523721 FMI 2 Engine alarm SPN 523721 FMI 2 Engine alarm SPN 523721 FMI 8 Engine alarm SPN 523721 FMI 8 Engine alarm SPN 523721 FMI 11 Engine alarm SPN 523722 FMI 8 Engine alarm SPN 523722 FMI 8 Engine alarm SPN 523723 FMI 11

Component

Fault

Controls

Link to system

Urea supply module heater temperature; duty cycle in failure range Urea supply module heater temperature; duty cycle in invalid range Sensor urea supply module temperature; plausibility error (cold start condition) Sensor urea supply module temperature; plausibility error (normal condition) Urea supply module temperature; duty cycle in invalid range Urea supply module temperature; duty cycle in failure range Urea supply module temperature measurement not available Urea supply module PWM signal; period outside valid range Detect faulty PWM signal from Supply Modul

Detection of AdBlue filled SCR system in Init-State

20-203

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523766 9

523767 9

523768 9

523769 9

Severity Instrument panel display error

Component

Engine alarm SPN 523766 FMI 9 Engine alarm SPN 523767 FMI 9 Engine alarm SPN 523768 FMI 9 Engine alarm SPN 523769 FMI 9

Fault

Controls

Link to system

Controls

Link to system

Timeout Error of CANReceive-Frame Active TSC1AE Timeout Error of CANReceive-Frame Passive TSC1AE Timeout Error of CANReceive-Frame Active TSC1AR Timeout Error of CANReceive-Frame Passive TSC1AR

Table 148 Cod. ART Spn Fmi

523770 9

523776 9

523777 9

523778 9

20-204

Severity Instrument panel display error

Engine alarm SPN 523770 FMI 9 Engine alarm SPN 523776 FMI 9 Engine alarm SPN 523777 FMI 9 Engine alarm SPN 523778 FMI 9

Component

Fault

Timeout Error of CANReceive-Frame Passive TSC1DE Timeout Error of CANReceive-Frame TSC1TE ­active Passive Timeout Error of CAN-Receive-Frame TSC1TE; Setpoint Active Timeout Errorof CAN-Receive-Frame TSC1TR

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523779 9

523788 0

523788 0

523788 0

523788 0

523788 12

523803 9

523867 12

523895 13

523896 13

Severity Instrument panel display error

Engine alarm SPN 523779 FMI 9 Engine alarm SPN 523788 FMI 0 Engine alarm SPN 523788 FMI 0 Engine alarm SPN 523788 FMI 0 Engine alarm SPN 523788 FMI 0 Engine alarm SPN 523788 FMI 12 Engine alarm SPN 523803 FMI 9 Engine alarm SPN 523867 FMI 12 Engine alarm SPN 523895 FMI 13 Engine alarm SPN 523896 FMI 13

Component

Fault

Controls

Link to system

Passive Timeout Error of CAN-Receive-Frame TSC1TR CAN-Transmit-Frame ComTrbChActr plausibility error; wastegate Timeout Error of CANTransmit-Frame ComTrbChActr; Wastegate CAN-Transmit-Frame ComTrbChActr disable error; wastegate CAN-Transmit-Frame ComTrbChActr “BusOffSatus”; Wastegate Timeout Error of CANTransmit-Frame TrbCH; Status Wastegate Timeout Error of CANReceive-Frame RxEngPres; Status burner airpump Timeout Error of CANTransmit-Frame UAA1 on CAN 2; Burner Air Pump Control Check of missing injector adjustment value programming (IMA) injector 1 (in firing order) check of missing injector adjustment value programming (IMA) injector 2 (in firing order)

20-205

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523897 13

523898 13

523899 13

523900 13

523909 5

523910 0

523910 0

523910 6

523910 7

523910 9

20-206

Severity Instrument panel display error

Engine alarm SPN 523897 FMI 13 Engine alarm SPN 523898 FMI 13 Engine alarm SPN 523899 FMI 13 Engine alarm SPN 523900 FMI 13 Engine alarm SPN 523909 FMI 5 Engine alarm SPN 523910 FMI 0 Engine alarm SPN 523910 FMI 0 Engine alarm SPN 523910 FMI 6 Engine alarm SPN 523910 FMI 7 Engine alarm SPN 523910 FMI 9

Component

Fault

check of missing injector adjustment value programming (IMA) injector 3 (in firing order) check of missing injector adjustment value programming (IMA) injector 4 (in firing order) check of missing injector adjustment value programming (IMA) injector 5 (in firing order) check of missing injector adjustment value programming (IMA) injector 6 (in firing order) SCR main relay: cable break

Air Pump; operating voltage error

Air Pump; powerstage over temperature

Air Pump; over current

Air pump; CAN communication interrupted no purge function available Air Pump; CAN communication lost

Controls

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523910 12

523910 14

Severity Instrument panel display error

Component

Engine alarm SPN 523910 FMI 12 Engine alarm SPN 523910 FMI 14

Fault

Controls

Link to system

Controls

Link to system

Air Pump; internal error

Air pump doesn´t achieve air mass flow setpoint

Engine control unit alarms - From SPN 523911 to SPN 523922 Table 149

Cod. ART Spn Fmi

523911 0

523911 3

523911 3

523911 4

523911 7

523911 11

Severity Instrument panel display error

Engine alarm SPN 523911 FMI 0 Engine alarm SPN 523911 FMI 3 Engine alarm SPN 523911 FMI 3 Engine alarm SPN 523911 FMI 4 Engine alarm SPN 523911 FMI 7 Engine alarm SPN 523911 FMI 11

Component

Fault

Burner dosing valve (DV2); overcurrent at the end of the injection phase Burner dosing valve (DV2); short circuit to battery Burner dosing valve (DV2); short circuit to battery on high side Burner dosing valve (DV2); short circuit to ground Burner dosing valve (DV2); blocked closed

Burner dosing valve (DV2); short circuit high side powerstage

20-207

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523911 12

523912 0

523912 1

523912 2

523912 3

523912 4

523913 3

523913 4

523914 3

20-208

Severity Instrument panel display error

Engine alarm SPN 523911 FMI 12 Engine alarm SPN 523912 FMI 0 Engine alarm SPN 523912 FMI 1

Engine alarm SPN 523912 FMI 2 Engine alarm SPN 523912 FMI 3 Engine alarm SPN 523912 FMI 4 Engine alarm SPN 523913 FMI 3 Engine alarm SPN 523913 FMI 4 Engine alarm SPN 523914 FMI 3

Component

Fault

Burner dosing valve (DV2); powerstage over temperature Physical range check high for burner dosing valve (DV2) downstream pressure; shut off regeneration Physical range check low for burner dosing valve (DV2) downstream pressure; shut off regeneration. When burner injector is actuated, the measured pressure does not rise above ca. 1250mbar abs (expected: ca. 2400mbar). Burner dosing valve (DV2) downstream pressure sensor; plausibility error Sensor error burner dosing valve (DV2) downstream pressure sensor; signal range check high Sensor error burner dosing valve (DV2) downstream pressure sensor; signal range check low Sensor error glow plug control diagnostic line voltage; signal range check high Sensor error glow plug control diagnostic line voltage; signal range check low Glow plug control; short circuit to battery

Controls

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523914 4

523914 5

523914 5

523914 11

523914 12

523915 0

523915 3

523915 3

Severity Instrument panel display error

Engine alarm SPN 523914 FMI 4 Engine alarm SPN 523914 FMI 5 Engine alarm SPN 523914 FMI 5 Engine alarm SPN 523914 FMI 11 Engine alarm SPN 523914 FMI 12 Engine alarm SPN 523915 FMI 0 Engine alarm SPN 523915 FMI 3 Engine alarm SPN 523915 FMI 3

Component

Fault

Controls

Link to system

Glow plug control; short circuit to ground

Glow plug control; open load

Glow plug control release line; short circuit error

Glow plug control; internal error

Glow plug control; powerstage over temperature

HCI dosing valve (DV1); overcurrent at the end of the injection phase HCI dosing valve (DV1); short circuit to battery high side HCI dosing valve (DV1); short circuit to battery

20-209

Calibrations and electronic diagnosis Table 150 Cod. ART Spn Fmi

523915 4

523915 7

523915 7

523915 11

523915 12

523916 0

523916 1

523916 2

523916 3

20-210

Severity Instrument panel display error

Engine alarm SPN 523915 FMI 4 Engine alarm SPN 523915 FMI 7 Engine alarm SPN 523915 FMI 7 Engine alarm SPN 523915 FMI 11 Engine alarm SPN 523915 FMI 12 Engine alarm SPN 523916 FMI 0 Engine alarm SPN 523916 FMI 1 Engine alarm SPN 523916 FMI 2 Engine alarm SPN 523916 FMI 3

Component

Fault

HCI dosing valve (DV1); short circuit to ground

HCI dosing valve (DV1); blocked open

HCI dosing valve (DV1); blocked closed

HCI dosing valve (DV1); short circuit high side powerstage HCI dosing valve (DV1); powerstage over temperature Physical range check high for HCI dosing valve (DV1) downstream pressure; shut off regeneration Physical range check low for HCI dosing valve (DV1) downstream pressure; shut off regeneration Sensor HCI dosing valve (DV1) downstream pressure; plausibility error Sensor error HCI dosing valve (DV1) downstream pressure; signal range check high

Controls

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523916 4

523917 0

523917 1

523917 2

523917 3

523917 4

523918 0

523918 1

523918 2

523918 3

Severity Instrument panel display error

Engine alarm SPN 523916 FMI 4 Engine alarm SPN 523917 FMI 0 Engine alarm SPN 523917 FMI 1 Engine alarm SPN 523917 FMI 2 Engine alarm SPN 523917 FMI 3 Engine alarm SPN 523917 FMI 4 Engine alarm SPN 523918 FMI 0 Engine alarm SPN 523918 FMI 1 Engine alarm SPN 523918 FMI 2 Engine alarm SPN 523918 FMI 3

Component

Fault

Controls

Link to system

Sensor error HCI dosing valve (DV1) downstream pressure; signal range check low Physical range check high for DV1 & DV2 upstream pressure; shut off regeneration Physical range check low for DV1 & DV2 upstream pressure; shut off regeneration Sensor DV1 & DV2 upstream pressure; plausibility error Sensor error DV1 & DV2 upstream pressure; signal range check high Sensor error DV1 & DV2 upstream pressure; signal range check low Physical range check high for DV1 & DV2 upstream temperature; shut off regeneration Physical range check low for DV1 & DV2 upstream temperature; shut off regeneration Sensor DV1 & DV2 upstream temperature; plausibility error Sensor error DV1 & DV2 upstream temperature; signal range check high

20-211

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523918 4

523919 0

523919 1

523919 2

523919 2

523919 3

523919 4

20-212

Severity Instrument panel display error

Engine alarm SPN 523918 FMI 4 Engine alarm SPN 523919 FMI 0 Engine alarm SPN 523919 FMI 1 Engine alarm SPN 523919 FMI 2 Engine alarm SPN 523919 FMI 2 Engine alarm SPN 523919 FMI 3 Engine alarm SPN 523919 FMI 4

Component

Fault

Sensor error DV1 & DV2 upstream temperature; signal range check low Physical range check high for airpump pressure; shut off regeneration Physical range check low for airpump pressure; shut off regeneration Sensor airpump pressure; plausibility error

Sensor air pump airpressure; plausibility error

Sensor error airpump pressure; signal range check high Sensor error airpump pressure; signal range check low

Controls

Link to system

Calibrations and electronic diagnosis Table 151 Cod. ART Spn Fmi

523920 0

523920 1

523920 2

523920 2

523920 3

523920 4

523921 0

523921 1

523921 2

Severity Instrument panel display error

Engine alarm SPN 523920 FMI 0 Engine alarm SPN 523920 FMI 1 Engine alarm SPN 523920 FMI 2 Engine alarm SPN 523920 FMI 2 Engine alarm SPN 523920 FMI 3 Engine alarm SPN 523920 FMI 4 Engine alarm SPN 523921 FMI 0 Engine alarm SPN 523921 FMI 1 Engine alarm SPN 523921 FMI 2

Component

Fault

Controls

Link to system

Physical range check high for exhaustgas back pressure burner; shut off regeneration Physical range check low for exhaustgas back pressure burner; shut off regeneration Sensor exhaust gas back pressure burner; plausibility error Sensor exhaustgas back pressure; plausibility error Sensor error exhaustgas back pressure burner; signal range check high Sensor error exhaustgas back pressure burner; signal range check low Physical range check high for burner temperature Physical range check low for burner temperature

Sensor burner temperature; plausibility error

20-213

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523921 3

523921 4

523921 11

523922 3

523922 4

523922 4

523922 5

523922 5

523922 7

523922 7

20-214

Severity Instrument panel display error

Engine alarm SPN 523921 FMI 3 Engine alarm SPN 523921 FMI 4 Engine alarm SPN 523921 FMI 11 Engine alarm SPN 523922 FMI 3 Engine alarm SPN 523922 FMI 4 Engine alarm SPN 523922 FMI 4 Engine alarm SPN 523922 FMI 5 Engine alarm SPN 523922 FMI 5 Engine alarm SPN 523922 FMI 7 Engine alarm SPN 523922 FMI 7

Component

Fault

Sensor error burner temperature; signal range check high Sensor error burner temperature; signal range check low Sensor burner temperature; plausibility error

Burner shut of valve; short circuit to battery

Burner shut of valve; short circuit to ground

Burner Shut Off Valve; short circuit to ground

Burner Shut Off Valve; open load

Burner shut off valve; open load

Shut Off Valve; blocked open

Shut Off Valve; blocked closed

Controls

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523922 12

523922 12

Severity Instrument panel display error

Component

Engine alarm SPN 523922 FMI 12 Engine alarm SPN 523922 FMI 12

Fault

Controls

Link to system

Controls

Link to system

Burner Shut Off Valve; powerstage over temperature Over temperature error on burner shut of valve

Engine control unit alarms - From SPN 523929 to SPN 524014 Table 152

Cod. ART Spn Fmi

523929 0

523929 1

523930 0

523930 1

523931 0

523931 1

Severity Instrument panel display error

Engine alarm SPN 523929 FMI 0 Engine alarm SPN 523929 FMI 1 Engine alarm SPN 523930 FMI 0 Engine alarm SPN 523930 FMI 1 Engine alarm SPN 523931 FMI 0 Engine alarm SPN 523931 FMI 1

Component

Fault

Fuel Balance Control integrator injector 1 (in firing order); maximum value exceeded Fuel Balance Control integrator injector 1 (in firing order); minimum value exceeded Fuel Balance Control integrator injector 2 (in firing order); maximum value exceeded Fuel Balance Control integrator injector 2 (in firing order); minimum value exceeded Fuel Balance Control integrator injector 3 (in firing order); maximum value exceeded Fuel Balance Control integrator injector 3 (in firing order); minimum value exceeded

20-215

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523932 0

523932 1

523933 0

523933 1

523934 0

523934 1

523935 12

523936 12

523938 9

20-216

Severity Instrument panel display error

Engine alarm SPN 523932 FMI 0 Engine alarm SPN 523932 FMI 1 Engine alarm SPN 523933 FMI 0 Engine alarm SPN 523933 FMI 1 Engine alarm SPN 523934 FMI 0 Engine alarm SPN 523934 FMI 1 Engine alarm SPN 523935 FMI 12 Engine alarm SPN 523936 FMI Engine alarm SPN 523938 FMI 9

Component

Fault

Fuel Balance Control integrator injector 4 (in firing order); maximum value exceeded Fuel Balance Control integrator injector 4 (in firing order); minimum value exceeded Fuel Balance Control integrator injector 5 (in firing order); maximum value exceeded Fuel Balance Control integrator injector 5 (in firing order); minimum value exceeded Fuel Balance Control integrator injector 6 (in firing order); maximum value exceeded Fuel Balance Control integrator injector 6 (in firing order); minimum value exceeded Timeout Error of CAN-Transmit-Frame EEC3VOL1; Engine send messages Timeout Error of CAN-Transmit-Frame EEC3VOL2; Engine send messages Timeout Error (BAM to packet) for CAN-ReceiveFrame AT1IGCVol1 information; factors & Sensorcalibration for NOX Sensor (SCR-system upstream cat; DPF-system downstream cat)

Controls

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

Severity Instrument panel display error

523939 9

Engine alarm SPN 523939 FMI 9

523940 9

Engine alarm SPN 523940 FMI 9

523941 9

Engine alarm SPN 523941 FMI 9

523942 9

Engine alarm SPN 523942 FMI 9

523943 9

Engine alarm SPN 523943 FMI 9

523946 0

Engine alarm SPN 523946 FMI 0

Component

Fault

Controls

Link to system

Timeout Error (BAM to BAM) for CAN-ReceiveFrame AT1IGCVol1 information; factors & Sensorcalibration for NOX Sensor (SCR-system upstream cat; DPF-system downstream cat) Timeout Error (PCK2PCK) for CAN-ReceiveFrame AT1IGCVol1 information; factors & Sensorcalibration for NOX Sensor (SCR-system upstream cat; DPFsystem downstream cat) Timeout Error (BAM to packet) for CAN-ReceiveFrame AT1OGCVol2 information; factors & Sensorcalibration for NOX Sensor (SCR-system downstream cat; DPFsystem downstream cat) Timeout Error (BAM to BAM) for CAN-Receive­ Frame AT1OGCVol2 information; factors & Sensorcalibration for NOX Sensor (SCR-system downstream cat; DPFsystem downstream cat) Timeout Error (PCK2PCK) for CAN-ReceiveFrame AT1OGCVol2 information; factors & Sensorcalibration for NOX Sensor (SCRsystem downstream cat; DPF-system downstream cat) Zerofuel calibration injector 1 (in firing order); maximum value exceeded

20-217

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523946 1

523947 0

523947 1

Severity Instrument panel display error

Component

Engine alarm SPN 523946 FMI 1 Engine alarm SPN 523947 FMI 0 Engine alarm SPN 523947 FMI 1

Fault

Controls

Link to system

Controls

Link to system

Zerofuel calibration injector 1 (in firing order); minimum value exceeded Zerofuel calibration injector 2 (in firing order); maximum value exceeded Zerofuel calibration injector 2 (in firing order); minimum value exceeded

Table 153 Cod. ART Spn Fmi

523948 0

523948 1

523949 0

523949 1

523950 0

20-218

Severity Instrument panel display error

Engine alarm SPN 523948 FMI 0 Engine alarm SPN 523948 FMI 1 Engine alarm SPN 523949 FMI 0 Engine alarm SPN 523949 FMI 1 Engine alarm SPN 523950 FMI 0

Component

Fault

Zerofuel calibration injector 3 (in firing order); maximum value exceeded Zerofuel calibration injector 3 (in firing order); minimum value exceeded Zerofuel calibration injector 4 (in firing order); maximum value exceeded Zerofuel calibration injector 4 (in firing order); minimum value exceeded Zerofuel calibration injector 5 (in firing order); maximum value exceeded

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523950 1

523951 0

523951 1

523960 0

523960 0

523960 1

523960 1

523973 14

523974 14

523975 14

Severity Instrument panel display error

Engine alarm SPN 523950 FMI 1 Engine alarm SPN 523951 FMI 0 Engine alarm SPN 523951 FMI 1 Engine alarm SPN 523960 FMI 0 Engine alarm SPN 523960 FMI 0 Engine alarm SPN 523960 FMI 1 Engine alarm SPN 523960 FMI 1 Engine alarm SPN 523973 FMI 14 Engine alarm SPN 523974 FMI 14 Engine alarm SPN 523975 FMI 14

Component

Fault

Controls

Link to system

Zerofuel calibration injector 5 (in firing order); minimum value exceeded Zerofuel calibration injector 6 (in firing order); maximum value exceeded Zerofuel calibration injector 6 (in firing order); minimum value exceeded High exhaust gas temperature EGR; warning threshold exceeded Physical range check high for EGR cooler downstream temperature High exhaust gas temperature EGR; shut off threshold exceeded Physical range check low for EGR cooler downstream temperature SCR Tamper detection; derating timer below limit 1 SCR Tamper detection; derating timer below limit 2 Urea quality; derating timer below limit 1

20-219

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523976 14

523977 14

523978 14

523980 14

523982 0

523982 1

523988 3

523988 4

523988 5

523988 12

20-220

Severity Instrument panel display error

Engine alarm SPN 523976 FMI 14 Engine alarm SPN 523977 FMI 14 Engine alarm SPN 523978 FMI 14 Engine alarm SPN 523980 FMI 14 Engine alarm SPN 523982 FMI 0 Engine alarm SPN 523982 FMI 1 Engine alarm SPN 523988 FMI 3 Engine alarm SPN 523988 FMI 4 Engine alarm SPN 523988 FMI 5 Engine alarm SPN 523988 FMI 12

Component

Fault

Controls

Urea qulaity; derating timer below limit 2

Urea tank level; derating timer below limit 1

Urea tank level; derating timer below limit 2

Bad quality of reduction agent detected

Powerstage diagnosis disabled; high battery voltage Powerstage diagnosis disabled; low battery voltage Charging lamp; short circuit to battery

Charging lamp; short circuit to ground

Charging load

lamp;

open

Charging lamp; over temperature

Link to system

Calibrations and electronic diagnosis Table 154 Cod. ART Spn Fmi

523989 0

523989 1

523990 0

523990 1

523992 9

523993 9

523995 13

523996 13

523998 4

Severity Instrument panel display error

Engine alarm SPN 523989 FMI 0 Engine alarm SPN 523989 FMI 1 Engine alarm SPN 523990 FMI 0 Engine alarm SPN 523990 FMI 1 Engine alarm SPN 523992 FMI 9 Engine alarm SPN 523993 FMI 9 Engine alarm SPN 523995 FMI 13 Engine alarm SPN 523996 FMI 13 Engine alarm SPN 523998 FMI 4

Component

Fault

Controls

Link to system

Fuel Balance Control integrator injector 7 (in firing order); maximum value exceeded Fuel Balance Control integrator injector 7 (in firing order); minimum value exceeded Fuel Balance Control integrator injector 8 (in firing order); maximum value exceeded Fuel Balance Control integrator injector 8 (in firing order); minimum value exceeded Timeout Error of CANReceive-Frame DM19Vol1; NOX sensor upstream Timeout Error of CANReceive-Frame DM19Vol2; NOX sensor downstream Check of missing injector adjustment value programming (IMA) injector 7 (in firing order) Check of missing injector adjustment value programming (IMA) injector 8 (in firing order) Injector cylinder bank 2 slave; short circuit

20-221

Calibrations and electronic diagnosis Cod. ART Spn Fmi

523999 12

524000 3

524000 4

524000 5

524001 3

524001 4

524001 5

524004 12

524005 12

524011 0

20-222

Severity Instrument panel display error

Engine alarm SPN 523999 FMI 12 Engine alarm SPN 524000 FMI 3 Engine alarm SPN 524000 FMI 4 Engine alarm SPN 524000 FMI 5 Engine alarm SPN 524001 FMI 3 Engine alarm SPN 524001 FMI 4 Engine alarm SPN 524001 FMI 5 Engine alarm SPN 524004 FMI 12 Engine alarm SPN 524005 FMI 12 Engine alarm SPN 524011 FMI 0

Component

Fault

Injector powerstage output Slave defect

Injector 7 (in firing order); short circuit

High side to low side short circuit in the injector 7 (in firing order) Injector 7 (in firing order); interruption of electric connection Injector 8 (in firing order); short circuit

High side to low side short circuit in the injector 8 (in firing order) Injector 8 (in firing order); interruption of electric connection Too many recognized misfires in cylinder 7 (in firing order) Too many recognized misfires in cylinder 8 (in firing order) Zerofuel calibration injector 7 (in firing order); maximum value exceeded

Controls

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

524011 1

524012 0

524012 1

524013 7

524013 7

524014 1

Severity Instrument panel display error

Engine alarm SPN 524011 FMI 1 Engine alarm SPN 524012 FMI 0 Engine alarm SPN 524012 FMI 1 Engine alarm SPN 524013 FMI 7 Engine alarm SPN 524013 FMI 7 Engine alarm SPN 524014 FMI 1

Component

Fault

Controls

Link to system

Zerofuel calibration injector 7 (in firing order); minimum value exceeded Zerofuel calibration injector 8 (in firing order); maximum value exceeded Zerofuel calibration injector 8 (in firing order); minimum value exceeded Burner operation is interrupted too often

Burner flame unintentional deleted

Air pressure glow plug flush line; below limit

20-223

Calibrations and electronic diagnosis Engine control unit alarms - From SPN 524016 to SPN 524069 Table 155

Cod. ART Spn Fmi

524016 2

524016 2

524016 11

524017 12

524017 12

524018 14

524019 11

524020 14

524021 11

20-224

Severity Instrument panel display error

Engine alarm SPN 524016 FMI 2 Engine alarm SPN 524016 FMI 2 Engine alarm SPN 524016 FMI 11 Engine alarm SPN 524017 FMI 12 Engine alarm SPN 524017 FMI 12 Engine alarm SPN 524018 FMI 14 Engine alarm SPN 524019 FMI 11 Engine alarm SPN 524020 FMI 14 Engine alarm SPN 524021 FMI 11

Component

Fault

Controls

Calculated amount of air is not plausible to HFM reading Amount of air is not plausible to pump speed

HFM sensor; electrical fault

Spark plug control unit (SPCU); internal error

Spark plug control unit (SPCU); electrical fault

DPF wasn´t regenerated, power reduction phase 1 (manuell regeneration request) Air Pump; blocked

air

lines

Engine power reduction due to low lambda

Fuel line pipe leak behind Shut Off Valve

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

524022 14

524023 14

524024 11

524025 5

524025 14

524028 2

524029 2

524030 7

524031 13

524033 7

Severity Instrument panel display error

Engine alarm SPN 524022 FMI 14 Engine alarm SPN 524023 FMI 14 Engine alarm SPN 524024 FMI 11 Engine alarm SPN 524025 FMI 5 Engine alarm SPN 524025 FMI 14 Engine alarm SPN 524028 FMI 2 Engine alarm SPN 524029 FMI 2 Engine alarm SPN 524030 FMI 7 Engine alarm SPN 524031 FMI 13 Engine alarm SPN 524033 FMI 7

Component

Fault

Controls

Link to system

DPF wasn´t regenerated, power reduction phase 2 (manuell regeneration request) DPF wasn´t regenerated, warning condition (manuell regeneration mode) Deviation of the exhaust gas temperature setpoint to actual value downstream (DOC) too high DPF system; operating voltage error

Particulate filter; regeneration not succesful

CAN message PROEGRActr; plausibility error Timeout Error of CANReceive-Frame ComEGRActr - exhaust gas recirculation positioner EGR actuator; internal error

EGR actuator; calibration error

EGR actuator; due to overload in Save Mode

20-225

Calibrations and electronic diagnosis Cod. ART Spn Fmi

524034 3

524034 4

524034 5

524034 12

524035 12

524036 12

524037 3

524037 4

524037 5

524038 9

20-226

Severity Instrument panel display error

Engine alarm SPN 524034 FMI 3 Engine alarm SPN 524034 FMI 4 Engine alarm SPN 524034 FMI 5 Engine alarm SPN 524034 FMI 12 Engine alarm SPN 524035 FMI 12 Engine alarm SPN 524036 FMI 12 Engine alarm SPN 524037 FMI 3 Engine alarm SPN 524037 FMI 4 Engine alarm SPN 524037 FMI 5 Engine alarm SPN 524038 FMI 9

Component

Fault

Disc separator; short circuit to battery

Disc separator; short circuit to ground

Disc Separator; open load

Disc Separator; powerstage over temperature

Injector diagnostics; time out error in the SPI communication Injector diagnostics Slave; time out error in the SPI communication Ashlamp; short circuit to battery

Ashlamp; short circuit to ground

Ashlamp; open load

Timeout error of CANReceive-Frame ComMS_Sys1TO (error memory Slave); Master-Slave internal CAN message

Controls

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

524039 9

Severity Instrument panel display error

Component

Severity Instrument panel display error

Component

Engine alarm SPN 524039 FMI 9

Fault

Controls

Link to system

Controls

Link to system

Timeout error of CANReceive-Frame ComMS_Sys2TO (error memory Slave); Master-Slave internal CAN message

Table 156 Cod. ART Spn Fmi

524040 9

524041 9

524042 9

524043 9

524044 9

524045 9

524046 9

Engine alarm SPN 524040 FMI 9 Engine alarm SPN 524041 FMI 9 Engine alarm SPN 524042 FMI 9 Engine alarm SPN 524043 FMI 9 Engine alarm SPN 524044 FMI 9 Engine alarm SPN 524045 FMI 9 Engine alarm SPN 524046 FMI 9

Fault

Timeout error of CANReceive-Frame ComMS_Sys3TO (error memory Slave); Master-Slave internal CAN message Timeout error of CANReceive-Frame ComMS_Sys4TO (error memory Slave); Master-Slave internal CAN message Timeout error of CANReceive-Frame ComMS_Sys5TO (error memory Slave); Master-Slave internal CAN message Timeout error of CANReceive-Frame ComMS_Sys6TO (error memory Slave); Master-Slave internal CAN message CAN message ComMS_ Sys7 not received from slave Master-Slave CAN; Message-Counter-Error of CAN-Receive-Frame ComMSMoFOvR Master-Slave CAN; Checksum-Error of CANReceive-Frame ComMSMoFOvR

20-227

Calibrations and electronic diagnosis Cod. ART Spn Fmi

524047 9

524048 9

524049 9

524052 11

524052 11

524052 11

524055 4

524057 2

524062 12

524062 12

20-228

Severity Instrument panel display error

Engine alarm SPN 524047 FMI 9 Engine alarm SPN 524048 FMI 9 Engine alarm SPN 524049 FMI 9 Engine alarm SPN 524052 FMI 11 Engine alarm SPN 524052 FMI 11 Engine alarm SPN 524052 FMI 11 Engine alarm SPN 524055 FMI 4 Engine alarm SPN 524057 FMI 2 Engine alarm SPN 524062 FMI 12 Engine alarm SPN 524062 FMI 12

Component

Fault

Master-Slave CAN; Messsage-Length-Error of CAN-Receive-Frame ComMSMoFOvR Timeout error CAN message ComMSMoFOvR1TO error memory Slave Message copy error in the Master / Slave data transfer Error memory Slave reports FID MSMonFC2; Shut-Off Path test error of fuel injection system Error memory Slave reports FID MSMonFC3; timeout of engine state messages (ComMS_ Sys1­7) from master ECU Master ECU and Slave ECU data sets or software are not identical Spark Plug Control Unit (SPCU); short circuit to ground Electric fuel pump; fuel pressure build up error

Regeneration inhibit switch not available; ComInhSwtNA Regeneration release switch not available; ComRegSwtNA

Controls

Link to system

Calibrations and electronic diagnosis Cod. ART Spn Fmi

524068 2

524069 9

Severity Instrument panel display error

Component

Engine alarm SPN 524068 FMI 2 Engine alarm SPN 524069 FMI 9

Fault

Controls

Link to system

Master ECU and Slave ECU have been identified as the same types Timeout Error of CANReceive-Frame MSMon_FidFCCTO; Master-Slave CAN communication faulty

20.5.2 - Transmission alarms

Transmission alarms - Introduction Table 157 Cod.

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

Description

Processor error (Arithmetics, Push, Pop, System Stack) Processor error (Register) Processor error (internal watchdog) Not implemented Processor error (external watchdog) Not implemented ECU in as-delivered condition without valid parameters Processor memory error (flash checksum) at initialization Processor memory error (flash checksum) during operation Application error - data fields incongruent with basic program Configuration error - no data field has been selected yet or the selected data field does not exist Internal processor memory error (RAM address error) at initialization Internal processor memory error (RAM address error) during operation External processor memory error (RAM address error) at initialization External processor memory error (RAM address error) during operation Processor memory error (EEPROM checksum 0 incorrect) Processor memory error (EEPROM checksum 0 incorrect) Processor memory error (EEPROM checksum 2 incorrect) Processor memory error (EEPROM checksum 3 incorrect) Processor memory error (EEPROM checksum 4 incorrect) Processor memory error (EEPROM checksum 5 incorrect) Processor memory error (EEPROM checksum 6 incorrect) Processor memory error (EEPROM checksum 7 incorrect) Processor error (external bus access incorrect) Processor error (instruction incorrect) Processor error (access to odd address, compiler error) Processor error (memory protection range indicator) Program error (no valid C167 command) Processor memory error (stack range undershot) Processor memory error (stack range exceeded) Non-maskable interrupt active without permission Local CAN – timeout TR1 message Local CAN – timeout TR5 message

Link

20-234 20-235 20-236 20-237 20-238 20-238 20-239 20-240 20-240 20-240 20-241 20-242 20-243 20-244 20-245 20-246 20-247 20-248 20-249 20-250 20-251 20-252 20-253 20-254 20-255 20-256 20-257 20-258 20-259 20-260 20-261 20-229

Calibrations and electronic diagnosis Table 158 Cod.

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 (SDF S240 / SDF S180+) 58 59 60 61 62 63 64 65 66

Description

Local CAN - timeout register2 Local CAN - timeout engine (EHS) message Local CAN – timeout KLECU1 message Local CAN – timeout KLECU2 message Local CAN - timeout register 6 Local CAN - timeout register 7 Local CAN - timeout register 8 Local CAN - timeout register 9 Local CAN - timeout register 10 Local CAN - timeout register 11 Local CAN - timeout register 12 Local CAN - timeout register 13 Local CAN - timeout register 14 CAN bus error – local CAN offline Voltage supply too low Supply voltage (term. 30) too high Internal main stage end switch not functioning Internal main stage end switch permanently ON (stuck) Hydrostatic unit outside tolerance Hydrostatic unit - ratio cannot be reached Max. hydrostatic unit high pressure reached Not implemented Impermissible control of transmission clutches Overspeed protection active (nAb > 6000 1/min) Not implemented Not implemented Loss of step during hydrostatic unit calibration Hydrostatic unit – implausible calibration data Not implemented CAN Bus error – local CAN, faulty communication Speed sensor transmission input - interruption or short-circuit to plus Speed sensor transmission input – sensor short circuit Speed sensor transmission input – speed too high

Link

20-262 20-263 20-264 20-265 20-266 20-267 20-268 20-270 20-271 20-272 20-273 20-274 20-275 20-276 20-277 20-278 20-279 20-280 20-281 20-282 20-283 20-283 20-284 20-284 20-285 20-285 20-286 20-288 20-289

Table 159 Cod.

67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 (SDF S240 / SDF S180+) 84 85 86 87 88 89

20-230

Description

Speed sensor transmission input - signal dropout Speed sensor ridge1/2 – Interruption or short to plus Speed sensor ridge1/2 – Sensor short circuit Speed sensor ridge 1/2 – speed too high Speed sensor ridge1/2 – signal dropout Speed sensor output 1 – Interruption or short to plus Speed sensor output 1 – Sensor short circuit Speed sensor output 1 – Speed too high Speed sensor output 1 – signal dropout Speed sensor ridge 3/4 – Interruption or short to plus Speed sensor ridge 3/4 – Sensor short circuit Speed sensor ridge 3/4 – Speed too high Speed sensor ridge 3/4 – signal dropout Speed sensor output 2 – Interruption or short to plus Speed sensor output 2 - sensor short circuit Speed sensor output 2 - speed too high Output speed too high; transmission ratio is limited Speed sensor transmission input – Implausible speed Speed sensor ridge 1/2 - implausible speed Speed sensor output 1 – implausible speed Speed sensor ridge 3/4 – Implausible speed Output speed – incongruent sense of rotation Speed sensor transmission input - implausible vehicle engine speed signal

Link

20-289 20-290 20-292 20-294 20-295 20-296 20-298 20-300 20-301 20-302 20-304 20-306 20-307 20-308 20-310 20-312 20-313 20-313 20-313 20-314 20-314 20-315 20-317

Calibrations and electronic diagnosis Cod.

90

91 92 (SDF S240 / SDF S180+) 93 (SDF S240 / SDF S180+) 94 (SDF S240 / SDF S180+) 95 (SDF S240 / SDF S180+) 96 97 98 99

Description

Vehicle accelerates from standstill despite absence of VDC requirement Not implemented Voltage at HP1 sensor smaller than valid range Voltage at HP 1 sensor above the valid range Voltage at HP 2 sensor smaller than the valid range Voltage at HP 2 sensor larger than valid range Input A0-S (BOC) - voltage too high Input A0-S (BOC) - incorrect signal BOC plausibility error between VDC and TCU Input A0. + (analog limp home or BOC input) - voltage too low

Link

20-318 20-319 20-320 20-321 20-323 20-324 20-325 20-326 20-327

Table 160 Cod.

100 101 102 103 104

Description

Not implemented Not implemented Not implemented Not implemented Lubrication pressure sensor - signal voltage above permitted range 105 Lubrication pressure sensor - lubrication pressure too low 106 Lubrication pressure sensor - lubrication pressure too low 107 Lubrication pressure sensor– Signal voltage below permitted range 108 Lubrication pressure sensor– lubrication pressure too high 109 Not implemented 110 Not implemented 111 Not implemented 112 System pressure sensor - signal voltage above permitted range 113 System pressure sensor - system pressure too low, no driving operation possible 114 System pressure sensor - system pressure too low, engine speed elevation initiated 115 System pressure sensor – signal voltage below permitted range 116 System pressure sensor - system pressure too high 117 System pressure sensor - pressure drop during gear change 118 System pressure sensor - system pressure too low, engine speed elevation without effect 119 Not implemented 120 Temperature sensor - interruption or short to plus 121 Temperature sensor - temperature gradient above permitted range 122 Temperature sensor - temperature too high 123 Temperature sensor - short to ground 124 Temperature sensor - temperature too low, limited driving operation 125 Temperature sensor - temperature gradient below permitted range 126 Temperature sensor - temperature too low, no driving operation 127 (SDF S180 / SDF S240 / High transmission temperature - limitation is active SDF S180+) 128 Not implemented 129 Not implemented 130 System pressure sensor – pressure drop during clutch 1 shift procedure 131 System pressure sensor – pressure drop during clutch 2 shift procedure 132 System pressure sensor – pressure drop during clutch 3 shift procedure

Link

20-328 20-329 20-329 20-330 20-330 20-331 20-332 20-333 20-333 20-334 20-335 20-335 20-336 20-337 20-338 20-338 20-339 20-340 20-340 20-340 20-342 20-342 20-342

20-231

Calibrations and electronic diagnosis Table 161 Cod.

133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157

158 159 160 (SDF S240 / SDF S180+) 161 (SDF S240 / SDF S180+) 162 163 164 165

Description

System pressure sensor – pressure drop during clutch 4 shift procedure System pressure sensor – pressure drop during clutch forward shift procedure System pressure sensor – pressure drop during clutch reverse shift procedure Oil pressure filter inlet – pressure filter soiled, change Not implemented Not implemented Not implemented Not implemented Not implemented Not implemented Not implemented Hydrostatic unit electronics - no response Hydrostatic unit electronics - wrong nominal value Hydrostatic unit electronics - index sensor does not provide a response Hydrostatic unit electronics - several initialization attempts Hydrostatic unit – loss of step after ignition ON Parking lock - engagement process aborted, first part, excessive path Parking lock - engagement process aborted, second part, excessive path Parking lock - engagement process aborted, first part, no pressure buildup Parking lock - engagement process aborted, second part, no pressure buildup Parking lock - inspection aborted, first part, excessive path Parking lock - inspection aborted, second part, excessive path Parking lock - inspection aborted, first part, no pressure buildup Parking lock - inspection aborted, second part, no pressure buildup Parking lock - check aborted, pressure buildup before neutral shift, excessive travel Not implemented Not implemented Calibration data HP sensors faulty; recalibration necessary Plausibility check of the HP sensors compared to system pressure (both sensors provide pressures > pSys) Not implemented Not implemented Not implemented Not implemented

Link

20-343 20-343 20-344 20-344 20-344 20-347 20-350 20-353 20-354 20-354 20-354 20-354 20-354 20-355 20-355 20-355 20-355 20-355 20-355 20-357 -

Table 162 Cod.

166 167 168 169 170 171 172 173 174 175 176

20-232

Description

Not implemented Not implemented Not implemented Not implemented Voltage supply hydrostatic unit electronics - short to plus Voltage supply hydrostatic unit electronics - short circuit or short to ground Not implemented Not implemented Not implemented Not implemented Solenoid valve four wheel drive - interruption of control

Link

20-358 20-359 20-360

Calibrations and electronic diagnosis Cod.

177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198

Description

Four wheel drive solenoid valve – false PWM signal Solenoid valve four wheel drive - short to plus Solenoid valve four wheel drive - short circuit or short to ground Not implemented Not implemented Not implemented Not implemented Solenoid valve clutch forward - interruption of control Solenoid valve clutch forward - faulty PWM signal Solenoid valve clutch forward - short to plus Solenoid valve clutch forward - short circuit or short to ground Solenoid valve clutch forward - clutch does not open Solenoid valve clutch forward - clutch does not close Solenoid valve clutch forward - differential speed too high, clutch slipping Not implemented Solenoid valve clutch reverse - interruption of the control Solenoid valve clutch reverse - faulty PWM signal Solenoid valve clutch reverse - short to plus Solenoid valve clutch reverse - short circuit or short to ground Clutch reverse solenoid valve – clutch does not open Clutch reverse solenoid valve – clutch does not close Solenoid valve clutch reverse - differential speed too high, clutch slipping

Link

20-362 20-364 20-366 20-368 20-370 20-372 20-374 20-376 20-378 20-380 20-382 20-384 20-386 20-388 20-390 20-392 20-394

Table 163 Cod.

199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229

Description

Not implemented Solenoid valve clutch 1 - interruption of control Solenoid valve clutch 1 - faulty signal PWM Solenoid valve clutch 1 - short to plus Solenoid valve clutch 1 - short circuit or short to ground Clutch 1 solenoid valve – clutch does not open Clutch 1 solenoid valve – clutch does not close Solenoid valve clutch 1 - differential speed too high, clutch slipping Not implemented Solenoid valve clutch 2 - interruption of control Solenoid valve clutch 2 - faulty signal PWM Solenoid valve clutch 2 - short to plus Solenoid valve clutch 2 - short circuit or short to ground Clutch 2 solenoid valve – clutch does not open Clutch 2 solenoid valve – clutch does not close Solenoid valve clutch 2 - differential speed too high, clutch slipping Not implemented Solenoid valve clutch 3 - interruption of control Solenoid valve clutch 3 - faulty signal PWM Solenoid valve clutch 3 - short to plus Solenoid valve clutch 3 - short circuit or short to ground Clutch 3 solenoid valve – clutch does not open Clutch 3 solenoid valve – clutch does not close Solenoid valve clutch 3 - differential speed too high, clutch slipping Not implemented Solenoid valve clutch 4 - interruption of control Solenoid valve clutch 4 - faulty signal PWM Solenoid valve clutch 4 - short to plus Solenoid valve clutch 4 - short circuit or short to ground Clutch 4 solenoid valve – clutch does not open Clutch 4 solenoid valve – clutch does not close

Link

20-396 20-398 20-400 20-402 20-404 20-405 20-406 20-407 20-409 20-411 20-413 20-415 20-416 20-417 20-418 20-420 20-422 20-424 20-426 20-427 20-428 20-429 20-431 20-433 20-435 20-437 20-438 20-233

Calibrations and electronic diagnosis Cod.

Description

Link

Solenoid valve clutch 4 - differential speed too high, clutch slip- 20-439 ping Not implemented -

230 231

Table 164 Cod.

232 232 (SDF S240 / SDF S180+) 233 234 234 (SDF S240 / SDF S180+) 235 235 (SDF S240 / SDF S180+) 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255

Description

Solenoid valve parking lock ON - interruption of control Solenoid valve brake oil cooling - interruption of control Not implemented Solenoid valve parking lock ON - short to plus Solenoid valve brake oil cooling - short circuit to plus Solenoid valve parking lock ON - short or short to ground Solenoid valve brake oil cooling - short to ground Solenoid valve parking lock ON - parking lock not engageable Solenoid valve parking lock ON - parking lock engaged but open again Not implemented Not implemented Solenoid valve parking lock OFF - interruption of control Not implemented Solenoid valve parking lock OFF - short to plus Solenoid valve parking lock OFF - short circuit or short to ground Not implemented Not implemented Not implemented Not implemented Not implemented Not implemented Not implemented Not implemented Not implemented Not implemented Not implemented Not implemented

Link

20-440 20-442 20-443 20-445 20-446 20-448 20-449 20-450 20-450 20-452 20-454 -

Transmission alarm 01 Description Processor error (Arithmetics, Push, Pop, System Stack) Cause False memory entries are identified in the control unit. As an error response, the valve power stage main switch is switched OFF. l l l l

Processor defective. Problem during programming. Sporadically occurring error due to an open circuit of the power supply. EMC (electromagnetic compatibility) problem.

Correction 1. 2.

3. 4.

If the error occurs immediately after a TCU programming procedure, the programming should be repeated. Make sure that the TCU has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. The TCU should be replaced if the error continues to occur. If the error does not occur again, it may be the case that the error is due to a one-off EMC interference (electromagnetic compatibility).

Table 165 For TCU pin assignment

20-234

See para. 20.5.2 - TCU pin assignment - page 20-456

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 02 Description Processor error (Register) Cause False memory entries are identified in the control unit. As an error response, the valve power stage main switch is switched OFF. l l l l

Processor defective Problem during programming. Sporadically occurring error due to an open circuit of the power supply. EMC (electromagnetic compatibility) problem.

Correction 1. 2.

3. 4.

If the error occurs immediately after a TCU programming procedure, the programming should be repeated. Make sure that the TCU has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. The TCU should be replaced if the error continues to occur. If the error does not occur again, it may be the case that the error is due to a one-off EMC interference (electromagnetic compatibility).

Table 166 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

20-235

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 03 Description Processor error (internal watchdog) Cause False memory entries are identified in the control unit. As an error response, the valve power stage main switch is switched OFF. l l l l

Processor defective. Problem during programming. Sporadically occurring error due to an open circuit of the power supply. EMC (electromagnetic compatibility) problem.

Correction 1. 2.

3. 4.

If the error occurs immediately after a TCU programming procedure, the programming should be repeated. Make sure that the TCU has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. The TCU should be replaced if the error continues to occur. If the error does not occur again, it may be the case that the error is due to a one-off EMC interference (electromagnetic compatibility).

Table 167 For TCU pin assignment

20-236

See para. 20.5.2 - TCU pin assignment - page 20-456

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 05 Description Processor error (external watchdog) Cause False memory entries are identified in the control unit. As an error response, the valve power stage main switch is switched OFF. l l l l

Processor defective. Problem during programming. Sporadically occurring error due to an open circuit of the power supply. EMC (electromagnetic compatibility) problem.

Correction 1. 2.

3. 4.

If the error occurs immediately after a TCU programming procedure, the programming should be repeated. Make sure that the TCU has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. The TCU should be replaced if the error continues to occur. If the error does not occur again, it may be the case that the error is due to a one-off EMC interference (electromagnetic compatibility).

Table 168 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

20-237

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 07 Description ECU in as-delivered condition without valid parameters Cause The parameters stored in the control unit are not valid. As an error response, the valve power stage main switch is switched OFF. Correction 1.

Check whether parameters are present (e.g. voltage supply 12V/24V; rear axle ratio; max. speed…), check their settings and correct them as far as possible. If this error occurs after re-programming please repeat accordingly.

Transmission alarm 08 Description Processor memory error (flash checksum) at initialization Cause False memory entries are identified in the control unit. l l l l

Processor defective. Problem during programming. Sporadically occurring error due to an open circuit of the power supply. EMC (electromagnetic compatibility) problem.

Correction 1. 2.

3.

If the error occurs immediately after a TCU programming procedure, the programming should be repeated. Make sure that the TCU has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. The TCU should be replaced if the error continues to occur.

20-238

Calibrations and electronic diagnosis 4.

If the error does not occur again, it may be the case that the error is due to a one-off EMC interference (electromagnetic compatibility).

Table 169 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 09 Description Processor memory error (flash checksum) during operation Cause False memory entries are identified in the control unit. As an error response, the valve power stage main switch is switched OFF. l l l l

Processor defective. Problem during programming. Sporadically occurring error due to an open circuit of the power supply. EMC (electromagnetic compatibility) problem.

Correction 1. 2.

3. 4.

If the error occurs immediately after a TCU programming procedure, the programming should be repeated. Make sure that the TCU has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. The TCU should be replaced if the error continues to occur. If the error does not occur again, it may be the case that the error is due to a one-off EMC interference (electromagnetic compatibility).

Table 170 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456 20-239

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 10 Description Application error - data fields incongruent with basic program Cause The parameters stored in the control unit are not valid. Correction 1.

It is necessary to reprogram the control unit. Please contact your ZF representative.

Transmission alarm 11 Description Configuration error - no data field has been selected yet or the selected data field does not exist Cause The parameters stored in the control unit are not valid. Correction 1.

It is necessary to reprogram the control unit. Please contact your ZF representative.

Transmission alarm 12 Description Internal processor memory error (RAM address error) at initialization. Cause False memory entries are identified in the control unit. As an error response, the valve power stage main switch is switched OFF. l l l l

Processor defective. Problem during programming. Sporadically occurring error due to an open circuit of the power supply. EMC (electromagnetic compatibility) problem.

20-240

Calibrations and electronic diagnosis Correction 1. 2.

If the error occurs immediately after a TCU programming procedure, the programming should be repeated. Make sure that the TCU has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. The TCU should be replaced if the error continues to occur. If the error does not occur again, it may be the case that the error is due to a one-off EMC interference (electromagnetic compatibility).

3. 4.

Table 171 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 13 Description Internal processor memory error (RAM address error) during operation. Cause False memory entries are identified in the control unit. As an error response, the valve power stage main switch is switched OFF. l l l l

Processor defective. Problem during programming. Sporadically occurring error due to an open circuit of the power supply. EMC (electromagnetic compatibility) problem.

Correction 1.

If the error occurs immediately after a TCU programming procedure, the programming should be repeated.

20-241

Calibrations and electronic diagnosis 2.

Make sure that the TCU has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. The TCU should be replaced if the error continues to occur. If the error does not occur again, it may be the case that the error is due to a one-off EMC interference (electromagnetic compatibility).

3. 4.

Table 172 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 14 Description External processor memory error (RAM address error) at initialization Cause False memory entries are identified in the control unit. As an error response, the valve power stage main switch is switched OFF. l l l l

Processor defective. Problem during programming. Sporadically occurring error due to an open circuit of the power supply. EMC (electromagnetic compatibility) problem.

Correction 1. 2.

If the error occurs immediately after a TCU programming procedure, the programming should be repeated. Make sure that the TCU has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V).

20-242

Calibrations and electronic diagnosis 3.

Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. The TCU should be replaced if the error continues to occur. If the error does not occur again, it may be the case that the error is due to a one-off EMC interference (electromagnetic compatibility).

4.

Table 173 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 15 Description External processor memory error (RAM address error) during operation. Cause False memory entries are identified in the control unit. As an error response, the valve power stage main switch is switched OFF. l l l l

Processor defective. Problem during programming. Sporadically occurring error due to an open circuit of the power supply. EMC (electromagnetic compatibility) problem.

Correction 1. 2.

3. 4.

If the error occurs immediately after a TCU programming procedure, the programming should be repeated. Make sure that the TCU has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. The TCU should be replaced if the error continues to occur. If the error does not occur again, it may be the case that the error is due to a one-off EMC interference (electromagnetic compatibility). 20-243

Calibrations and electronic diagnosis Table 174 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 16 Description Processor memory error (EEPROM checksum 0 incorrect). Cause The parameters stored in the control unit (manufacturer data and transmission settings) have been changed. l l l

Incorrectly performed change to control unit parameters. Control unit has an internal defect. Error that occurs sporadically due to an open circuit of the voltage supply.

Correction 1. 2. 3.

4.

Use the diagnosis tool to check the control unit configuration and correct erroneous settings where necessary. Correct the control unit checksum by resetting the checksum error (see diagnosis tool instructions). Ensure that the control unit has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. Replace the control unit if the error continues to occur.

Table 175 For TCU pin assignment

20-244

See para. 20.5.2 - TCU pin assignment - page 20-456

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 17 Description Processor memory error (EEPROM checksum 0 incorrect) Cause The parameters stored in the control unit (manufacturer data and transmission settings) have been changed. l l l

Incorrectly performed change to control unit parameters. Control unit has an internal defect. Error that occurs sporadically due to an open circuit of the voltage supply.

Correction 1. 2. 3.

4.

Use the diagnosis tool to check the control unit configuration and correct erroneous settings where necessary. Correct the control unit checksum by resetting the checksum error (see diagnosis tool instructions). Ensure that the control unit has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. Replace the control unit if the error continues to occur.

Table 176 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

20-245

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 18 Description Processor memory error (EEPROM checksum 2 incorrect). Cause The parameters stored in the control unit (manufacturer data and transmission settings) have been changed. l l l

Incorrectly performed change to control unit parameters. Control unit has an internal defect. Error that occurs sporadically due to an open circuit of the voltage supply.

Correction 1. 2. 3.

4.

Use the diagnosis tool to check the control unit configuration and correct erroneous settings where necessary. Correct the control unit checksum by resetting the checksum error (see diagnosis tool instructions). Ensure that the control unit has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. Replace the control unit if the error continues to occur.

Table 177 For TCU pin assignment

20-246

See para. 20.5.2 - TCU pin assignment - page 20-456

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 19 Description Processor memory error (EEPROM checksum 3 incorrect) Cause The parameters stored in the control unit (manufacturer data and transmission settings) have been changed. l l l

Incorrectly performed change to control unit parameters. Control unit has an internal defect. Error that occurs sporadically due to an open circuit of the voltage supply.

Correction 1. 2. 3.

4.

Use the diagnosis tool to check the control unit configuration and correct erroneous settings where necessary. Correct the control unit checksum by resetting the checksum error (see diagnosis tool instructions). Ensure that the control unit has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. Replace the control unit if the error continues to occur.

Table 178 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

20-247

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 20 Description Processor memory error (EEPROM checksum 4 incorrect) Cause The parameters stored in the control unit (manufacturer data and transmission settings) have been changed. l l l

Incorrectly performed change to control unit parameters. Control unit has an internal defect. Error that occurs sporadically due to an open circuit of the voltage supply.

Correction 1. 2. 3.

4.

Use the diagnosis tool to check the control unit configuration and correct erroneous settings where necessary. Correct the control unit checksum by resetting the checksum error (see diagnosis tool instructions). Ensure that the control unit has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. Replace the control unit if the error continues to occur.

Table 179 For TCU pin assignment

20-248

See para. 20.5.2 - TCU pin assignment - page 20-456

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 21 Description Processor memory error (EEPROM checksum 5 incorrect) Cause The parameters stored in the control unit (manufacturer data and transmission settings) have been changed. l l l

Incorrectly performed change to control unit parameters. Control unit has an internal defect. Error that occurs sporadically due to an open circuit of the voltage supply.

Correction 1. 2. 3.

4.

Use the diagnosis tool to check the control unit configuration and correct erroneous settings where necessary. Correct the control unit checksum by resetting the checksum error (see diagnosis tool instructions). Ensure that the control unit has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. Replace the control unit if the error continues to occur.

Table 180 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

20-249

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 22 Description Processor memory error (EEPROM checksum 6 incorrect) Cause The parameters stored in the control unit (manufacturer data and transmission settings) have been changed. l l l

Incorrectly performed change to control unit parameters. Control unit has an internal defect. Error that occurs sporadically due to an open circuit of the voltage supply.

Correction 1. 2. 3.

4.

Use the diagnosis tool to check the control unit configuration and correct erroneous settings where necessary. Correct the control unit checksum by resetting the checksum error (see diagnosis tool instructions). Ensure that the control unit has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. Replace the control unit if the error continues to occur.

Table 181 For TCU pin assignment

20-250

See para. 20.5.2 - TCU pin assignment - page 20-456

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 23 Description Processor memory error (EEPROM checksum 7 incorrect) Cause The parameters stored in the control unit (manufacturer data and transmission settings) have been changed. l l l

Incorrectly performed change to control unit parameters. Control unit has an internal defect. Error that occurs sporadically due to an open circuit of the voltage supply.

Correction 1. 2. 3.

4.

Use the diagnosis tool to check the control unit configuration and correct erroneous settings where necessary. Correct the control unit checksum by resetting the checksum error (see diagnosis tool instructions). Ensure that the control unit has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. Replace the control unit if the error continues to occur.

Table 182 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

20-251

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 24 Description Processor error (external bus access incorrect) Cause Faulty access operations are detected in the control unit. l l l l

Processor defective. Problem during programming. Error that occurs sporadically due to an open circuit of the voltage supply. EMC (electromagnetic compatibility) problem.

Correction 1. 2.

3. 4.

If the error occurs immediately after programming the control unit, the programming should be repeated. Ensure that the control unit has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. Replace the control unit if the error continues to occur. If the error does not occur again, it may be the case that the error is due to a one-off EMC interference (electromagnetic compatibility).

Table 183 For TCU pin assignment

20-252

See para. 20.5.2 - TCU pin assignment - page 20-456

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 25 Description Processor error (instruction incorrect) Cause Faulty access operations are detected in the control unit. l l l l

Processor defective. Problem during programming. Error that occurs sporadically due to an open circuit of the voltage supply. EMC (electromagnetic compatibility) problem.

Correction 1. 2.

3. 4.

If the error occurs immediately after programming the control unit, the programming should be repeated. Ensure that the control unit has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. Replace the control unit if the error continues to occur. If the error does not occur again, it may be the case that the error is due to a one-off EMC interference (electromagnetic compatibility).

Table 184 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

20-253

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 26 Description Processor error (access to odd address, compiler error) Cause Faulty access operations are detected in the control unit. l l l l

Processor defective. Problem during programming. Error that occurs sporadically due to an open circuit of the voltage supply. EMC (electromagnetic compatibility) problem.

Correction 1. 2.

3. 4.

If the error occurs immediately after programming the control unit, the programming should be repeated. Ensure that the control unit has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. Replace the control unit if the error continues to occur. If the error does not occur again, it may be the case that the error is due to a one-off EMC interference (electromagnetic compatibility).

Table 185 For TCU pin assignment

20-254

See para. 20.5.2 - TCU pin assignment - page 20-456

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 27 Description Processor error (memory protection range indicator) Cause Faulty access operations are detected in the control unit. l l l l

Processor defective. Problem during programming. Error that occurs sporadically due to an open circuit of the voltage supply. EMC (electromagnetic compatibility) problem.

Correction 1. 2.

3. 4.

If the error occurs immediately after programming the control unit, the programming should be repeated. Ensure that the control unit has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. Replace the control unit if the error continues to occur. If the error does not occur again, it may be the case that the error is due to a one-off EMC interference (electromagnetic compatibility).

Table 186 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

20-255

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 28 Description Program error (no valid C167 command) Cause Faulty access operations are detected in the control unit. l l l l

Processor defective. Problem during programming. Error that occurs sporadically due to an open circuit of the voltage supply. EMC (electromagnetic compatibility) problem.

Correction 1. 2.

3. 4.

If the error occurs immediately after programming the control unit, the programming should be repeated. Ensure that the control unit has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. Replace the control unit if the error continues to occur. If the error does not occur again, it may be the case that the error is due to a one-off EMC interference (electromagnetic compatibility).

Table 187 For TCU pin assignment

20-256

See para. 20.5.2 - TCU pin assignment - page 20-456

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 29 Description Processor memory error (stack range undershot) Cause Faulty access operations are detected in the control unit. l l l l

Processor defective. Problem during programming. Error that occurs sporadically due to an open circuit of the voltage supply. EMC (electromagnetic compatibility) problem.

Correction 1. 2.

3. 4.

If the error occurs immediately after programming the control unit, the programming should be repeated. Ensure that the control unit has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. Replace the control unit if the error continues to occur. If the error does not occur again, it may be the case that the error is due to a one-off EMC interference (electromagnetic compatibility).

Table 188 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

20-257

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 30 Description Processor memory error (stack range exceeded) Cause Faulty access operations are detected in the control unit. l l l l

Processor defective. Problem during programming. Error that occurs sporadically due to an open circuit of the voltage supply. EMC (electromagnetic compatibility) problem.

Correction 1. 2.

3. 4.

If the error occurs immediately after programming the control unit, the programming should be repeated. Ensure that the control unit has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. Replace the control unit if the error continues to occur. If the error does not occur again, it may be the case that the error is due to a one-off EMC interference (electromagnetic compatibility).

Table 189 For TCU pin assignment

20-258

See para. 20.5.2 - TCU pin assignment - page 20-456

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 31 Description Non-maskable interrupt active without permission Cause Faulty access operations are detected in the control unit. l l l l

Processor defective. Problem during programming. Error that occurs sporadically due to an open circuit of the voltage supply. EMC (electromagnetic compatibility) problem.

Correction 1. 2.

3. 4.

If the error occurs immediately after programming the control unit, the programming should be repeated. Ensure that the control unit has a stable voltage supply. With the ignition switched ON and using a voltmeter, check the following on connector A21/1 (see below); the voltage across the connectors of terminal 30 (steady plus) against terminal 31 (ground) and on terminal 15 against terminal 31. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. Replace the control unit if the error continues to occur. If the error does not occur again, it may be the case that the error is due to a one-off EMC interference (electromagnetic compatibility).

Table 190 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

20-259

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 32 Description Local CAN - timeout TR1 message Cause The control unit detects false or unsent CAN bus signals in the periodic data transmission between TCU and VDC. l l l l l l

Open circuit or short circuit of the local CAN bus connection between VDC and transmission control unit. Faulty termination of the CAN bus connection. Transmission control unit is offline or has an insufficient voltage supply. TCU or VDC has an internal defect. A control unit connected to the local CAN bus has an internal defect. Incompatible control unit software in the TCU or VDC.

Correction The cause of the absence of the message in the TCU must be located. If the error is automatically reset, it is a sporadically occurring error or is due to an excessive bus load. 1. 2. 3. 4. 5.

6.

If one of the errors TCU 47 (2Fh) or 63 (3Fh) is also active, the elimination of these errors shall be given priority. If one of the errors TCU 33 (21h) or 35 (23h) is also recorded and if error 47 (2Fh) is inactive, the VDC should be examined first. Check the voltage supply of the transmission control unit. Check the internal CAN connection for open circuits - in particular with regard to faulty plug connections such as corroded or damaged plug contacts. Check the terminating resistor belonging to the CAN connection. Check the resistance using an ohmmeter with the ignition switched OFF and with adapter A21/1 disconnected. The resistance value must be 120 Ω ± 10 Ω. Replace the TCU if the value measured at the TCU deviates. If a deviation is measured at the TCU mating connector, each control unit that is connected to the local CAN bus should be examined for a CAN connection defect after the wiring harness has been ruled out as the cause of the error (see Repair Instructions of the respective control units). Check the program versions of the TCU and VDC and correct them where necessary.

20-260

Calibrations and electronic diagnosis Table 191 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 33 Description Local CAN – timeout TR5 message Cause The control unit detects false or unsent CAN bus signals in the periodic data transmission between TCU and VDC. l l l l l l

Open circuit or short circuit of the local CAN bus connection between VDC and transmission control unit. Faulty termination of the CAN bus connection. Transmission control unit is offline or has an insufficient voltage supply. TCU or VDC has an internal defect. A control unit connected to the local CAN bus has an internal defect. Incompatible control unit software in the TCU or VDC.

Correction The cause of the absence of the message in the TCU must be located. If the error is automatically reset, it is a sporadically occurring error or is due to an excessive bus load. 1. 2. 3. 4.

If one of the errors TCU 47 (2Fh) or 63 (3Fh) is also active, the elimination of these errors should be given priority. If one of the errors TCU 32 (20h) or 35 (23h) is also recorded and if error 47 (2Fh) is inactive, the VDC should be examined first. Check the voltage supply of the transmission control unit. Check the internal CAN connection for open circuits - in particular with regard to faulty plug connections such as corroded or damaged plug contacts.

20-261

Calibrations and electronic diagnosis 5.

Check the terminating resistor belonging to the CAN connection. Check the resistance using an ohmmeter with the ignition switched OFF and with adapter A21/1 disconnected. The resistance value must be 120 Ω ± 10 Ω. Replace the TCU if the value measured at the TCU deviates. If a deviation is measured at the TCU mating connector, each control unit that is connected to the local CAN bus should be examined for a CAN connection defect after the wiring harness has been ruled out as the cause of the error (see Repair Instructions of the respective control units). Check the program versions of the TCU and VDC and correct them where necessary.

6.

Table 192 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 34 Description Local CAN - timeout register2 Cause The control unit detects false or unsent CAN bus signals in the periodic data transmission between TCU and VDC. l l l l l l

Open circuit or short circuit of the local CAN bus connection between VDC and transmission control unit. Faulty termination of the CAN bus connection. Transmission control unit is offline or has an insufficient voltage supply. TCU or VDC has an internal defect. A control unit connected to the local CAN bus has an internal defect. Incompatible control unit software in the TCU or VDC.

Correction The cause of the absence of the message in the TCU must be located. If the error is automatically reset, it is a sporadically occurring error or is due to an excessive bus load. 1. 2. 3.

If one of the errors TCU 47 (2Fh) or 63 (3Fh) is also active, the elimination of these errors should be given priority. Check the voltage supply of the transmission control unit. Check the internal CAN connection for open circuits - in particular with regard to faulty plug connections such as corroded or damaged plug contacts.

20-262

Calibrations and electronic diagnosis 4.

Check the terminating resistor belonging to the CAN connection. Check the resistance using an ohmmeter with the ignition switched OFF and with adapter A21/1 disconnected. The resistance value must be 120 Ω ± 10 Ω. Replace the TCU if the value measured at the TCU deviates. If a deviation is measured at the TCU mating connector, each control unit that is connected to the local CAN bus should be examined for a CAN connection defect after the wiring harness has been ruled out as the cause of the error (see Repair Instructions of the respective control units). Check the program versions of the TCU and VDC and correct them where necessary.

5.

Table 193 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 35 Description Local CAN - timeout engine (EHS) message Cause The control unit detects false or unsent CAN bus signals in the periodic data transmission between TCU and VDC. l l l l l l

Open circuit or short circuit of the local CAN bus connection between VDC and transmission control unit. Faulty termination of the CAN bus connection. Transmission control unit is offline or has an insufficient voltage supply. TCU or VDC has an internal defect. A control unit connected to the local CAN bus has an internal defect. Incompatible control unit software in the TCU or VDC.

Correction The cause of the absence of the message in the TCU must be located. If the error is automatically reset, it is a sporadically occurring error or is due to an excessive bus load. 1. 2. 3.

If error VDC 240 (F0h) is active, the elimination of this error should be given priority. If one of the errors TCU32 (20h) to 46 (2Eh) is also recorded and if error 47 (2Fh) is inactive, the VCU should be examined. Check the voltage supply of the transmission control unit. 20-263

Calibrations and electronic diagnosis 4.

Check the internal CAN connection for open circuits - in particular with regard to faulty plug connections such as corroded or damaged plug contacts. Check the terminating resistor belonging to the CAN connection. Check the resistance using an ohmmeter with the ignition switched OFF and with adapter A21/1 disconnected. The resistance value must be 120 Ω ± 10 Ω. Replace the TCU if the value measured at the TCU deviates. If a deviation is measured at the TCU mating connector, each control unit that is connected to the local CAN bus should be examined for a CAN connection defect after the wiring harness has been ruled out as the cause of the error (see Repair Instructions of the respective control units). Check the program versions of the TCU and VDC and correct them where necessary.

5.

6.

Table 194 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 36 Description Local CAN – timeout KLECU1 message Cause The control unit detects false or unsent CAN bus signals in the periodic data transmission between TCU and VDC. l l l l l l

Open circuit or short circuit of the local CAN bus connection between VDC and transmission control unit. Faulty termination of the CAN bus connection. Transmission control unit is offline or has an insufficient voltage supply. TCU or VDC has an internal defect. A control unit connected to the local CAN bus has an internal defect. Incompatible control unit software in the TCU or VDC.

Correction The cause of the absence of the message in the TCU must be located. If the error is automatically reset, it is a sporadically occurring error or is due to an excessive bus load. 1.

If one of the errors TCU 47 (2Fh) or 63 (3Fh) is also active, the elimination of these errors should be given priority.

20-264

Calibrations and electronic diagnosis 2.

If one of the errors TCU 32 to 35 or 37 to 46 is also active, it should be verified that the transmission control unit is online using the diagnosis tool (see diagnosis tool manual). Check the voltage supply of the transmission control unit. Check the internal CAN connection for open circuits - in particular with regard to faulty plug connections such as corroded or damaged plug contacts. Check the terminating resistor belonging to the CAN connection. Check the resistance using an ohmmeter with the ignition switched OFF and with adapter A21/1 disconnected. The resistance value must be 120 Ω ± 10 Ω. Replace the TCU if the value measured at the TCU deviates. If a deviation is measured at the TCU mating connector, each control unit that is connected to the local CAN bus should be examined for a CAN connection defect after the wiring harness has been ruled out as the cause of the error (see Repair Instructions of the respective control units). Check the program versions of the TCU and VDC and correct them where necessary.

3. 4. 5.

6.

Table 195 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 37 Description Local CAN – timeout KLECU2 message Cause The control unit detects false or unsent CAN bus signals in the periodic data transmission between TCU and VDC. l l l l l l

Open circuit or short circuit of the local CAN bus connection between VDC and transmission control unit. Faulty termination of the CAN bus connection. Transmission control unit is offline or has an insufficient voltage supply. TCU or VDC has an internal defect. A control unit connected to the local CAN bus has an internal defect. Incompatible control unit software in the TCU or VDC.

Correction The cause of the absence of the message in the TCU must be located. If the error is automatically reset, it is a sporadically occurring 20-265

Calibrations and electronic diagnosis error or is due to an excessive bus load. 1. 2.

If one of the errors TCU 47 (2Fh) or 63 (3F) is also active, the elimination of these errors should be given priority. If one of the errors TCU 32 to 36 or 38 to 46 is also active, use the diagnosis tool to verify that the transmission control unit is online (see diagnosis tool manual). Check the voltage supply of the transmission control unit. Check the internal CAN connection for open circuits - in particular with regard to faulty plug connections such as corroded or damaged plug contacts. Check the terminating resistor belonging to the CAN connection. Check the resistance using an ohmmeter with the ignition switched OFF and with adapter A21/1 disconnected. The resistance value must be 120 Ω ± 10 Ω. Replace the TCU if the value measured at the TCU deviates. If a deviation is measured at the TCU mating connector, each control unit that is connected to the local CAN bus should be examined for a CAN connection defect after the wiring harness has been ruled out as the cause of the error (see Repair Instructions of the respective control units). Check the program versions of the TCU and VDC and correct them where necessary.

3. 4. 5.

6.

Table 196 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 38 Description Local CAN - timeout register 6 Cause The control unit detects false or unsent CAN bus signals in the periodic data transmission between TCU and VDC. l l l l l l

Open circuit or short circuit of the local CAN bus connection between VDC and transmission control unit. Faulty termination of the CAN bus connection. Transmission control unit is offline or has an insufficient voltage supply. TCU or VDC has an internal defect. A control unit connected to the local CAN bus has an internal defect. Incompatible control unit software in the TCU or VDC.

20-266

Calibrations and electronic diagnosis Correction The cause of the absence of the message in the TCU must be located. If the error is automatically reset, it is a sporadically occurring error or is due to an excessive bus load. 1. 2.

If one of the errors TCU 47 (2Fh) or 63 (3Fh) is also active, the elimination of these errors shall be given priority. If one of the errors TCU 32 (20h) to 37 (25h) or 39 (27h) to 46 (2Eh) is also active, use the diagnosis tool to verify that the VDC is online (see diagnosis tool manual). Check the voltage supply of the transmission control unit. Check the internal CAN connection for open circuits - in particular with regard to faulty plug connections such as corroded or damaged plug contacts. Check the terminating resistor belonging to the CAN connection. Check the resistance using an ohmmeter with the ignition switched OFF and with adapter A21/1 disconnected. The resistance value must be 120 Ω ± 10 Ω. Replace the TCU if the value measured at the TCU deviates. If a deviation is measured at the TCU mating connector, each control unit that is connected to the local CAN bus should be examined for a CAN connection defect after the wiring harness has been ruled out as the cause of the error (see Repair Instructions of the respective control units). Check the program versions of the TCU and VDC and correct them where necessary.

3. 4. 5.

6.

Table 197 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 39 Description Local CAN - timeout register 7 Cause The control unit detects false or unsent CAN bus signals in the periodic data transmission between TCU and VDC. l l l l

Open circuit or short circuit of the local CAN bus connection between VDC and transmission control unit. Faulty termination of the CAN bus connection. Transmission control unit is offline or has an insufficient voltage supply. TCU or VDC has an internal defect. 20-267

Calibrations and electronic diagnosis l l

A control unit connected to the local CAN bus has an internal defect. Incompatible control unit software in the TCU or VDC.

Correction The cause of the absence of the message in the TCU must be located. If the error is automatically reset, it is a sporadically occurring error or is due to an excessive bus load. 1. 2.

If one of the errors TCU 47 (2Fh) or 63 (3Fh) is also active, the elimination of these errors shall be given priority. If one of the errors TCU 32 (20h) to 38 (26h) or 40 (28h) to 46 (2Eh) is also active, it should be verified that the VDC is online using the diagnosis tool (see diagnosis tool manual). Check the voltage supply of the transmission control unit. Check the internal CAN connection for open circuits - in particular with regard to faulty plug connections such as corroded or damaged plug contacts. Check the terminating resistor belonging to the CAN connection. Check the resistance using an ohmmeter with the ignition switched OFF and with adapter A21/1 disconnected. The resistance value must be 120 Ω ± 10 Ω. Replace the TCU if the value measured at the TCU deviates. If a deviation is measured at the TCU mating connector, each control unit that is connected to the local CAN bus should be examined for a CAN connection defect after the wiring harness has been ruled out as the cause of the error (see Repair Instructions of the respective control units). Check the program versions of the TCU and VDC and correct them where necessary.

3. 4. 5.

6.

Table 198 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 40 Description Local CAN - timeout register 8 Cause The control unit detects false or unsent CAN bus signals in the periodic data transmission between TCU and VDC. l

Open circuit or short circuit of the local CAN bus connection between VDC and transmission control unit.

20-268

Calibrations and electronic diagnosis l l l l l

Faulty termination of the CAN bus connection. Transmission control unit is offline or has an insufficient voltage supply. TCU or VDC has an internal defect. A control unit connected to the local CAN bus has an internal defect. Incompatible control unit software in the TCU or VDC.

Correction The cause of the absence of the message in the TCU must be located. If the error is automatically reset, it is a sporadically occurring error or is due to an excessive bus load. 1. 2. 3. 4. 5.

6.

If one of the errors TCU 47 (2Fh) or 63 (3Fh) is also active, the elimination of these errors shall be given priority. If one of the errors TCU 32 (20h) to 39 (27h) or 41 (29h) to 46 (2Eh) is also active, use the diagnosis tool to verify that VDC is online (see diagnosis tool manual). Check the voltage supply of the transmission control unit. Check the internal CAN connection for open circuits - in particular with regard to faulty plug connections such as corroded or damaged plug contacts. Check the terminating resistor belonging to the CAN connection. Check the resistance using an ohmmeter with the ignition switched OFF and with adapter A21/1 disconnected. The resistance value must be 120 Ω ± 10 Ω. Replace the TCU if the value measured at the TCU deviates. If a deviation is measured at the TCU mating connector, each control unit that is connected to the local CAN bus should be examined for a CAN connection defect after the wiring harness has been ruled out as the cause of the error (see Repair Instructions of the respective control units). Check the program versions of the TCU and VDC and correct them where necessary.

Table 199 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

20-269

Calibrations and electronic diagnosis Transmission alarm 41 Description Local CAN - timeout register 9 Cause The control unit detects false or unsent CAN bus signals in the periodic data transmission between TCU and VDC. l l l l l l

Open circuit or short circuit of the local CAN bus connection between VDC and transmission control unit. Faulty termination of the CAN bus connection. Transmission control unit is offline or has an insufficient voltage supply. TCU or VDC has an internal defect. A control unit connected to the local CAN bus has an internal defect. Incompatible control unit software in the TCU or VDC.

Correction The cause of the absence of the message in the TCU must be located. If the error is automatically reset, it is a sporadically occurring error or is due to an excessive bus load. 1. 2. 3. 4. 5.

6.

If one of the errors TCU 47 (2Fh) or 63 (3Fh) is also active, the elimination of these errors should be given priority. If one of the errors TCU 32 (20h) to 40 (28h) or 42 (2Ah) to 46 (2Eh) is also active, use the diagnosis tool to verify that the VDC is online (see diagnosis tool manual). Check the voltage supply of the transmission control unit. Check the internal CAN connection for open circuits - in particular with regard to faulty plug connections such as corroded or damaged plug contacts. Check the terminating resistor belonging to the CAN connection. Check the resistance using an ohmmeter with the ignition switched OFF and with adapter A21/1 disconnected. The resistance value must be 120 Ω ± 10 Ω. Replace the TCU if the value measured at the TCU deviates. If a deviation is measured at the TCU mating connector, each control unit that is connected to the local CAN bus should be examined for a CAN connection defect after the wiring harness has been ruled out as the cause of the error (see Repair Instructions of the respective control units). Check the program versions of the TCU and VDC and correct them where necessary.

Table 200 For TCU pin assignment

20-270

See para. 20.5.2 - TCU pin assignment - page 20-456

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 42 Description Local CAN - timeout register 10 Cause The control unit detects false or unsent CAN bus signals in the periodic data transmission between TCU and VDC. l l l l l l

Open circuit or short circuit of the local CAN bus connection between VDC and transmission control unit. Faulty termination of the CAN bus connection. Transmission control unit is offline or has an insufficient voltage supply. TCU or VDC has an internal defect. A control unit connected to the local CAN bus has an internal defect. Incompatible control unit software in the TCU or VDC.

Correction The cause of the absence of the message in the TCU must be located. If the error is automatically reset, it is a sporadically occurring error or is due to an excessive bus load. 1. 2. 3. 4. 5.

6.

If one of the errors TCU 47 (2Fh) or 63 (3Fh) is also active, the elimination of these errors should be given priority. If one of the errors TCU 32 (20h) to 41 (29h) or 43 (2Bh) to 46 (2Eh) is also active, use the diagnosis tool to verify that the VDC is online (see diagnosis tool manual). Check the voltage supply of the transmission control unit. Check the internal CAN connection for open circuits - in particular with regard to faulty plug connections such as corroded or damaged plug contacts. Check the terminating resistor belonging to the CAN connection. Check the resistance using an ohmmeter with the ignition switched OFF and with adapter A21/1 disconnected. The resistance value must be 120 Ω ± 10 Ω. Replace the TCU if the value measured at the TCU deviates. If a deviation is measured at the TCU mating connector, each control unit that is connected to the local CAN bus should be examined for a CAN connection defect after the wiring harness has been ruled out as the cause of the error (see Repair Instructions of the respective control units). Check the program versions of the TCU and VDC and correct them where necessary.

20-271

Calibrations and electronic diagnosis Table 201 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 43 Description Local CAN - timeout register 11 Cause The control unit detects false or unsent CAN bus signals in the periodic data transmission between TCU and VDC. l l l l l l

Open circuit or short circuit of the local CAN bus connection between VDC and transmission control unit. Faulty termination of the CAN bus connection. Transmission control unit is offline or has an insufficient voltage supply. TCU or VDC has an internal defect. A control unit connected to the local CAN bus has an internal defect. Incompatible control unit software in the TCU or VDC.

Correction The cause of the absence of the message in the TCU must be located. If the error is automatically reset, it is a sporadically occurring error or is due to an excessive bus load. 1. 2. 3. 4.

If one of the errors TCU 47 (2Fh) or 63 (3Fh) is also active, the elimination of these errors should be given priority. If one of the errors TCU 32 (20h) to 42 (2Ah) or 44 (2Ch) to 46 (2Eh) is also active, use the diagnosis tool to verify that the VDC is online (see diagnosis tool manual). Check the voltage supply of the transmission control unit. Check the internal CAN connection for open circuits - in particular with regard to faulty plug connections such as corroded or damaged plug contacts.

20-272

Calibrations and electronic diagnosis 5.

Check the terminating resistor belonging to the CAN connection. Check the resistance using an ohmmeter with the ignition switched OFF and with adapter A21/1 disconnected. The resistance value must be 120 Ω ± 10 Ω. Replace the TCU if the value measured at the TCU deviates. If a deviation is measured at the TCU mating connector, each control unit that is connected to the local CAN bus should be examined for a CAN connection defect after the wiring harness has been ruled out as the cause of the error (see Repair Instructions of the respective control units). Check the program versions of the TCU and VDC and correct them where necessary.

6.

Table 202 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 44 Description Local CAN - timeout register 12 Cause The control unit detects false or unsent CAN bus signals in the periodic data transmission between TCU and VDC. l l l l l l

Open circuit or short circuit of the local CAN bus connection between VDC and transmission control unit. Faulty termination of the CAN bus connection. Transmission control unit is offline or has an insufficient voltage supply. TCU or VDC has an internal defect. A control unit connected to the local CAN bus has an internal defect. Incompatible control unit software in the TCU or VDC.

Correction The cause of the absence of the message in the TCU must be located. If the error is automatically reset, it is a sporadically occurring error or is due to an excessive bus load. 1. 2. 3.

If one of the errors TCU 47 (2Fh) or 63 (3Fh) is also active, the elimination of these errors should be given priority. If one of the errors TCU 32 (20h) to 43 (2Bh) or 45 (2Dh) to 46 (2Eh) is also active, use the diagnosis tool to verify that the VDC is online (see diagnosis tool manual). Check the voltage supply of the transmission control unit. 20-273

Calibrations and electronic diagnosis 4.

Check the internal CAN connection for open circuits - in particular with regard to faulty plug connections such as corroded or damaged plug contacts. Check the terminating resistor belonging to the CAN connection. Check the resistance using an ohmmeter with the ignition switched OFF and with adapter A21/1 disconnected. The resistance value must be 120 Ω ± 10 Ω. Replace the TCU if the value measured at the TCU deviates. If a deviation is measured at the TCU mating connector, each control unit that is connected to the local CAN bus should be examined for a CAN connection defect after the wiring harness has been ruled out as the cause of the error (see Repair Instructions of the respective control units). Check the program versions of the TCU and VDC and correct them where necessary.

5.

6.

Table 203 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 45 Description Local CAN - timeout register 13 Cause The control unit detects false or unsent CAN bus signals in the periodic data transmission between TCU and VDC. l l l l l l

Open circuit or short circuit of the local CAN bus connection between VDC and transmission control unit. Faulty termination of the CAN bus connection. Transmission control unit is offline or has an insufficient voltage supply. TCU or VDC has an internal defect. A control unit connected to the local CAN bus has an internal defect. Incompatible control unit software in the TCU or VDC.

Correction The cause of the absence of the message in the TCU must be located. If the error is automatically reset, it is a sporadically occurring error or is due to an excessive bus load. 1.

If one of the errors TCU 47 (2Fh) or 63 (3Fh) is also active, the elimination of these errors should be given priority.

20-274

Calibrations and electronic diagnosis 2.

If one of the errors TCU 32 (20h) to 44 (2Ch) or 46 (2Eh) is also active, use the diagnosis tool to verify that the VDC is online (see diagnosis tool manual). Check the voltage supply of the transmission control unit. Check the internal CAN connection for open circuits - in particular with regard to faulty plug connections such as corroded or damaged plug contacts. Check the terminating resistor belonging to the CAN connection. Check the resistance using an ohmmeter with the ignition switched OFF and with adapter A21/1 disconnected. The resistance value must be 120 Ω ± 10 Ω. Replace the TCU if the value measured at the TCU deviates. If a deviation is measured at the TCU mating connector, each control unit that is connected to the local CAN bus should be examined for a CAN connection defect after the wiring harness has been ruled out as the cause of the error (see Repair Instructions of the respective control units). Check the program versions of the TCU and VDC and correct them where necessary.

3. 4. 5.

6.

Table 204 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 46 Description Local CAN - timeout register 14 Cause The control unit detects false or unsent CAN bus signals in the periodic data transmission between TCU and VDC. As an error response, the vehicle is brought to a standstill in a controlled manner. l l l l l l

Open circuit or short circuit of the local CAN bus connection between VDC and transmission control unit. Faulty termination of the CAN bus connection. Transmission control unit is offline or has an insufficient voltage supply. TCU or VDC has an internal defect. A control unit connected to the local CAN bus has an internal defect. Incompatible control unit software in the TCU or VDC.

20-275

Calibrations and electronic diagnosis Correction The cause of the absence of the message in the TCU must be located. If the error is automatically reset, it is a sporadically occurring error or is due to an excessive bus load. 1. 2.

If one of the errors TCU 47 (2Fh) or 63 (3Fh) is also active, the elimination of these errors should be given priority. If one of the errors TCU 32 (20h) to 45 (2Dh) is also active, use the diagnosis tool to verify that the VDC is online (see diagnosis tool manual). Check the voltage supply of the transmission control unit. Check the internal CAN connection for open circuits - in particular with regard to faulty plug connections such as corroded or damaged plug contacts. Check the terminating resistor belonging to the CAN connection. Check the resistance using an ohmmeter with the ignition switched OFF and with adapter A21/1 disconnected. The resistance value must be 120 Ω ± 10 Ω. Replace the TCU if the value measured at the TCU deviates. If a deviation is measured at the TCU mating connector, each control unit that is connected to the local CAN bus should be examined for a CAN connection defect after the wiring harness has been ruled out as the cause of the error (see Repair Instructions of the respective control units). Check the program versions of the TCU and VDC and correct them where necessary.

3. 4. 5.

6.

Table 205 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 47 Description CAN bus error – local CAN offline Cause The control unit detects an open circuit to the periodic data transmission between TCU and VDC. l l l l

Short circuit of the local CAN bus connection between the transmission control unit and the VDC. Faulty termination of the CAN bus connection. VDC is offline or has an insufficient voltage supply. TCU has an internal defect.

20-276

Calibrations and electronic diagnosis l

A control unit connected to the local CAN bus has an internal defect.

Correction The cause of the open circuit in the data transmission must be localized via the local CAN. If the error is reset automatically, then this is an error that occurs sporadically. 1.

Use the diagnosis tool to verify that the TCU is online (see diagnosis tool manual). The most probable cause is a CAN connection short circuit. Therefore, check the internal CAN connection for a short circuit – in particular with regard to faulty plug connections. Check the terminating resistor belonging to the CAN connection. Check the resistance using an ohmmeter with the ignition switched OFF and with adapter A21/1 disconnected. The resistance value must be 120 Ω ± 10 Ω. Replace the TCU if the value measured at the TCU deviates. If a deviation is measured at the TCU mating connector, each control unit that is connected to the local CAN bus should be examined for a CAN connection defect after the wiring harness has been ruled out as the cause of the error (see Repair Instructions of the respective control units).

2.

Table 206 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 48 Description Voltage supply too low Cause Depending upon the power supply of the vehicle, the control unit detects a voltage below 9 V or 18 V on the supply input of terminal 30 for a period of at least 1.5 seconds. As an error response, the valve power stage main switch is switched OFF. l l l l l

The voltage supply on terminal 30 voltage is missing – defective fuse. The alternator control unit is defective. Vehicle battery insufficiently charged. Faulty wiring (supply or ground cable). Incorrectly set control unit parameters. (supply voltage 12V/24V). 20-277

Calibrations and electronic diagnosis Correction The cause of the nonexistent or insufficiently stable supply voltage to the control unit (terminal 30) must be localized. 1.

Make sure that the TCU has a stable voltage supply. For this purpose, on connector A21/1 (vehicle side), check the voltage on the connector of terminal 30 (steady plus) against terminal 31 (ground) whilst the ignition is switched OFF using a voltmeter. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Where necessary, check the fuse of the TCU terminal 30. If the error occurs after a (sluggish) vehicle start, the vehicle battery may not be charged sufficiently. Recharge the battery to ensure that it is sufficiently charged. In the same way as Point 1, check the voltage at terminal 30 (steady plus) against terminal 31 (ground) whilst the engine is running. If the measured voltage does not correspond to the vehicle power supply, the wiring to the alternator – especially the ground wiring – should be checked. Check the function of the alternator as well as the settings of the alternator control unit. Check the setting of the control unit parameter for the supply voltage (12V/24V).

2. 3. 4.

Table 207 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 49 Description Supply voltage (term. 30) too high Cause Depending on the power supply of the vehicle, the control unit detects a voltage above 15 V or 30 V on the supply input of terminal 30 for a period of at least 1 second. As an error response, the valve power stage main switch is switched OFF. l l l

The alternator control unit is defective. Faulty wiring (supply or ground cable). Incorrectly set control unit parameters. (12V/24V).

Correction The cause of the excessive supply voltage to the control unit (terminal 30) must be localized. 20-278

Calibrations and electronic diagnosis 1. 2.

Check the setting of the control unit parameter for the supply voltage (12V/24V). Make sure that the TCU has a stable voltage supply. For this purpose, on connector A21/1 (vehicle side), check the voltage on the connector of terminal 30 (steady plus) against terminal 31 (ground) whilst the ignition is switched OFF using a voltmeter. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). In the same way as Point 2, check the voltage at terminal 30 (steady plus) against terminal 31 (ground) whilst the engine is running. If the measured voltage does not correspond to the vehicle power supply, the wiring to the alternator – especially the ground wiring – should be checked. Check the function of the alternator as well as the settings of the alternator control unit.

3.

Table 208 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 50 Description Internal main stage end switch not functioning Cause The semiconductor switch integrated in the control unit could not be switched on. As an error response, the valve power stage main switch is switched OFF. l l l

The voltage supply on terminal 30 voltage is missing – defective fuse. TCU has an internal defect. A control element has a short to ground.

Correction The cause for the faulty control of the semiconductor switch should be located. 1.

Make sure that the TCU has a stable voltage supply. For this purpose, on connector A21/1 (vehicle side), check the voltage on the connector of terminal 30 (steady plus) against terminal 31 (ground) whilst the ignition is switched OFF using a voltmeter. The measured voltage should correspond to the respective vehicle power supply (12V or 24V). Where necessary, check the fuse of the TCU terminal 30.

20-279

Calibrations and electronic diagnosis 2.

Check the wiring of the TCU for a short to ground. Delete error and wait for at least 10 seconds after the ignition has been switched OFF. The TCU has to be replaced should error TCU 50 continue to occur following ignition ON.

Table 209 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 526 - Installation position TCU

Transmission alarm 51 Description Internal main stage end switch permanently ON (stuck) Cause The semiconductor switch integrated in the control unit is permanently switched ON. As an error response, the valve power stage main switch is switched OFF. l l l

The voltage supply has an error. TCU has an internal defect. A control element has a short-circuit to plus (supply voltage).

Correction The cause for the faulty control of the semiconductor switch should be located. 1.

Check the wiring of the TCU for a short-circuit to plus (supply voltage), particularly on connector A21/1. Delete the error and wait at least 10 seconds after ignition OFF. The TCU must be replaced should error TCU 51 continue to occur following ignition ON.

Table 210 For TCU pin assignment

20-280

See para. 20.5.2 - TCU pin assignment - page 20-456

Calibrations and electronic diagnosis

Fig. 526 - Installation position TCU

Transmission alarm 52 Description Hydrostatic unit outside tolerance Cause The calibration process of the hydrostatic unit that is automatically activated in neutral position supplies values outside of the permissible tolerance. l l l

Inadequate oil supply in the hydrostatic unit. Defective wiring. Hydrostatic unit has an internal defect.

Correction The cause of the incorrect calibration process should be located. 1. 2. 3. 4. 5. 6. 7.

If one of the errors TCU 113 (71h) or 118 (76h) is also active, the elimination of this error should be carried out as a priority. Delete error. Once the ignition is OFF, wait for at least 10 seconds, then start the vehicle and bring the transmission temperature to above 20 °C. If the error does not occur again, the issue was a one time calibration error – no further measures are required. Perform a recalibration of the hydrostatic unit using the diagnosis tool. Following successful calibration, switch the ignition OFF and wait for at least 10 seconds, then start the vehicle. Check the wiring - in particular with regard to faulty plug connections such as corroded or damaged plug contacts from the TCU to the HCU and from the HCU to the stepping motor. The TCU has to be replaced should error TCU 52 (34h) continue to occur following ignition ON. The stepping motor has to be replaced should error TCU 52 (34h) continue to occur following ignition ON. The hydrostatic unit has to be replaced should error TCU 52 (34h) continue to occur following ignition ON.

Table 211 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

20-281

Calibrations and electronic diagnosis

Fig. 527 - Installation position HCU

Transmission alarm 53 Description Hydrostatic unit - ratio cannot be reached Cause The hydrostatic unit cannot set the stipulated transmission ratio. l l l

Inadequate oil supply in the hydrostatic unit. Defective wiring. Hydrostatic unit has an internal defect.

Correction The cause of the incorrect transmission ratio should be located. 1. 2. 3. 4. 5. 6. 7.

If one of the errors TCU 113 (71h), 114 (72h) or 118 (76h) is also active, the elimination of this error should be carried out as a priority. Delete error. Once the ignition is OFF, wait for at least 10 seconds, then start the vehicle and bring the transmission temperature to above 20 °C. If the error does not occur again, the issue was a one time calibration error – no further measures are required. Perform a recalibration of the hydrostatic unit using the diagnosis tool. Following successful calibration, switch the ignition OFF and wait for at least 10 seconds, then start the vehicle. Check the wiring - in particular with regard to faulty plug connections such as corroded or damaged plug contacts from the TCU to the HCU and from the HCU to the stepping motor. The TCU has to be replaced should error TCU 52 (34h) continue to occur following ignition ON. The stepping motor has to be replaced should error TCU 52 (34h) continue to occur following ignition ON. The hydrostatic unit has to be replaced should error TCU 52 (34h) continue to occur following ignition ON.

Table 212 For TCU pin assignment

20-282

See para. 20.5.2 - TCU pin assignment - page 20-456

Calibrations and electronic diagnosis

Fig. 527 - Installation position HCU

Transmission alarm 54 Description Max. hydrostatic unit high pressure reached Cause The maximum permitted hydrostatic unit high pressure and thus, the maximum possible traction force are reached. To protect the hydrostatic unit from overloading transmission ratio and thus, vehicle speed is reduced until the hydrostatic high pressure falls below the max. permitted value. Correction The required traction force must be reduced. 1. 2.

If one of the errors TCU 52 (34h) or 53 (35h) is also active, the elimination of this error should be given priority. If one of the errors TCU 92, 93, 94, 95 (5Ch, 5Dh, 5Eh, 5Fh) or 160, 161, 162 (A0h, A1h, A2h) is also active, the elimination of this error should be given priority. If the error occurs alone, this is a protective function of the transmission from overloading, no further measures are required. If error 54 (36h) reoccurs, the load should be reduced.

3.

Transmission alarm 56 Description Impermissible control of transmission clutches Cause Clutches are being actuated although such combinations are not permissible. l l l

TCU has an internal defect. Wiring defective (wiring to the clutch valve is erroneously on supply voltage) Problem during programming.

Correction 1.

If the error occurs immediately after a TCU programming procedure, the programming should be repeated. 20-283

Calibrations and electronic diagnosis 2.

Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. If the error occurs repeatedly, the wiring must be checked and where necessary, replaced. If the wiring is ok, then replace the TCU.

Transmission alarm 57 (SDF S240 / SDF S180+) Description Overspeed protection active (nAb > 6000 1/min) Cause The output speed of the transmission reaches values above 6000 1/min. To protect the transmission, it is switched into neutral. Power flow is again possible as soon as the output speed is significantly reduced below 6000 1/min. The error remains for approx. 5 min, that the transmission can cool down. During this period the max. permitted output speed is limited. Correction 1.

The vehicle is moved too fast (downhill in overrun mode, possibly actuated clutch). The vehicle must be moved with the operating brake within the permitted speed.

Transmission alarm 60 Description Loss of step during hydrostatic unit calibration Cause The calibration process of the hydrostatic unit that is automatically activated in neutral position indicates a loss of step. l l l

Inadequate oil supply in the hydrostatic unit. Faulty wiring. Hydrostatic unit has an internal defect.

Correction The cause of the loss of step should be located. 1. 2. 3. 4. 5. 6. 7. 8.

If one of the errors TCU 113 (71h), 114 (72h) or 118 (76h) is also active, the elimination of this error should be carried out as a priority. Delete error. Once the ignition is OFF, wait for at least 10 seconds, then start the vehicle and bring the transmission temperature to above 20 °C. If the error does not occur again, this concerns an operating error – no further measures are required. Perform a recalibration using the diagnosis tool. Following successful calibration, switch the ignition OFF and wait for at least 10 seconds, then start the vehicle. Check the wiring - in particular with regard to faulty plug connections such as corroded or damaged plug contacts from the TCU to the HCU and from the HCU to the stepping motor. If the TCU 60 (3Ch) error occurs repeatedly after ignition ON, then replace the HCU. If the TCU 60 (3Ch) error occurs repeatedly after ignition ON, then replace the stepping motor. The hydrostatic unit should be replaced if error TCU 60 (3Ch) continues to occur following ignition ON.

Table 213 For TCU pin assignment

20-284

See para. 20.5.2 - TCU pin assignment - page 20-456

Calibrations and electronic diagnosis

Fig. 527 - Installation position HCU

Transmission alarm 61 Description Hydrostatic unit – implausible calibration data Cause The calibration data of the hydrostatic unit is recognized as invalid following ignition ON. As an error response, it is no longer possible to drive. l l l

TCU contains invalid calibration data. TCU has an internal defect. Faulty calibrating process.

Correction A calibration should be performed. 1.

Start the manual calibration process with the diagnosis tool or activate the automatic calibration by engaging the parking lock, the process may take a few minutes. Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. The TCU should be replaced if the error continues to occur.

2.

Transmission alarm 63 Description CAN Bus error – local CAN, faulty communication Cause The compatibility test of TCU and VDC is incongruent. l l l l

The TCU or VDC has an incorrect program version. TCU or VDC has an internal defect. Faulty wiring. EMC (electromagnetic compatibility) problem.

20-285

Calibrations and electronic diagnosis Correction The cause of the incompatibility should be located. 1. 2.

If one of the errors TCU 32 (20h), 33 (21h), or 35 (23h) is also active, the elimination of this error should be given priority. Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. If the error does not occur again, then this concerns an incorrect diagnosis – no further measures are required. Using the diagnosis tool, read out the software version of the VDC and TCU and ascertain whether they are compatible. A reprogramming should be performed where necessary. Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. If the error continues to occur, the wiring between TCU and VDC (vehicle wiring; CAN lines) must be checked and where necessary, replaced. Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the ignition ON. If the error reoccurs, TCU and / or VDC should be replaced.

3. 4. 5.

Transmission alarm 64 Description Speed sensor transmission input - interruption or short-circuit to plus Cause The speed sensor has an open circuit or a short-circuit to plus. As an error response max. traveling speed is reduced. l l l l

Short-term sensor malfunction. Faulty wiring. Sensor has an internal defect. TCU has an internal defect.

Correction The cause of the incorrect signal must be located. If the error is reset automatically, then this is an error that occurs sporadically. 1. 2. 3. 4.

Delete error. Once the ignition is OFF, wait for at least 10 seconds, then switch the ignition ON, and start the engine. Set the engine speed to 1000 rpm and, using the diagnosis tool, check the sensor value. If this value only slightly deviates from 1347 rpm, the issue was a one time incorrect diagnosis– no further measures are required. If the error continues to occur, the TCU should be removed and connector A21/7 (grey) checked for faulty plug connections such as corroded or damaged plug contacts. Check the sensor resistance. For this purpose, determine the sensor resistance on the mating connector to plug connection A21/7 (grey) using an ohmmeter when the ignition is switched OFF. The sensor should be replaced if the value deviates greatly from 1 kW. If the error continues to occur, switch the ignition ON and start the engine. Unplug the sensor when the engine is running. The TCU should be replaced if the speed does not change.

Table 214 For TCU pin assignment

20-286

See para. 20.5.2 - TCU pin assignment - page 20-456

Calibrations and electronic diagnosis

Fig. 528 - Inductive sensor / Speed sensor transmission input

Fig. 528 - Installation position HCU 20-287

Calibrations and electronic diagnosis Transmission alarm 65 Description Speed sensor transmission input – sensor short circuit Cause The speed sensor has a short circuit. As an error response max. traveling speed is reduced. l l l l

Short-term sensor malfunction. Faulty wiring. Sensor has an internal defect. TCU has an internal defect.

Correction The cause of the incorrect signal must be located. If the error is reset automatically, then this is an error that occurs sporadically. 1. 2. 3. 4.

Delete error. Once the ignition is OFF, wait for at least 10 seconds, then switch the ignition ON, and start the engine. Set the engine speed to 1000 rpm and, using the diagnosis tool, check the sensor value. If this value only slightly deviates from 1347 rpm, the issue was a one time incorrect diagnosis– no further measures are required. If the error continues to occur, the TCU should be removed and connector A21/7 (grey) checked for faulty plug connections such as corroded or damaged plug contacts. Check the sensor resistance. For this purpose, determine the sensor resistance on the mating connector to plug connection A21/7 (grey) using an ohmmeter when the ignition is switched OFF. The sensor should be replaced if the value deviates greatly from 1 kW. If the error continues to occur, switch the ignition ON and start the engine. Unplug the sensor when the engine is running. The TCU should be replaced if the speed does not change.

Table 215 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 528 - Inductive sensor / Speed sensor transmission input

20-288

Calibrations and electronic diagnosis

Fig. 528 - Installation position HCU

Transmission alarm 66 Description Speed sensor transmission input – speed too high Cause The transmission input speed is above 3500 rpm (engine speed > 2600 rpm). l

Engine races in overrun mode.

Correction The transmission input speed should be reduced. 1.

The speed should be reduced.

Transmission alarm 67 Description Speed sensor transmission input - signal dropout Cause The continuity of the speed sensor speed pulses was interrupted for a short period. l l l l l

Short-term sensor malfunction. Short-term TCU malfunction. Sensor has an internal defect. TCU has an internal defect. Mechanical defect in the shifting drum

Correction The cause of the signal dropout should be located. 1.

If one of the errors TCU 64 (40h) or 65 (41h) is also active, the repair of this error should be carried out as a priority.

20-289

Calibrations and electronic diagnosis 2.

Delete error. Once the ignition is OFF, wait for at least 10 seconds, then apply the parking brake, switch the ignition ON, and start the engine. Set the engine speed to 1000 rpm and, using the diagnosis tool, check the sensor value. If this value only slightly deviates from 1347 rpm, the issue was a one-time incorrect diagnosis– no further measures are required. If the error continues to occur, the TCU should be removed and connector A21/7 (grey) checked for faulty plug connections such as corroded or damaged plug contacts. If the error continues to occur, the sensor should be replaced. If the error continues to occur, the TCU should be replaced. If the error continues to occur, the shifting drum should be checked for mechanical damage.

3. 4. 5. 6.

Table 216 For TCU pin assignment

See para. 20.5.2 - TCU pin assignment - page 20-456

Fig. 528 - Inductive sensor / Speed sensor transmission input

Transmission alarm 68 Description Speed sensor ridge1/2 – Interruption or short to plus Cause The speed sensor has an open circuit or a short to plus. As an error response max. traveling speed is reduced. l l l l

Short-term sensor malfunction. Faulty wiring. Sensor has an internal defect. TCU has an internal defect.

Correction The cause of the incorrect signal must be located. If the error is reset automatically, then this is an error that occurs sporadically. 1.

Delete error. Once the ignition is OFF, wait for at least 10 seconds, then apply the parking brake, switch the ignition ON, and start the engine and select a direction of travel, in doing so, the vehicle should remain stationary. Using the throttle hand lever, set the engine speed to 1000 rpm and, using the diagnosis tool, check the sensor value. If this value only slightly deviates from 700 rpm, this issue was a one time incorrect diagnosis – no further measures are required.

20-290

Calibrations and electronic diagnosis 2. 3. 4.

If the error continues to occur, the TCU should be removed and connector A21/6 (black) checked for faulty plug connections such as corroded or damaged plug contacts. Check the sensor resistance. For this purpose, determine the sensor resistance on the mating connector to plug connection A21/6 (black) using an ohmmeter when the ignition is switched OFF. The sensor should be replaced if the value deviates greatly from 1 kW. If the error continues to occur, switch the ignition ON and start the engine. Unplug the sensor when the engine is running. The TCU should be replaced if the speed does not change.

Fig. 529 - Inductive sensor/Speed sensor ridge 1/2

20-291

Calibrations and electronic diagnosis

Fig. 530 - Wiring diagram TCU

Transmission alarm 69 Description Speed sensor ridge1/2 – Sensor short circuit Cause The speed sensor has a short circuit. As an error response max. traveling speed is reduced. l l l l

Short-term sensor malfunction. Faulty wiring. Sensor has an internal defect. TCU has an internal defect.

Correction The cause of the incorrect signal must be located. If the error is reset automatically, then this is an error that occurs sporadically. 1.

Delete error. Once the ignition is OFF, wait for at least 10 seconds, then apply the parking brake, switch the ignition ON, and start the engine and select a direction of travel, in doing so, the vehicle should remain stationary. Using the throttle hand lever, set the engine speed to 1000 rpm and, using the diagnosis tool, check the sensor value. If this value only slightly deviates from 700 rpm, this issue was a one time incorrect diagnosis – no further measures are required.

20-292

Calibrations and electronic diagnosis 2. 3. 4.

If the error continues to occur, the TCU should be removed and connector A21/6 (black) checked for faulty plug connections such as corroded or damaged plug contacts. Check the sensor resistance. For this purpose, determine the sensor resistance on the mating connector to plug connection A21/6 (black) using an ohmmeter when the ignition is switched OFF. The sensor should be replaced if the value deviates greatly from 1 kΩ. If the error continues to occur, switch the ignition ON and start the engine. Unplug the sensor when the engine is running. The TCU should be replaced if the speed does not change

Fig. 530 - Inductive sensor/Speed sensor ridge 1/2

20-293

Calibrations and electronic diagnosis

Fig. 530 - Wiring diagram TCU

Transmission alarm 70 Description Speed sensor ridge 1/2 – speed too high Cause The speed of the planetary carrier 1/2 is above 3500 rpm. l

Engine races in overrun mode at low speeds.

Correction The speed of the planetary carrier 1/2 should be reduced. 1.

The speed should be reduced

20-294

Calibrations and electronic diagnosis Transmission alarm 71 Description Speed sensor ridge1/2 – signal dropout Cause The continuity of the speed sensor speed pulses was interrupted for a short period. l l l l l

Short-term sensor malfunction. Short-term TCU malfunction. Sensor has an internal defect. TCU has an internal defect. Mechanical defect in the shifting drum.

Correction The cause of the signal dropout should be located. 1. 2.

3. 4. 5. 6.

If one of the errors TCU 68 (44h) or 69 (45h) is also active, the repair of this error should be carried out as a priority. Delete error. Once the ignition is OFF, wait for at least 10 seconds, then apply the parking brake, switch the ignition ON, and start the engine and select a direction of travel, in doing so, the vehicle should remain stationary. Set the engine speed to 1000 rpm and, using the diagnosis tool, check the sensor value. If this value only slightly deviates from 700 rpm, this issue was a one time incorrect diagnosis – no further measures are required. If the error continues to occur, the TCU should be removed and connector A21/6 (black) checked for faulty plug connections such as corroded or damaged plug contacts. If the error continues to occur, the sensor should be replaced. If the error continues to occur, the TCU should be replaced. If the error continues to occur, the shifting drum should be checked for mechanical damage.

Fig. 530 - Inductive sensor/Speed sensor ridge 1/2

20-295

Calibrations and electronic diagnosis

Fig. 530 - Wiring diagram TCU

Transmission alarm 72 Description Speed sensor output 1 – Interruption or short to plus Cause The speed sensor has an open circuit or a short to plus. As an error response max. traveling speed is reduced. l l l l

Short-term sensor malfunction. Faulty wiring. Sensor has an internal defect. TCU has an internal defect.

Correction The cause of the incorrect signal must be located. If the error is reset automatically, then this is an error that occurs sporadically. 1.

Delete error. Once the ignition is OFF, wait for at least 10 seconds, then switch the ignition ON, and start the engine. Carry out a test drive with constant speed forward and check the values of the speed sensors output 1, output 2 and ridge 3/4 using the diagnosis tool. If the speed values only differ slightly, this issue is a one time incorrect diagnosis– no further measures are required.

20-296

Calibrations and electronic diagnosis 2. 3. 4.

If the error continues to occur, the TCU should be removed and connector A21/10 (orange) checked for faulty plug connections such as corroded or damaged plug contacts. Check the sensor resistance. For this purpose, determine the sensor resistance on the mating connector to plug connection A21/10 (orange) using an ohmmeter when the ignition is switched OFF. The sensor should be replaced if the value deviates greatly from 1 kΩ. If the error continues to occur, the TCU should be replaced.

Fig. 531 - Inductive sensor / Speed sensor output 1

20-297

Calibrations and electronic diagnosis

Fig. 531 - Wiring diagram TCU

Transmission alarm 73 Description Speed sensor output 1 – Sensor short circuit Cause The speed sensor has a short circuit. As an error response max. traveling speed is reduced l l l l

Short-term sensor malfunction Faulty wiring Sensor has an internal defect TCU has an internal defect

Correction The cause of the incorrect signal must be located. If the error is reset automatically, then this is an error that occurs sporadically. 1.

Delete error. Once the ignition is OFF, wait for at least 10 seconds, then switch the ignition ON, and start the engine. Carry out a test drive with constant speed forward and check the values of the speed sensors output 1, output 2 and ridge 3/4 using the diagnosis tool. If the speed values only differ slightly, this issue is a one time incorrect diagnosis– no further measures are required.

20-298

Calibrations and electronic diagnosis 2. 3. 4.

If the error continues to occur, the TCU should be removed and connector A21/10 (orange) checked for faulty plug connections such as corroded or damaged plug contacts. Check the sensor resistance. For this purpose, determine the sensor resistance on the mating connector to plug connection A21/10 (orange) using an ohmmeter when the ignition is switched OFF. The sensor should be replaced if the value deviates greatly from 1 kW. If the error continues to occur, the TCU should be replaced.

Fig. 531 - Inductive sensor / Speed sensor output 1

20-299

Calibrations and electronic diagnosis

Fig. 531 - Wiring diagram TCU

Transmission alarm 74 Description Speed sensor output 1 – Speed too high Cause The speed of output 1 is above 6000 rpm (approx. 68 km/ (standard version) or 57 km/h (heavy duty version) vehicle speed). As an error response shift to neutral is performed and the output speed is limited to max. 4500 rpm (for 5 min). l

Vehicle in overrun mode with excessive vehicle speed.

Correction The speed of output 1 should be reduced. 1.

Traveling speed should be reduced.

20-300

Calibrations and electronic diagnosis Transmission alarm 75 Description Speed sensor output 1 – signal dropout Cause The continuity of the speed sensor speed pulses was interrupted for a short period l l l l l

Short-term sensor malfunction Short-term TCU malfunction Sensor has an internal defect TCU has an internal defect Mechanical defect in the shifting drum

Correction The cause of the signal dropout should be located. 1. 2.

3. 4. 5. 6. 7.

If one of the errors TCU 72 (48h) or 73 (49h) is also active, the elimination of this error should be given priority. Delete error. Once the ignition is OFF, wait for at least 10 seconds, then switch the ignition ON, and start the engine. Carry out a test drive with constant speed forward and check the values of the speed sensors output 1, output 2 and ridge 3/4 using the diagnosis tool. If the speed values only differ slightly, this issue is a one time incorrect diagnosis– no further measures are required. If the error continues to occur, the TCU should be removed and connector A21/10 (orange) checked for faulty plug connections such as corroded or damaged plug contacts. If the error continues to occur, check the sensor wheel through the opening of the sensor cover for damage and where necessary, replace it. If the error continues to occur, the sensor should be replaced. If the error continues to occur, the TCU should be replaced. If the error continues to occur, the shifting drum should be checked for mechanical damage.

Fig. 531 - Inductive sensor / Speed sensor output 1

20-301

Calibrations and electronic diagnosis

Fig. 531 - Wiring diagram TCU

Transmission alarm 76 Description Speed sensor ridge 3/4 – Interruption or short to plus Cause The speed sensor has an open circuit or a short to plus. As an error response max. traveling speed is reduced. l l l l

Short-term sensor malfunction. Faulty wiring. Sensor has an internal defect. TCU has an internal defect.

Correction The cause of the incorrect signal must be located. If the error is reset automatically, then this is an error that occurs sporadically. 1.

Delete error. Once the ignition is OFF, wait for at least 10 seconds, then switch the ignition ON, and start the engine. Carry out a test drive with constant speed forward and check the values of the speed sensors output 1, output 2 and ridge 3/4 using the diagnosis tool. If the speed values only differ slightly, this issue is a one time incorrect diagnosis– no further measures are required.

20-302

Calibrations and electronic diagnosis 2. 3. 4.

If the error continues to occur, the TCU should be removed and connector A21/8 (brown) checked for faulty plug connections such as corroded or damaged plug contacts. Check the sensor resistance. For this purpose, determine the sensor resistance on the mating connector to plug connection A21/8 (brown) using an ohmmeter with the ignition switched OFF. The sensor should be replaced if the value deviates greatly from 1 kW. If the error continues to occur, the TCU should be replaced.

Fig. 532 - Inductive sensor/Speed sensor ridge 3/4

20-303

Calibrations and electronic diagnosis

Fig. 532 - Wiring diagram TCU

Transmission alarm 77 Description Speed sensor ridge 3/4 – Sensor short circuit Cause The speed sensor has a short circuit. As an error response max. traveling speed is reduced. l l l l

Short-term sensor malfunction. Faulty wiring. Sensor has an internal defect. TCU has an internal defect.

Correction The cause of the incorrect signal must be located. If the error is reset automatically, then this is an error that occurs sporadically. 1.

Delete error. Once the ignition is OFF, wait for at least 10 seconds, then switch the ignition ON, and start the engine. Carry out a test drive with constant speed forward and check the values of the speed sensors output 1, output 2 and ridge 3/4 using the diagnosis tool. If the speed values only differ slightly, this issue is a one time incorrect diagnosis– no further measures are required

20-304

Calibrations and electronic diagnosis 2. 3. 4.

If the error continues to occur, the TCU should be removed and connector A21/8 (brown) checked for faulty plug connections such as corroded or damaged plug contacts. Check the sensor resistance. For this purpose, determine the sensor resistance on the mating connector to plug connection A21/8 (brown) using an ohmmeter with the ignition switched OFF. The sensor should be replaced if the value deviates greatly from 1 kW. If the error continues to occur, the TCU should be replaced.

Fig. 532 - Inductive sensor/Speed sensor ridge 3/4

20-305

Calibrations and electronic diagnosis

Fig. 532 - Wiring diagram TCU

Transmission alarm 78 Description Speed sensor ridge 3/4 – Speed too high Cause The speed of planetary carrier 3/4 is above 6000 rpm. l

Vehicle in overrun mode with excessive vehicle speed.

Correction The speed of the planetary carrier 3/4 should be reduced. 1.

Traveling speed should be reduced.

20-306

Calibrations and electronic diagnosis Transmission alarm 79 Description Speed sensor ridge 3/4 – signal dropout Cause The continuity of the speed sensor speed pulses was interrupted for a short period. l l l l l

Short-term sensor malfunction. Short-term TCU malfunction. Sensor has an internal defect. TCU has an internal defect. Mechanical defect in the shifting drum

Correction The cause of the signal dropout should be located. 1. 2.

3. 4. 5. 6.

If one of the errors TCU 76 (4Ch) or 77 (4Dh) is also active, the elimination of this error should be given priority. Delete error. Once the ignition is OFF, wait for at least 10 seconds, then switch the ignition ON, and start the engine. Carry out a test drive with constant speed forward and check the values of the speed sensors output 1, output 2 and ridge 3/4 using the diagnosis tool. If the speed values only differ slightly, this issue is a one time incorrect diagnosis– no further measures are required. If the error continues to occur, the TCU should be removed and connector A21/8 (brown) checked for faulty plug connections such as corroded or damaged plug contacts. If the error continues to occur, the sensor should be replaced. If the error continues to occur, the TCU should be replaced. If the error continues to occur, the shifting drum should be checked for mechanical damage.

Fig. 532 - Inductive sensor/Speed sensor ridge 3/4

20-307

Calibrations and electronic diagnosis

Fig. 532 - Wiring diagram TCU

Transmission alarm 80 Description Speed sensor output 2 – Interruption or short to plus Cause The speed sensor has an open circuit or a short to plus. As an error response max. traveling speed is reduced. l l l l

Short-term sensor malfunction. Faulty wiring. Sensor has an internal defect. TCU has an internal defect.

Correction The cause of the incorrect signal must be located. If the error is reset automatically, then this is an error that occurs sporadically. 1.

Delete error. Once the ignition is OFF, wait for at least 10 seconds, then switch the ignition ON, and start the engine. Carry out a test drive with constant speed forward and check the values of the speed sensors output 1, output 2 and ridge 3/4 using the diagnosis tool. If the speed values only differ slightly, this issue is a one time incorrect diagnosis – no further measures are required.

20-308

Calibrations and electronic diagnosis 2. 3. 4.

If the error continues to occur, the TCU should be removed and checked for faulty plug connections such as corroded or damaged plug contacts on connector A21/9 (green). Check the sensor resistance. For this purpose, determine the sensor resistance on the mating connector to plug connection A21/9 (green) using an ohmmeter when the ignition is switched OFF. The sensor should be replaced if the value deviates greatly from 1 kW. If the error continues to occur, the TCU should be replaced.

Fig. 533 - Inductive sensor/Speed sensor output 2

20-309

Calibrations and electronic diagnosis

Fig. 533 - Wiring diagram TCU

Transmission alarm 81 Description Speed sensor output 2 - sensor short circuit Cause The speed sensor has a short circuit. As an error response max. traveling speed is reduced. l l l l

Short-term sensor malfunction. Faulty wiring. Sensor has an internal defect. TCU has an internal defect.

Correction The cause of the incorrect signal must be located. If the error is reset automatically, then this is an error that occurs sporadically. 1.

Delete error. Once the ignition is OFF, wait for at least 10 seconds, then switch the ignition ON, and start the engine. Carry out a test drive with constant speed forward and check the values of the speed sensors output 1, output 2 and ridge 3/4 using the diagnosis tool. If the speed values only differ slightly, this issue is a one time incorrect diagnosis– no further measures are required.

20-310

Calibrations and electronic diagnosis 2. 3. 4.

If the error continues to occur, the TCU should be removed and checked for faulty plug connections such as corroded or damaged plug contacts on connector A21/9 (green). Check the sensor resistance. For this purpose, determine the sensor resistance on the mating connector to plug connection A21/9 (green) using an ohmmeter when the ignition is switched OFF. The sensor should be replaced if the value deviates greatly from 1 kW. If the error continues to occur, the TCU should be replaced.

Fig. 533 - Inductive sensor/Speed sensor output 2

20-311

Calibrations and electronic diagnosis

Fig. 533 - Wiring diagram TCU

Transmission alarm 82 Description Speed sensor output 2 - speed too high. Cause The speed of output 2 is above 6000 rpm (approx. 68 km/h (standard version) or 57 km/h (heavy duty version) vehicle speed). As an error response shift to neutral is performed and the output speed is limited to max. 4500 rpm (for 5 min). l

Vehicle in overrun mode with excessive vehicle speed.

Correction The speed of output 2 should be reduced. 1.

Traveling speed should be reduced.

20-312

Calibrations and electronic diagnosis Transmission alarm 83 (SDF S240 / SDF S180+) Description Output speed too high; transmission ratio is limited. Cause The output speed of the transmission reaches unusually high values (> max. permitted speed). Therefore transmission ratio is reduced. The ratio is reduced more strongly, the higher the output speed increases. The error is set from >5600rpm (until 6000 rpm, then the overspeed protection with shift to neutral is applied). Correction 1.

The vehicle is moved too fast (downhill in overrun mode, possibly actuated clutch). The vehicle must be moved with the operating brake at the permitted speed

Transmission alarm 84 Description Speed sensor transmission input – Implausible speed Cause Taking the hydrostatic unit position and the engaged clutches into consideration, the measured speeds are not plausible. As an error response a substitute value from another speed information is used. In case of several speed sensor errors the transmission is switched into neutral. l l l l

Short-term hydrostatic unit malfunction. Short-term malfunction during speed measurement. HCU malfunction. Hydrostatic unit has an internal defect.

Correction The cause for the missing plausibility of the speed signals should be located. 1.

If the errors TCU 64 (40h), 65 (41h) or 67 (43h) also occur (electric error), the elimination of these errors should be given priority. The errors indicate a false input speed. If the errors TCU 52 (34h), 53 (35h) or 61 (3Dh) also occur (hydrostatic error), the elimination of these errors should be given priority. The errors indicate a permanent hydrostatic unit defect. If the error TCU 85 (55h) also occurs, the elimination of this error should be given priority. Delete error. Wait for at least 10 seconds after the ignition has been switched OFF. Switch ignition ON and start the engine. The transmission temperature should be above 20 °C. If the error ceases to occur, the issue was a short-term hydrostatic unit malfunction– no further measures are required. Check the program version and perform a reprogramming where necessary. If the error ceases to occur, the issue was an old software status – no further measures are required. If the errors 144 (90h), 145 (91h) or 146 (92h) also occur (hydrostatic electronic error), the elimination of these errors should be given priority. Delete error. Wait for at least 10 seconds after the ignition has been switched OFF. Switch ignition ON and start the engine. If the error ceases to occur, the issue was a HCU malfunction.

2. 3.

4. 5.

Transmission alarm 85 Description Speed sensor ridge 1/2 - implausible speed Cause Taking the hydrostatic unit position and the engaged clutches into consideration, the measured speeds are not plausible. A value which is calculated on the basis of other transmission speeds is used as an error response. In case of further speed sensor errors the transmission is shifted to neutral l l l l l

Short-term hydrostatic unit malfunction. Short-term malfunction during speed measurement. HCU malfunction. Hydrostatic unit has an internal defect. Malfunction of the range clutches.

Correction The cause for the missing plausibility of the speed signals should be located.

20-313

Calibrations and electronic diagnosis 1.

If the errors TCU 68 (44h), 69 (45h) or 71 (47h) occur (electronic errors), the elimination of these errors should be given priority. The errors indicate a false speed of planetary carrier 1/2. If the errors TCU 52 (34h), 53 (35h) or 61 (3Dh) also occur (hydrostatic error), the elimination of these errors should be given priority. The errors indicate a permanent hydrostatic unit defect. If the error TCU 84 (54h) also occurs, the elimination of this error should be given priority. Delete error. Wait for at least 10 seconds after the ignition has been switched OFF. Switch ignition ON and start the engine. The transmission temperature should be above 20 °C. If the error ceases to occur, the issue was a short-term hydrostatic unit malfunction– no further measures are required. Check the program version and perform a reprogramming where necessary. If the error ceases to occur, the issue was an old software status – no further measures are required. If the errors 144 (90h), 145 (91h) or 146 (92h) also occur (hydrostatic electronic error), the elimination of these errors should be given priority. Delete error. Wait for at least 10 seconds after the ignition has been switched OFF. Switch ignition ON and start the engine. If the error ceases to occur, the issue was a HCU malfunction. If error TCU 87 (57h) also occurs, this means that there is a malfunction in a range clutch and the elimination of this should be given priority. K1 corresponds to TCU 200 (C8h) … 205 (CDh); K2 corresponds to TCU 208 (D0h) … 213 (D5h); K3 corresponds to TCU 216 (D8h) … 221 (DDh); K4 corresponds to TCU 224 (E0h) … 229 (E5h)

2. 3.

4. 5. 6.

Transmission alarm 86 Description Speed sensor output 1 – implausible speed Cause Taking the hydrostatic unit position and the engaged clutches into consideration, the measured speeds are not plausible. The error 86 (56h) often occurs in conjunction with error 87 (57h). A value which is calculated on the basis of other transmission speeds is used as an error response. In case of further speed sensor errors the transmission is shifted to neutral. l l

Short-term malfunction during speed measurement. Malfunction during the actuation of the direction clutches.

Correction The cause for the missing plausibility of the speed signals should be located 1.

If the errors TCU 72 (48h), 73 (49h), 75 (4Bh), 80 (50h), 81 (51h) or 82 (52h) occur (electric errors nAb1 and nAb2), the elimination of these errors should be given priority. The errors indicate a false input speed. Check the program version and perform a reprogramming where necessary. If the error ceases to occur, the issue was an old software status – no further measures are required. If errors TCU 188 (BCh) and 189 (BDh) occur for KV or 196 (C4) - or 197 (C5) occur for KR, this means that there is a malfunction in the direction clutch and the elimination of this should be given priority. If error TCU 88 (58h) also occurs, this means that there is a defect in the speed sensor of output side 1 or output side 2. The sensor should be replaced.

2. 3. 4.

Transmission alarm 87 Description Speed sensor ridge 3/4 – Implausible speed Cause Taking the hydrostatic unit position and the engaged clutches into consideration, the measured speeds are not plausible. A value which is calculated on the basis of other transmission speeds is used as an error response. In case of further speed sensor errors the transmission is shifted to neutral. l l l

Short-term malfunction during speed measurement. Malfunction during the actuation of the direction clutches. Malfunctions of the range clutches.

Correction The cause for the missing plausibility of the speed signals should be located. 1. 2.

If the errors TCU 77 (4Dh), 78 (4Eh) or 79 (4Fh) occur (electric errors), the elimination of these errors should be given priority. The errors indicate a false speed recording of planetary carrier 3/4. Check the program version and perform a reprogramming where necessary. If the error ceases to occur, the issue was an old software status – no further measures are required.

20-314

Calibrations and electronic diagnosis 3.

If error TCU 85 (55h) also occurs, this means that there is a malfunction in a range clutch and the elimination of this should be given priority. m a) K1 corresponds to TCU 200 (C8h) … 205 (CDh). m b) K2 corresponds to TCU 208 (D0h) … 213 (D5h). m c) K3 corresponds to TCU 216 (D8h) … 221 (DDh). m d) K4 corresponds to TCU 224 (E0h) … 229 (E5h). If error TCU 86 (56h) also occurs in conjunction with 87 (57h), this means that there is a malfunction in one direction clutch and the elimination of this should be given priority. m a) KV corresponds to TCU 188 (BCh) und 189 (BDh). m b) KR corresponds to TCU 196 (C4h) und 197 (C5h).

4.

Transmission alarm 88 Description Output speed – incongruent sense of rotation Cause The sense of rotation determined by the output speed sensors does not match the sense of rotation which is stored in the control unit (TCU). l l l l

A sensor has been replaced. Faulty wiring. TCU was replaced. Reprogramming of the TCU or changed parameters.

Correction Calibration is performed automatically when the ignition is switched OFF (after the vehicle has been moved). 1. 2. 3.

Delete error. Ignition ON and move the vehicle. Once the ignition is OFF, wait for at least 10 seconds, then switch the ignition ON. If the error continues to occur, the output speed sensors must be replaced. If the error continues to occur, the TCU must be replaced.

Fig. 533 - Inductive sensor/Speed sensor output 1 20-315

Calibrations and electronic diagnosis

Fig. 533 - Inductive sensor/Speed sensor output 2

20-316

Calibrations and electronic diagnosis

Fig. 533 - Wiring diagram TCU

Transmission alarm 89 Description Speed sensor transmission input - implausible vehicle engine speed signal Cause Taking the transmission input speed and the transmission ratio into consideration, the engine speed is not plausible. l l l

Short-term vehicle engine speed sensor malfunction. Speed sensor has an internal defect. Faulty CAN bus connection (transmission - CAN or vehicle - CAN).

Correction The cause for the missing plausibility of the speed signals should be located. 1. 2. 3. 4.

If one of the errors TCU 64 (40h), 65 (41h) or 67 (43h) is also active (electric error), the elimination of this error should be given priority. If error TCU 84 (54h) is also active, the elimination of this error should be given priority. If engine control unit and VDC errors are also active, the elimination of these errors should be given priority. Check the CAN bus connection between the vehicle engine and the VDC. If the error ceases to occur, the issue was a CAN bus connection malfunction – no further measures are required. 20-317

Calibrations and electronic diagnosis 5.

The vehicle engine speed sensor has to be replaced should the error continue to occur.

Fig. 533 - Inductive sensor/Speed sensor transmission input

Transmission alarm 90 Description Vehicle accelerates from standstill despite absence of VDC requirement Cause A speed is recorded on the transmission output when the vehicle is under standstill control, despite the absence of VDC requirement. The transmission is shifted to neutral in connection with an actuation of the clutch or the brake, as an error response. The direction of travel can no longer be preselected. l l l l l

Short-term stepping motor or hydrostatic unit malfunction Faulty wiring Speed sensor has an internal defect Stepping motor has an internal defect External forces move the vehicle from standstill control

Correction The cause of the false hydrostatic unit activation should be located. 1. 2. 3. 4. 5.

If the speed sensor errors TCU 64 (40h), 65 (41h), 68 (44h), 69 (45h) or 85 (55h) are also active, the elimination of these errors should be given priority. If the hydrostatic unit errors TCU 144 (90h), 145 (91h), 146 (92h), 170 (AAh) or 171 (ABh) are also active, the correction of these errors should be given priority. Perform a calibration of the hydrostatic unit using the diagnosis tool. If the error TCU 60 (3Ch) (loss of step) also occurs, this error should be eliminated. Disassemble the HCU and check the wiring – in particular with regard to defective plug connections such as corroded or damaged plug contacts. If the error occurs in a driving situation with large external forces (e.g. use of a cable winch), this can also have the consequence that the standstill control is left and that this error is activated. This is an overload of the transmission and must be prevented.

20-318

Calibrations and electronic diagnosis 6.

The hydrostatic unit has to be replaced should the error continue to occur.

Fig. 533 - Installation position HCU

Transmission alarm 92 (SDF S240 / SDF S180+) Description Voltage at HP1 sensor smaller than valid range Cause Signal voltage of the high pressure sensor 1 does not reach the min. necessary value. As an error response, the estimated high pressure is used instead of the high pressure sensor. This is less accurate and can therefore lead to limitations of the driving operation. The TCU error 0xA0 is set as a subsequent error. l l l

Faulty wiring. Sensor has an internal defect. TCU has an internal defect

Correction The cause of the incorrect signal must be located. If the error is reset automatically, then this is an error that occurs sporadically. 1. 2. 3. 4. 5.

Delete error. Once the ignition is OFF, wait for at least 10 seconds, then switch the ignition ON, and start the engine. Perform a test journey. If the error does not reoccur, no further measures are required. If the error continues to occur, the TCU should be removed and connector A21/4 (green) checked for faulty plug connections such as corroded or damaged plug contacts. Disassemble the complete wiring harness between A21/4 and the passage into the interior of the transmission and check for incorrect plug connections and corroded or damaged plug contacts. If no error is detected, disassemble the cartridge and check the inner wiring (faulty plug connections as well as corroded or damaged plug contacts). If no error is detected in the wiring, replace the sensor (the high pressure sensor 1 is connected to the „short“ cable). If the error continues to occur, the TCU should be replaced.

20-319

Calibrations and electronic diagnosis

Fig. 533 - Wiring diagram TCU

Transmission alarm 93 (SDF S240 / SDF S180+) Description Voltage at HP 1 sensor above the valid range Cause Signal voltage of the high pressure sensor 1 exceeds the max. permitted value. As an error response, the estimated high pressure is used instead of the high pressure sensor. This is less accurate and can therefore lead to limitations of the driving operation. The TCU error 0xA0 is set as a subsequent error. l l l

Faulty wiring. Sensor has an internal defect. TCU has an internal defect.

Correction The cause of the incorrect signal must be located. If the error is reset automatically, then this is an error that occurs sporadically. 1.

Delete error. Once the ignition is OFF, wait for at least 10 seconds, then switch the ignition ON, and start the engine. Perform a test journey. If the error does not reoccur, no further measures are required.

20-320

Calibrations and electronic diagnosis 2.

If the error continues to occur, the TCU should be removed and connector A21/4 (green) checked for faulty plug connections such as corroded or damaged plug contacts. Disassemble the complete wiring harness between A21/4 and the passage into the interior of the transmission and check for incorrect plug connections and corroded or damaged plug contacts. If no error is detected, disassemble the cartridge and check the inner wiring (faulty plug connections as well as corroded or damaged plug contacts). If no error is detected in the wiring, replace the sensor (the high pressure sensor 1 is connected to the „short“ cable). If the error continues to occur, the TCU should be replaced.

3. 4. 5.

Fig. 533 - Wiring diagram TCU

Transmission alarm 94 (SDF S240 / SDF S180+) Description Voltage at HP 2 sensor smaller than the valid range Cause Signal voltage of the high pressure sensor 2 does not reach the min. necessary value. As an error response, the estimated high pressure is used instead of the high pressure sensor. This is less accurate and can therefore lead to limitations of the driving operation. The TCU error 0xA0 is set as a subsequent error. l l

Faulty wiring. Sensor has an internal defect. 20-321

Calibrations and electronic diagnosis l

TCU has an internal defect.

Correction The cause of the incorrect signal must be located. If the error is reset automatically, then this is an error that occurs sporadically. 1. 2. 3. 4. 5.

Delete error. Once the ignition is OFF, wait for at least 10 seconds, then switch the ignition ON, and start the engine. Perform a test journey. If the error does not reoccur, no further measures are required. If the error continues to occur, the TCU should be removed and connector A21/4 (green) checked for faulty plug connections such as corroded or damaged plug contacts. Disassemble the complete wiring harness between A21/4 and the passage into the interior of the transmission and check for incorrect plug connections and corroded or damaged plug contacts. If no error is detected, disassemble the cartridge and check the inner wiring (faulty plug connections as well as corroded or damaged plug contacts). If no error is detected in the wiring, replace the sensor (the high pressure sensor 2 is connected to the „long“ cable). If the error continues to occur, the TCU should be replaced.

Fig. 533 - Wiring diagram TCU

20-322

Calibrations and electronic diagnosis Transmission alarm 95 (SDF S240 / SDF S180+) Description Voltage at HP 2 sensor larger than valid range Cause Signal voltage of the high pressure sensor 2 exceeds the max. permitted value. As an error response, the estimated high pressure is used instead of the high pressure sensor. This is less accurate and can therefore lead to limitations of the driving operation. The TCU error 0xA0 is set as a subsequent error. l l l

Faulty wiring. Sensor has an internal defect. TCU has an internal defect.

Correction The cause of the incorrect signal must be located. If the error is reset automatically, then this is an error that occurs sporadically. 1. 2. 3. 4. 5.

Delete error. Once the ignition is OFF, wait for at least 10 seconds, then switch the ignition ON, and start the engine. Perform a test journey. If the error does not reoccur, no further measures are required. If the error continues to occur, the TCU should be removed and connector A21/4 (green) checked for faulty plug connections such as corroded or damaged plug contacts. Disassemble the complete wiring harness between A21/4 and the passage into the interior of the transmission and check for incorrect plug connections and corroded or damaged plug contacts. If no error is detected, disassemble the cartridge and check the inner wiring (faulty plug connections as well as corroded or damaged plug contacts). If no error is detected in the wiring, replace the sensor (the high pressure sensor 2 is connected to the „long“ cable). If the error continues to occur, the TCU should be replaced.

20-323

Calibrations and electronic diagnosis

Fig. 533 - Wiring diagram TCU

Transmission alarm 96 Description Input A0-S (BOC) - voltage too high Cause The applied voltage on the input exceeds the maximum permissible value. l l l

Faulty wiring. TCU has an internal defect. Overvoltage on the vehicle side.

Correction 1. 2. 3.

On the TCU, check the wiring of connector A21/1 – in particular with regard to faulty plug connections such as corroded or damaged plug contacts. Check voltage at the input (Pin 5). Term.15 - voltage may not be considerably exceeded. If the error continues to occur, the TCU should be replaced.

20-324

Calibrations and electronic diagnosis

Fig. 533 - Wiring diagram TCU

Transmission alarm 97 Description Input A0-S (BOC) - incorrect signal Cause The applied voltage value on the input is outside the valid range. l l

Faulty wiring. TCU has an internal defect.

Correction 1. 2. 3.

On the TCU, check the wiring of connector A21/1 – in particular with regard to faulty plug connections such as corroded or damaged plug contacts. Check voltage at the input (Pin5). If the error continues to occur, the TCU should be replaced.

20-325

Calibrations and electronic diagnosis

Fig. 533 - Wiring diagram TCU

Transmission alarm 98 Description BOC plausibility error between VDC and TCU Cause Der The signal comparison between VDC and TCU results in an implausible combination. l l l l

Faulty wiring. Incompatible software combination. TCU has an internal defect. VDC has an internal defect.

Correction 1. 2. 3. 4.

Check the wiring of connector A21/1, pin 6 on the TCU. Check both of the software versions for compatibility and, where necessary, create compatibility by programming the control units. The TCU should be replaced if the wiring is correct and the error is active. The VDC should be checked if the TCU is OK yet the error remains active.

20-326

Calibrations and electronic diagnosis

Fig. 533 - Wiring diagram TCU

Transmission alarm 99 Description Input A0. + (analog limp home or BOC input) - voltage too low Cause The applied voltage on the input exceeds the minimum permissible value. l l l

Faulty wiring. Supply on the vehicle side is insufficient. TCU has an internal defect.

Correction 1. 2.

On the TCU, check the wiring of connector A21/1 – in particular with regard to faulty plug connections such as corroded or damaged plug contacts. Check the power supply of the input (BOC). If the error continues to occur, the TCU should be replaced.

20-327

Calibrations and electronic diagnosis

Fig. 533 - Wiring diagram TCU

Transmission alarm 104 Description Lubrication pressure sensor - signal voltage above permitted range Cause The signal voltage of the lubrication pressure sensor is above the maximum value of 4.5 V or 4.75V (depending on the used sensor type). A restriction of the traveling speed takes place as an error response l l l l

The transmission-internal wiring has a short to plus (supply voltage). Sensor has an internal defect. TCU has an internal defect. Incorrect setting of the sensor type or wrong sensor installed.

Correction The cause of the false signal voltage value on the sensor should be located 1.

Check the correct setting of the sensor type. Use the service tool to set the correct pressure sensor type.

20-328

Calibrations and electronic diagnosis 2.

Assemble the adapter for pressure sensors between the lubrication pressure sensor and the wiring harness and, when the ignition is switched ON, measure the voltage between signal and ground. If the measured voltage is greater than 4.5 V or 4.7 V (depending on the used sensor type), it must be checked whether there is a defective wiring harness (see next point); otherwise replace the lubrication pressure sensor. If the measured voltage is greater than 4.5 V or 4.75 V (depending on the used sensor type), connector A21/2 is to be unplugged from the TCU and the voltage is to be measured again on the adapter. The transmission-internal wiring harness should be replaced if the voltage value remains unchanged (short-circuit in the wiring harness). If the error continues to occur, the TCU should be replaced.

3. 4.

Transmission alarm 105 Description Lubrication pressure sensor - lubrication pressure too low. Cause The lubrication pressure measured using the lubrication pressure sensor (10 bar/20 bar sensor) fell below 0.5 bar. As an error response, the vehicle speed is restricted and the transmission switches into neutral after 10 seconds. In addition, the engine speed is raised in order to increase the flow rate of the lubrication pressure pump. l l l l l l l

The lubrication pressure pump has an internal defect. Leakage in the lubrication pressure circuit. Transmission oil level is too low. Leakage in the suction channel of the lubrication pressure pump. Suction filter clogged. Lubrication pressure sensor has an internal defect. Incorrect setting of the sensor type or wrong sensor installed.

Correction The cause of the drop in lubrication pressure or the insufficient oil feed rate should be located. 1. 2. 3.

Check the transmission oil level. Use the diagnosis tool to check the set sensor type. Connect a manometer to the designated „lubrication pressure“ measuring connection and check the lubrication pressure when the engine is running. Compare the pressure measurement value with the manometer with the value displayed using the diagnosis tool. The lubrication pressure sensor should be replaced if the determined values deviate from each other by more than 0.5 bar. Check the shifting drum, the oil cooler, oil pipes as well as the rear axle lubrication for leakages. Check the lubrication pressure relief valves. Replace the lubrication pressure pump.

4. 5. 6.

Transmission alarm 106 Description Lubrication pressure sensor - lubrication pressure too low Cause The lubrication pressure measured using the lubrication pressure sensor (10 bar/ 20 bar sensor) is in the range of 0.5 to 1 bar. As an error response, the vehicle speed is restricted and the engine speed is raised in order to increase the flow rate of the lubrication pressure pump. l l l l l l l

The lubrication pressure pump has an internal defect. Leakage in the lubrication pressure circuit. Transmission oil level is too low. Leakage in the suction channel of the lubrication pressure pump. Suction filter clogged. Lubrication pressure sensor has an internal defect. Incorrect setting of the sensor type or wrong sensor installed.

Correction The cause of the drop in lubrication pressure or the insufficient oil feed rate should be located. 1. 2.

Check the transmission oil level. Use the diagnosis tool to check the set sensor type.

20-329

Calibrations and electronic diagnosis 3.

Connect a manometer to the designated „lubrication pressure“ measuring connection and check the lubrication pressure when the engine is running. Compare the pressure measurement value with the manometer with the value displayed using the diagnosis tool. The lubrication pressure sensor should be replaced if the determined values deviate from each other by more than 0.5 bar. Check the shifting drum, the oil cooler, oil pipes as well as the rear axle lubrication for leakages. Check the lubrication pressure relief valves. Replace the lubrication pressure pump.

4. 5. 6.

Transmission alarm 107 Description Lubrication pressure sensor– Signal voltage below permitted range Cause The signal voltage of the lubrication pressure sensor is below the minimum value of 0.5 V or 0.25 V (depending on the used sensor type). As an error response, the vehicle speed is restricted l l l l

The transmission-internal wiring has a short to ground. Sensor has an internal defect. TCU has an internal defect. Incorrect setting of the sensor type or wrong sensor installed.

Correction The cause of the false signal voltage value on the sensor should be located. 1.

Assemble the adapter for pressure sensors between the lubrication pressure sensor and the wiring harness and, when the ignition is switched ON, measure the voltage between supply voltage and ground using the voltmeter. If the voltage is below 5 V, the plug connection is to be unplugged from the lubrication pressure sensor and the voltage should be measured. If the voltage remains below 5 V, the plug connection should also be unplugged from the system pressure sensor. The system pressure sensor should be replaced if the voltage is now greater than or equal to 5 V (short circuit system pressure sensor). Otherwise, the transmission-internal wiring harness should be replaced. Assemble the adapter for pressure sensors between the lubrication pressure sensor and the wiring harness and, when the ignition is switched ON, measure the voltage between signal and ground using the voltmeter. If the voltage is below 0.5 V or 0.25 V (depending on the used sensor type), the lubrication pressure sensor should be replaced. The TCU should be replaced if no measure is effective.

2. 3.

Transmission alarm 108 Description Lubrication pressure sensor– lubrication pressure too high Cause The lubrication pressure measured using the lubrication pressure sensor (10 bar / 20 bar sensor) is above 9.5 bar or 10 bar. As an error response, the vehicle speed is restricted and the engine is limited in order to decrease the flow rate of the lubrication pressure pump. l l l

Lubrication pressure relief valve does not open. Lubrication pressure sensor has an internal defect. Incorrect setting of the sensor type or wrong sensor installed.

Correction The cause of the lubrication pressure increase should be located. 1.

2. 3. 4.

Connect a manometer to the designated „lubrication pressure“ measuring connection and check the lubrication pressure when the engine is running. Compare the pressure measurement value with the manometer with the value displayed using the diagnosis tool. The lubrication pressure sensor should be replaced if the determined values deviate from each other by more than 0.5 bar. Use the diagnosis tool to check the set sensor type. Inspection of the lubrication pressure relief valves. If no measures are effective, an inspection of the shifting drum, the oil cooler as well as the rear axle lubrication, if necessary, should be performed.

20-330

Calibrations and electronic diagnosis Transmission alarm 112 Description System pressure sensor - signal voltage above permitted range. Cause The signal voltage of the system pressure sensor is above the maximum value of 4.5 V or 4.75 V (depending on the used sensor type). A targeted error response via the restriction of the traveling speed takes place. The transmission is shifted into neutral if a clutch slip is detected. l l l l

The transmission-internal wiring has a short to plus Sensor has an internal defect. TCU has an internal defect. Incorrect setting of the sensor type or wrong sensor installed.

Correction The cause of the false signal voltage value on the sensor should be located 1. 2.

3. 4.

Check the correct setting of the sensor type. Use the service tool to set the correct pressure sensor type. Assemble the adapter for pressure sensors between the system pressure sensor and the wiring harness and, when the ignition is switched ON, measure the voltage between signal and ground using a voltmeter. If the measured voltage is greater than 4.5 V or 4.75 V (depending on the used sensor type), check for a defective wiring harness (see next point), otherwise the system pressure sensor should be replaced. If the measured voltage is greater than 4.5 V or 4.75 V (depending on the used sensor type), connector A21/2 is to be unplugged from the TCU and the voltage is to be measured again on the adapter. The transmission-internal wiring harness should be replaced if the voltage value remains unchanged. The TCU should be replaced if no measure is effective.

20-331

Calibrations and electronic diagnosis

Fig. 533 - Wiring diagram TCU

Transmission alarm 113 Description System pressure sensor - system pressure too low, no driving operation possible Cause The system pressure measured using the system pressure sensor (50 bar sensor) fell below 20 bar. The traveling speed is restricted as an error response and the transmission switches into neutral after 20 seconds. If the error occurs when the vehicle is stationary or if the vehicle comes to a stop within 20 seconds, it is not possible to drive off, even before the 20 seconds have expired. l l l l

Transmission oil level too low. The system pressure sensor is defective. The system pressure pump is defective. Leakage in the system pressure circuit.

Correction The cause of the drop in system pressure or the insufficient oil feed rate should be located. If the error is automatically reset, this means that it was possible to increase the system pressure to at least 22 bar. 1.

Transmission oil level check.

20-332

Calibrations and electronic diagnosis 2. 3.

Check suction filter and pressure filter. Assemble a manometer on the designated „system pressure“ measuring connection and check the pressure when the engine is running. Compare the pressure measurement value with the manometer with the value displayed using the diagnosis tool. The system pressure sensor should be replaced if the determined values deviate from each other by more than 1 bar. Check the hydrostatic unit and the shifting drum for leakages. Replace the system pressure pump.

4. 5.

Transmission alarm 114 Description System pressure sensor - system pressure too low, engine speed elevation initiated Cause The system pressure measured using the system pressure sensor (50 bar sensor) fell below 26 bar for at least 2 seconds. The engine speed is raised as an error response in order to increase the flow rate of the system pressure pump. l l l l

Transmission oil level too low. The system pressure sensor is defective. The system pressure pump is defective. Leakage in the system pressure circuit.

Correction The cause of the drop in system pressure or the insufficient oil feed rate should be located. If the error is automatically reset, this means that it was possible to increase the system pressure to at least 29 bar via the increased engine speed. 1.

If one of the errors TCU 113 (71h) (pSys<20bar) or 118 (76h) (pSys<25bar) is also active, the elimination of this error should be given priority. Transmission oil level check. Check suction filter and pressure filter. Assemble a manometer on the designated „system pressure“ measuring connection and check the system pressure with the engine running. Compare the pressure measurement value with the manometer with the value displayed using the diagnosis tool. The system pressure sensor should be replaced if the determined values deviate from each other by more than 1 bar. The system pressure pump must be replaced. Check the suction filter. If no measure is effective, an inspection of the hydrostatic unit and the shifting drum for leakages should be performed.

2. 3. 4. 5. 6. 7.

Transmission alarm 115 Description System pressure sensor – signal voltage below permitted range Cause The signal voltage of the system pressure sensor is below the minimum value of 0.5 V. A targeted error response via the restriction of the traveling speed takes place. The transmission is shifted into neutral if a clutch slip is detected l l l

The transmission-internal wiring of the sensor supply has a short to ground Sensor has an internal defect TCU has an internal defect

Correction The error is activated if a voltage value below the minimum value is applied to the TCU input 1.

2. 3.

Assemble the adapter for pressure sensors between the system pressure sensor and the wiring harness and, when the ignition is switched ON, measure the voltage between pins 1 and 2 using the voltmeter (supply voltage of system and lubrication pressure sensor). If the voltage is below 5 V, the plug connection is to be unplugged from the system pressure sensor and the voltage should be measured. If the voltage remains below 5 V, the plug connection should also be unplugged from the lubrication pressure sensor. The lubrication pressure sensor should be replaced if the voltage is now greater than or equal to 5 V. Otherwise, the transmission-internal wiring harness should be replaced. The voltage between pins 1 and 3 should be measured on the system pressure sensor (pressure sensor signal). The voltage should amount to approx. 0.5 V when the ignition is ON but the engine is off, otherwise the system pressure sensor should be replaced. The TCU should be replaced if no measure is effective.

20-333

Calibrations and electronic diagnosis

Fig. 533 - Wiring diagram TCU

Transmission alarm 116 Description System pressure sensor - system pressure too high Cause The system pressure measured using the system pressure sensor (50 bar sensor) is above 45 bar (or above 35 bar in new software). The engine speed is restricted as an error response in order to decrease the flow rate of the system pressure pump. Furthermore, the traveling speed is restricted (approx.20 km/h). l l l

The system pressure setting is too high. The system pressure pump is defective. The system pressure sensor is defective.

Correction The cause of the system pressure increase should be located. 1.

Assemble a manometer on the designated „system pressure“ measuring connection and check the pressure when the engine is running. Compare the pressure measurement value with the manometer with the value displayed using the diagnosis tool. The system pressure sensor should be replaced if the determined values deviate from each other by more than 1 bar.

20-334

Calibrations and electronic diagnosis 2.

The system pressure pump must be replaced.

Transmission alarm 117 Description System pressure sensor - pressure drop during gear change Cause A system pressure drop of more than 5 bar takes place during multiple gear changes in succession (min. 20). l l l l

The preload pressure of the pressure accumulator is too low. Leakage in the system pressure circuit. The system pressure sensor is defective. The system pressure pump is defective.

Correction The cause of the drop in system pressure or the insufficient oil feed rate should be located. 1.

If one of the errors TCU 113 (71h), 114 (72h), or 118 (76h) is also active (system pressure too low), the elimination of this error should be given priority. Check whether an error between TCU 130 (82h) and 135 (87h) is also active; the treatment of this error should be given priority. Assemble a manometer on the designated „system pressure“ measuring connection and check the system pressure when the engine is running. Compare the pressure measurement value with the manometer with the value displayed using the diagnosis tool. The system pressure sensor should be replaced if the determined values deviate from each other by more than 1 bar. Check the pressure accumulator preload pressure. Delete error and perform a test run in such a manner that at least 25 clutch changes occur (preferably shift several times through the complete driving range forward and reverse). If the error does not occur, the issue may be a short-term malfunction in the oil circuit. No further measure is necessary in this case. The system pressure pump must be replaced. If no measure is effective, an inspection of the hydrostatic unit and the shifting drum for leakages should be performed.

2. 3. 4. 5. 6. 7.

Transmission alarm 118 Description System pressure sensor - system pressure too low, engine speed elevation without effect Cause The system pressure measured using the system pressure sensor (50 bar sensor) fell below 25 bar for at least 2 seconds. The engine speed rise displayed an insufficient effect. The restriction of the traveling speed is restricted as an error response, a change in direction of travel can only be performed whilst stationary. l l l l l

The controller setting on the system pressure pump is too low. The system pressure pump has an internal defect. Leakage in the system pressure circuit. Transmission oil level is too low. System pressure sensor has an internal defect.

Correction The cause of the drop in system pressure or the insufficient oil feed rate should be located. If the error is automatically reset, this means that it was possible to increase the system pressure to at least 27 bar via the increased engine speed. 1. 2. 3. 4. 5. 6.

If the error TCU 113 (71 h) also occurs (system pressure < 20bar), the elimination of this error should be given priority. Transmission oil level check. Check suction filter and pressure filter. Assemble a manometer on the designated „system pressure“ measuring connection and check the pressure when the engine is running. Compare the pressure measurement value with the manometer with the value displayed using the diagnosis tool. The system pressure sensor should be replaced if the determined values deviate from each other by more than 1 bar. Check the hydrostatic unit and the shifting drum for leakages. Replace the system pressure pump.

20-335

Calibrations and electronic diagnosis Transmission alarm 120 Description Temperature sensor - interruption or short to plus Cause A line open circuit or a short circuit to the supply voltage is diagnosed by the TCU for the temperature sensor. As an error response, the restriction of the traveling speed takes place. l l l l

The transmission-internal wiring is damaged or interrupted. The plug connection belonging to the sensor on the TCU is loose or has a poor contact. Sensor has an internal defect. TCU has an internal defect.

Correction The cause of the false sensor signal should be located. 1. 2.

3. 4. 5.

Check the plug connection on the temperature sensor for a defective connection, in particular with regard to faulty plug connections such as corroded or damaged plug contacts. Check the sensor resistance. For this purpose, determine the resistance between the two pins on the sensor-sided connector using an ohmmeter when the sensor is unplugged. The resistance value should amount to approx. 1 kΩ or, on older vehicles (production date prior to 06/2007) approx. 2 kΩ (at approx. 23°C). The sensor should be replaced in the event of damage or significant resistance value deviations. Dismantle the TCU and check plug connection A21/2 as well as the wiring harness for a faulty connection, in particular also with regard to faulty plug connections such as corroded or damaged plug contacts. Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the engine on. The TCU has to be replaced should the error occur again. The temperature sensor and the transmission-internal wiring harness should be replaced if no measure is effective on a sustained basis.

20-336

Calibrations and electronic diagnosis

Fig. 533 - Wiring diagram TCU

Transmission alarm 121 Description Temperature sensor - temperature gradient above permitted range Cause The transmission oil temperature increases unusually quickly. l l l l l

The transmission oil cooler is dirty or damaged. The transmission temperature controller is defective. The cooler bypass valve is defective. Increased thermal input in the transmission caused by mechanical damage or defective brake setting. Temperature sensor defective.

Correction The cause of the increased heat entry in the transmission should be located. 1. 2. 3.

If one of the errors TCU 120 (78h) or 123 (7Bh) is also active (temperature sensor error), the elimination of this error should be given priority. Inspect the transmission oil cooler for contamination and damage. Check the connection lines from the transmission to the transmission oil cooler for damage. 20-337

Calibrations and electronic diagnosis 4. 5. 6. 7. 8.

Check the transmission temperature controller. Check the brake setting of the rear axle. Replace the temperature sensor. Check the cooler bypass valve. If no measure is effective, an inspection of the transaxle should be performed.

Transmission alarm 122 Description Temperature sensor - temperature too high Cause The transmission oil temperature exceeded 95 °C for at least 4 seconds. As an error response, the vehicle speed is restricted and the engine derate setting is deactivated. l l l l l l

The transmission oil cooler is dirty or damaged. The transmission temperature controller is defective. Cooler bypass valve has an internal defect. Increased thermal input in the transmission caused by mechanical damage or defective brake setting. Temperature sensor has an internal defect. Temperature sensor is incorrectly parameterized.

Correction The cause of the increased heat entry in the transmission should be located. 1.

If one of the errors TCU 120 (78h) or 123 (7Bh) is also active (temperature sensor error), the elimination of this error should be given priority. Inspect the transmission oil cooler for contamination and damage. Check the connection lines from the transmission to the transmission oil cooler for damage. Check the transmission temperature controller. Check the brake setting of the rear axle. If the error occurs following a programming of the TCU, check the parameterization of the temperature sensor using the diagnosis tool and correct it where necessary. Check the transmission oil temperature using the diagnosis tool. The temperature sensor should be replaced if the measured oil temperature does not drop below 95 °C when the vehicle is idling, even after an extended period of time. Check the cooler bypass valve. If no measure is effective, an inspection of the transaxle should be performed.

2. 3. 4. 5. 6. 7. 8. 9.

Transmission alarm 123 Description Temperature sensor - short to ground Cause A short to ground is diagnosed for the temperature sensor in the TCU. The restriction of the traveling speed is restricted as an error response. l l l

The transmission-internal wiring is damaged. Sensor has an internal defect. TCU has an internal defect.

Correction The cause of the false sensor signal should be located. 1.

2. 3. 4.

Check the sensor resistance. For this purpose, determine the resistance between the two pins on the sensor-sided connector using an ohmmeter when the sensor is unplugged. The resistance value should amount to approx. 1 kW ± 100 W or, on older vehicles (production date before 06/2007) approx. 2 kW (at approx. 23°C). The sensor should be replaced in the event of damage or resistance value deviations. Dismantle the TCU and check plug connection A21/2 as well as the wiring harness for a faulty connection and damage. Delete error. Once the ignition is OFF, wait for at least 10 seconds and then switch the engine on. The TCU has to be replaced should the error occur again. The temperature sensor and the transmission-internal wiring harness should be replaced if no measure is effective on a sustained basis.

20-338

Calibrations and electronic diagnosis

Fig. 533 - Wiring diagram TCU

Transmission alarm 124 Description Temperature sensor - temperature too low, limited driving operation. Cause The transmission oil temperature is in the range of 25 °C and -5 °C. It is possible to operate the vehicle, but at a restricted traveling speed (only first driving range), the cold start condition display occurs. l l l

Transmission oil temperature too low. Transmission temperature controller defective. Temperature sensor has an internal defect.

Correction The activation of the error shows an operation of the vehicle in low outside temperatures 1.

The full operation of the vehicle is automatically permitted once a transmission oil temperature of -5 °C is reached, no further measures are required (up to 0°C engine speed limitations are still active).

20-339

Calibrations and electronic diagnosis 2.

If the cold start condition is not reset despite the warm-up period of the vehicle, first check the transmission temperature controller. If no measure is effective check the transmission oil temperature using the diagnosis tool. The temperature sensor should be replaced if the measured oil temperature does not rise above -5 °C during the operation of the vehicle, even after an extended period of time.

Transmission alarm 125 Description Temperature sensor - temperature gradient below permitted range. Cause Contrary to expectations, the transmission oil temperature does not increase. l l

The transmission temperature controller is defective. Temperature sensor defective.

Correction The cause for the lack of increase in the transmission oil temperature should be located. 1. 2.

Check the transmission temperature controller. Check the sensor resistance. For this purpose, determine the resistance between the two pins on the sensor-sided connector using an ohmmeter when the sensor is unplugged. The resistance value should amount to approx. 1 kW± 100 W or, on older vehicles (production date before 06/2007) approx. 2 kΩ (at approx. 23°C). The sensor should be replaced in the event of damage or resistance value deviations.

Transmission alarm 126 Description Temperature sensor - temperature too low, no driving operation. Cause The transmission oil temperature is below -25 °C. An operation of the vehicle is not permissible, the cold start condition display occurs. l l l l

Transmission oil temperature too low. Transmission temperature controller defective. Temperature sensor defective. Temperature sensor is incorrectly parameterized.

Correction The activation of the error shows an operation of the vehicle in low outside temperatures. 1.

Restricted driving operation is possible once a transmission oil temperature of -25 °C is reached. The full operation of the vehicle is automatically permitted once a transmission oil temperature of -5 °C is reached, no further measures are required. If the error occurs following a programming of the TCU, check the parameterization of the temperature sensor using the diagnosis tool and correct it where necessary. Check the transmission temperature controller if the cold start condition is not reset despite the warm-up period of the vehicle. Check the transmission oil temperature using the diagnosis tool if the cold start condition is not reset despite the warm-up period of the vehicle. The temperature sensor should be replaced if the measured oil temperature does not rise above -5 °C during the operation of the vehicle, even after an extended period of time.

2. 3. 4.

Transmission alarm 127 (SDF S180 / SDF S240 / SDF S180+) Description High transmission temperature - limitation is active. Cause The transmission oil temperature is between +90 °C and +95°C. The maximum permitted engine speed is lowered from 2100 1/min to 1700 1/min and the max. permitted transmission ratio is limited (approx. 40 km/h @ 95°C). Furthermore, engine boost is deactivated. l l l l l l

The transmission oil cooler is dirty or damaged. The transmission temperature controller is defective. Cooler bypass valve has an internal defect. Increased thermal input in the transmission caused by mechanical damage or defective brake setting. Temperature sensor has an internal defect. Temperature sensor is incorrectly parameterized.

20-340

Calibrations and electronic diagnosis Correction The cause of the increased heat entry in the transmission should be located. 1. 2. 3. 4. 5. 6. 7. 8. 9.

If one of the errors TCU 120 (78h) or 123 (7Bh) is also active (temperature sensor error), the elimination of this error should be given priority. Inspect the transmission oil cooler for contamination and damage. Check the connection lines from the transmission to the transmission oil cooler for damage. Check the transmission temperature controller. Check the brake setting of the rear axle. If the error occurs following a programming of the TCU, check the parameterization of the temperature sensor using the diagnosis tool and correct it where necessary. Check the transmission oil temperature using the diagnosis tool. The temperature sensor should be replaced if the measured oil temperature does not drop below 90 °C when the vehicle is idling, even after an extended period of time. Check the cooler bypass valve. If no measure is effective, an inspection of the transaxle should be performed.

Fig. 533 - Wiring diagram TCU

20-341

Calibrations and electronic diagnosis Transmission alarm 130 Description System pressure sensor – pressure drop during clutch 1 shift procedure. Cause A system pressure drop of more than 5 bar takes place during multiple gear changes in succession (min. 10) in range clutch 1. The restriction of the traveling speed is restricted as an error response. l l l

Leakage in the oil circuit of range clutch 1. The system pressure sensor is defective. System pressure pump is defective.

Correction The cause of the drop in system pressure or the insufficient oil feed rate should be located. 1.

If one of the errors TCU 113 (71h), 114 (72h), 118 (76h) (system pressure too low) or 117 (75h) (system pressure drops during gear changes) is active, the elimination of these errors should be given priority. Assemble a manometer on the designated „system pressure“ measuring connection and check the system pressure when the engine is running. Compare the pressure measurement value with the manometer with the value displayed using the diagnosis tool. The system pressure sensor should be replaced if the determined values deviate from each other by more than 1 bar. Delete error and perform a test run in such a manner that at least 15 clutch changes from K1 to K2 occur. If the error does not occur, the issue may be a short-term malfunction in the oil circuit. No further measure is necessary in this case. The system pressure pump must be replaced. If no measures are effective, an inspection of the hydrostatic unit and the shifting drum for leakages should be performed.

2. 3. 4. 5.

Transmission alarm 131 Description System pressure sensor – pressure drop during clutch 2 shift procedure. Cause A system pressure drop of more than 5 bar takes place during multiple gear changes in succession (min. 10) in range clutch 2. The restriction of the traveling speed is restricted as an error response. l l l

Leakage in the oil circuit of range clutch 2. The system pressure sensor is defective. The system pressure pump is defective.

Correction The cause of the drop in system pressure or the insufficient oil feed rate should be located. 1.

If one of the errors TCU 113 (71h), 114 (72h), 118 (76h) (system pressure too low) or 117 (75h) (system pressure drops during gear changes) is active, the elimination of these errors should be given priority. Assemble a manometer on the designated „system pressure“ measuring connection and check the pressure when the engine is running. Compare the pressure measurement value with the manometer with the value displayed using the diagnosis tool. The system pressure sensor should be replaced if the determined values deviate from each other by more than 1 bar. Delete error and perform a test run in such a manner that at least 15 clutch changes from K1 to K2 occur. If the error does not occur, the issue may be a short-term malfunction in the oil circuit. No further measure is necessary in this case. The system pressure pump must be replaced. If no measures are effective, an inspection of the hydrostatic unit and the shifting drum for leakages should be performed.

2. 3. 4. 5.

Transmission alarm 132 Description System pressure sensor – pressure drop during clutch 3 shift procedure. Cause A system pressure drop of more than 5 bar takes place during multiple gear changes in succession (min. 10) in range clutch 3. The restriction of the traveling speed is restricted as an error response. l l l

Leakage in the oil circuit of range clutch 3. The system pressure sensor is defective. The system pressure pump is defective.

Correction The cause of the drop in system pressure or the insufficient oil feed rate should be located. 20-342

Calibrations and electronic diagnosis 1.

If one of the errors TCU 113 (71h), 114 (72h), 118 (76h) (system pressure too low) or 117 (75h) (system pressure drops during gear changes) is active, the elimination of these errors should be given priority. Assemble a manometer on the designated „system pressure“ measuring connection and check the pressure when the engine is running. Compare the pressure measurement value with the manometer with the value displayed using the diagnosis tool. The system pressure sensor should be replaced if the determined values deviate from each other by more than 1 bar. Delete error and perform a test run in such a manner that at least 15 clutch changes from K2 to K3 occur. If the error does not occur, the issue may be a short-term malfunction in the oil circuit. No further measure is necessary in this case. The system pressure pump must be replaced. If no measures are effective, an inspection of the hydrostatic unit and the shifting drum for leakages should be performed.

2. 3. 4. 5.

Transmission alarm 133 Description System pressure sensor – pressure drop during clutch 4 shift procedure. Cause A system pressure drop of more than 5 bar takes place during multiple gear changes in succession (min. 10) in range clutch 4. The restriction of the traveling speed is restricted as an error response. l l l

Leakage in the oil circuit of range clutch 4. The system pressure sensor is defective. The system pressure pump is defective.

Correction The cause of the drop in system pressure or the insufficient oil feed rate should be located. 1.

If one of the errors TCU 113 (71h), 114 (72h), 118 (76h) (system pressure too low) or 117 (75h) (system pressure drops during gear changes) is active, the elimination of these errors should be given priority. Assemble a manometer on the designated „system pressure“ measuring connection and check the system pressure when the engine is running. Compare the pressure measurement value with the manometer with the value displayed using the diagnosis tool. The system pressure sensor should be replaced if the determined values deviate from each other by more than 1 bar. Delete error and perform a test run in such a manner that at least 15 clutch changes from K3 to K4 occur. If the error does not occur, the issue may be a short-term malfunction in the oil circuit. No further measure is necessary in this case. The system pressure pump must be replaced. If no measure is effective, an inspection of the hydrostatic unit and the shifting drum for leakages should be performed.

2. 3. 4. 5.

Transmission alarm 134 Description System pressure sensor – pressure drop during clutch forward shift procedure. Cause A system pressure drop of more than 5 bar takes place during multiple direction clutch forward gear changes in succession (min. 10). The traveling speed is restricted as an error response. l l l

Leakage in the direction clutch forward oil circuit. The system pressure sensor is defective. The system pressure pump is defective.

Correction The cause of the drop in system pressure or the insufficient oil feed rate should be located. 1. 2. 3. 4. 5.

If one of the errors TCU 113 (71h), 114 (72h), 118 (76h) (system pressure too low) or 117 (75h) (system pressure drops during gear changes) is active, the elimination of these errors should be given priority. Assemble a manometer on the designated „system pressure“ measuring connection and check the pressure with the engine running. Compare the pressure measurement value with the manometer with the value displayed using the diagnosis tool. The system pressure sensor should be replaced if the determined values deviate from each other by more than 1 bar. Delete error and perform a test run in such a manner that at least 15 clutch changes from KV to KB occur. If the error does not occur, the issue may be a short-term malfunction in the oil circuit. No further measure is necessary in this case. The system pressure pump must be replaced. If no measure is effective, an inspection of the hydrostatic unit and the shifting drum for leakages should be performed.

20-343

Calibrations and electronic diagnosis Transmission alarm 135 Description System pressure sensor – pressure drop during clutch reverse shift procedure. Cause A system pressure drop of more than 5 bar takes place during multiple direction clutch reverse gear changes in succession (min. 10). The restriction of the traveling speed is restricted as an error response. l l l

Leakage in the direction clutch reverse oil circuit. The system pressure sensor is defective. The system pressure pump is defective.

Correction The cause of the drop in system pressure or the insufficient oil feed rate should be located. 1.

If one of the errors TCU 113 (71h), 114 (72h), 118 (76h) (system pressure too low) or 117 (75h) (system pressure drops during gear changes) is active, the elimination of these errors should be given priority. Assemble a manometer on the designated „system pressure“ measuring connection and check the pressure when the engine is running. Compare the pressure measurement value with the manometer with the value displayed using the diagnosis tool. The system pressure sensor should be replaced if the determined values deviate from each other by more than 1 bar. Delete error and perform a test run in such a manner that at least 15 clutch changes from KV to KB occur. If the error does not occur, the issue may be a short-term malfunction in the oil circuit. No further measure is necessary in this case. The system pressure pump must be replaced. If no measures are effective, an inspection of the hydrostatic unit and the shifting drum for leakages should be performed.

2. 3. 4. 5.

Transmission alarm 136 Description Oil pressure filter inlet – pressure filter soiled, change. Cause The oil filter in the system pressure circuit is tested with regard to its filter function via a maintenance switch. If the generated differential pressure on the filter is too great, the filter effect is insufficient and the pressure filter should be replaced. l l l l

Filter has not been replaced for a long period of time. The transmission oil contains contaminants. Bypass valve in the filter head defective. Maintenance switch defective.

Correction 1.

Check the condition of the pressure filter. It is essential that the filter is replaced if the service interval has been reached or exceeded. Changing the suction filter and the pressure filter together is recommended. If unusual metallic parts are found in the filter that indicate a defect to the transaxle, the transaxle should be inspected for damage. The maintenance switch should be replaced if the oil filter exchange is ineffective. The entire filter head should be replaced if no measure is effective.

2. 3. 4.

Transmission alarm 144 Description Hydrostatic unit electronics - no response. Cause The TCU receives no valid response signal from the hydrostatic unit electronics (HCU). The restriction of the traveling speed as well as the limiting of the engine speed take place as an error response. l l l l

Short-term HCU malfunction. HCU has an internal defect. The transmission-internal wiring is false. Defective TCU.

Correction The cause of the faulty HCU response signal should be located. 1.

Dismantle the HCU and check the plug connection of the HCU for a defective connection (loose, bent, or corroded contacts) and damage.

20-344

Calibrations and electronic diagnosis 2. 3. 4. 5.

Dismantle the TCU and check plug connections A21/4 and A21/5 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. Ensure that plug connection A21/5 is reassembled. Using a voltmeter, measure the voltage between pins 6 and 7 on connector A23 with the ignition ON. The transmission-internal wiring should be checked and, where necessary, replaced if the measured voltage is more than 1 V below the vehicle power supply. Start the engine and, with the aid of the diagnosis tool, ascertain the status of the HCU response signal. The HCU should be replaced if the measured value is below 20% on a sustained basis. The TCU should be replaced if no measure is effective on a sustained basis.

Fig. 533 - Installation position HCU

20-345

Calibrations and electronic diagnosis

Fig. 533 - Installation position TCU

20-346

Calibrations and electronic diagnosis

Fig. 533 - Wiring diagram TCU

Transmission alarm 145 Description Hydrostatic unit electronics - wrong nominal value. Cause The target value specification from the TCU to hydrostatic unit electronics (HCU) is outside of the valid range. The restriction of the traveling speed as well as the limiting of the engine speed take place as an error response. l l l l

Short-term HCU malfunction. HCU has an internal defect. The transmission-internal wiring is false. Defective TCU.

Correction The cause of the incorrect HCU activation should be located 1.

Start the engine and, with the aid of the diagnosis tool, ascertain the status of the HCU response signal. If the measured value is in the range of 35% and 50% on a sustained basis, the issue was a short-term HCU malfunction. If the error does not occur again during a test drive, no further measures are required. 20-347

Calibrations and electronic diagnosis 2. 3. 4. 5.

Dismantle the HCU and check the plug connection of the HCU for a defective connection (loose, bent, or corroded contacts) and damage. Dismantle the TCU and check plug connections A21/4 and A21/5 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. Ensure that plug connection A21/5 is reassembled. Using a voltmeter, measure the voltage between pins 6 and 7 on connector A23 with the ignition ON. The transmission-internal wiring should be checked and, where necessary, replaced if the measured voltage is more than 1 V below the vehicle power supply. The TCU should be replaced if no measure is effective on a sustained basis.

Fig. 533 - Installation position HCU

20-348

Calibrations and electronic diagnosis

Fig. 533 - Installation position TCU

20-349

Calibrations and electronic diagnosis

Fig. 533 - Wiring diagram TCU

Transmission alarm 146 Description Hydrostatic unit electronics - index sensor does not provide a response Cause The index sensor integrated in the stepping motor either provides no response or an incorrect response. The restriction of the traveling speed is restricted as an error response. l l

Short-term stepping motor unit malfunction. Permanent stepping motor unit defect.

Correction 1. 2.

3.

If one of the errors TCU 144 (90h) or 145 (91h) is also active, the elimination of these errors should be given priority. Short-term malfunctions may occur, especially following a long service life of the vehicle at low exterior temperatures or following a transmission oil change. Therefore, perform three calibrations of the hydrostatic unit in succession using the diagnosis tool. If the calibrations are successfully completed and no error occurs during a mandatory subsequent test drive, no further measures are required. Dismantle the HCU and check the plug connection of the HCU for a defective connection (loose, bent, or corroded contacts) and damage.

20-350

Calibrations and electronic diagnosis 4.

The stepping motor has to be replaced and the fork on the hydrostatic unit needs to be checked for damage should the error occur again. Furthermore, the wiring running from the HCU to the stepping motor should be checked for damage, especially bent, corroded, or pushed-back pins.

Fig. 533 - Installation position HCU

20-351

Calibrations and electronic diagnosis

Fig. 533 - Installation position TCU

20-352

Calibrations and electronic diagnosis

Fig. 533 - Wiring diagram TCU

Transmission alarm 147 Description Hydrostatic unit electronics - several initialization attempts. Cause The hydrostatic unit electronics are initialized when the ignition is switched ON. It is documented that more than one attempt was required for a flawless initialization, especially at low transmission oil temperatures. l l

Vehicle initial operation at a low transmission oil temperature. Short-term stepping motor unit malfunction.

Correction The activation of the error shows that multiple attempts were required for an initialization. This is not a functional impairment of the transmission, no measures are required

20-353

Calibrations and electronic diagnosis Transmission alarm 148 Description Hydrostatic unit – loss of step after ignition ON. Cause An error occurred during the functional test of the hydrostatic unit that is performed upon engine start. The transmission is switched into neutral as an error response. l l l

Cold start problems. Vehicle battery insufficiently charged. Stepping motor or hydrostatic unit defects.

Correction 1. 2. 3. 4. 5.

From time to time, the stepping motor is unable to move the swash plate of the hydrostatic unit into the activated position. If the error does not occur again during a test drive or following a new start, no further measures are required. If the error occurs after a (sluggish) vehicle start, the vehicle battery may not be charged sufficiently. Recharge the battery to ensure that it is sufficiently charged. Short-term malfunctions may occur, especially following a long service life of the vehicle or following a transmission oil change. Therefore, perform three calibrations of the hydrostatic unit in succession using the diagnosis tool. If the calibrations are successfully completed and no error occurs during a mandatory subsequent test drive, no further measures are required. The stepping motor has to be replaced and the fork on the hydrostatic unit needs to be checked for damage should the error occur again. If no measures are effective, an inspection of the hydrostatic unit should be performed.

Transmission alarm 149 Description Parking lock - engagement process aborted, first part, excessive path. Cause The engagement of the parking lock failed, an impermissible vehicle movement was diagnosed Correction This error occurs in conjunction with error TCU 236 (ECh), see description of error TCU 236 (ECh) for repair information

Transmission alarm 150 Description Parking lock - engagement process aborted, second part, excessive path. Cause The engagement of the parking lock failed, an impermissible vehicle movement was diagnosed. Correction This error occurs in conjunction with error TCU 236 (ECh), see description of error TCU 236 (ECh) for repair information.

Transmission alarm 151 Description Parking lock - engagement process aborted, first part, no pressure buildup. Cause The engagement of the parking lock failed, no hydrostatic high pressure was built up. Correction This error occurs in conjunction with error TCU 236 (ECh), see description of error TCU 236 (ECh) for repair information.

Transmission alarm 152 Description Parking lock - engagement process aborted, second part, no pressure buildup. Cause The engagement of the parking lock failed, no hydrostatic high pressure was built up. Correction This error occurs in conjunction with error TCU 236 (ECh), see description of error TCU 236 (ECh) for repair information.

20-354

Calibrations and electronic diagnosis Transmission alarm 153 Description Parking lock - inspection aborted, first part, excessive path. Cause The check for the proper engagement of the parking lock failed, an impermissible vehicle movement was diagnosed. Correction This error occurs in conjunction with error TCU 236 (ECh), see description of error TCU 236 (ECh) for repair information.

Transmission alarm 154 Description Parking lock - inspection aborted, second part, excessive path. Cause The check for the proper engagement of the parking lock failed, an impermissible vehicle movement was diagnosed. Correction This error occurs in conjunction with error TCU 236 (ECh), see description of error TCU 236 (ECh) for repair information.

Transmission alarm 155 Description Parking lock - inspection aborted, first part, no pressure buildup. Cause The check for the proper engagement of the parking lock failed, no hydrostatic high pressure was built up. Correction This error occurs in conjunction with error TCU 236 (ECh), see description of error TCU 236 (ECh) for repair information.

Transmission alarm 156 Description Parking lock - inspection aborted, second part, no pressure buildup. Cause The check for the proper engagement of the parking lock failed, no hydrostatic high pressure was built up. Correction This error occurs in conjunction with error TCU 236 (ECh), see description of error TCU 236 (ECh) for repair information.

Transmission alarm 157 Description Parking lock - check aborted, pressure buildup before neutral shift, excessive travel. Cause The check for the proper engagement of the parking lock failed. Correction This error occurs in conjunction with error TCU 236 (ECh), see description of error TCU 236 (ECh) for repair information.

Transmission alarm 160 (SDF S240 / SDF S180+) Description Calibration data HP sensors faulty; recalibration necessary. Cause With regard to the calibration data of the high pressure sensors an implausibility has been detected. This can have the following reasons: l l l l l

Not yet any valid calibration data in the TCU (e.g. after TCU exchange or faulty reprogramming of the TCU). An electric error of the HP sensors was detected (0x5C; 0x5D; 0x5E; 0x5F). Implausible values of both HP sensors have been detected (error 0xA1; both sensors show pressures> pSys). Implausible values between the measured high pressure values and the estimated high pressures have been detected. The automatic high pressure sensor calibration has determined a new preceding sign (e.g. after disassembly of the sensors).

20-355

Calibrations and electronic diagnosis Correction The cause of the faulty calibration data should be detected. 1. 2. 3. 4.

5.

Check the error memory for electric errors of the high pressure sensors (0x5C; 0x5D; 0x5E; 0x5F). If at least one of these errors can be found in the error memory, the elimination of these errors should be given priority. If an error occurred after replacing the TCU / reprogramming the TCU, calibration of the high pressure sensor should be carried out (see below). If an error occurred after disassembly of the HP sensors, calibration of the high pressure sensor should be carried out (see below). The high pressure sensor calibration is carried out as follows: m Start engine and bring direction of travel lever / transmission into N, engage parking lock / parking brake. m Put engine speed in idle position and wait approx. 2 min. m Preselect direction of travel (V or R). m Switch ignition OFF and wait approx. 10 s. After that error 0xAO should no longer occur. If the error reoccurs despite successful calibration, check the high pressure sensors using the diagnosis tool (in particular for implausible values). Exchange the high pressure sensors where necessary.

Fig. 533 - Wiring diagram TCU

20-356

Calibrations and electronic diagnosis Transmission alarm 161 (SDF S240 / SDF S180+) Description Plausibility check of the HP sensors compared to system pressure (both sensors provide pressures > pSys). Cause An implausibility was detected between the two high pressure sensors. Both sensors show pressures that are higher than the system pressure. Error 0xA0 is set as consequential error and the high pressure sensors are no longer used. With immediate effect the high pressure estimate is used for drive functions. This is more imprecise and can therefore lead to functional restrictions. Correction 1. 2.

High pressure sensors should be checked using the diagnosis tool. If a high pressure sensor has values considerably higher than 5 bar even when the engine is not running, this sensor must be exchanged. During normal operation only one high pressure sensor may have values higher than the system pressure. With a range shift of the transmission the high pressure side in the hydrostatic unit is also changed. Thanks to this information the defective high pressure sensor can be detected.

Fig. 533 - Wiring diagram TCU

20-357

Calibrations and electronic diagnosis Transmission alarm 170 Description Voltage supply hydrostatic unit electronics - short to plus. Cause The supply voltage is permanently applied to the hydrostatic unit electronics (HCU). The restriction of the traveling speed as well as the limiting of the engine speed take place as an error response. l l l

TCU has an internal defect. HCU has an internal defect. The transmission-internal wiring has a short to plus.

Correction The cause of the incorrect HCU supply should be located. 1. 2. 3. 4.

Dismantle the HCU and check the plug connection of the HCU for a defective connection (loose, bent, or corroded contacts) and damage. Dismantle the TCU and check plug connections A21/4 and A21/5 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. Ensure that plug connectors A21/4 and A21/5 are disconnected from the TCU. Using a voltmeter, measure the voltage between pins 6 and 7 on connector A23 whilst the ignition is ON. The transmission-internal wiring must be checked for a short to plus and, where necessary, replaced if voltage is applied between the pins. The TCU and/or the HCU should be replaced if no measure is effective on a sustained basis.

20-358

Calibrations and electronic diagnosis

Fig. 533 - Wiring diagram TCU

Transmission alarm 171 Description Voltage supply hydrostatic unit electronics - short circuit or short to ground. Cause A short to ground is diagnosed for the hydrostatic unit electronics (HCU) in the TCU. The restriction of the traveling speed as well as the limiting of the engine speed take place as an error response. l l l

TCU has an internal defect. HCU has an internal defect. The transmission-internal wiring is incorrect.

Correction The cause of the incorrect HCU supply should be located. 1. 2.

Dismantle the HCU and check the plug connection of the HCU for a defective connection (loose, bent, or corroded contacts) and damage. Dismantle the TCU and check plug connections A21/4 and A21/5 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. 20-359

Calibrations and electronic diagnosis 3.

Ensure that plug connectors A21/4 and A21/5 are connected to the TCU. Using a voltmeter, measure the voltage between pins 6 and 7 on connector A23 when the ignition is ON. The transmission-internal wiring should be checked for a short circuit or a short to ground and, where necessary, replaced if the measured voltage is more than 1 V below the vehicle power supply. The TCU and/or the HCU should be replaced if no measure is effective on a sustained basis.

4.

Fig. 533 - Wiring diagram TCU

Transmission alarm 176 Description Solenoid valve four wheel drive - interruption of control. Cause A line open circuit for the four wheel drive control solenoid valve is diagnosed in the TCU. l l l l

The plug connection belonging to the solenoid valve on the TCU is loose or has a poor contact. The solenoid valve has an internal defect. TCU has an internal defect. The transmission-internal wiring is damaged or interrupted.

Correction The cause of the faulty valve control should be located. 20-360

Calibrations and electronic diagnosis 1. 2. 3. 4.

Check the plug connection on the four wheel drive control solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage. Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 2.5 W. The solenoid valve should be replaced in the event of damage or resistance value deviations. Dismantle the TCU and check plug connection A21/5 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 534 - Solenoid valve four wheel drive

20-361

Calibrations and electronic diagnosis

Fig. 534 - Wiring diagram TCU

Transmission alarm 177 Description Four wheel drive solenoid valve – false PWM signal. Cause The PWM control of the four wheel drive control solenoid valve is faulty. l l

TCU has an internal defect. Transmission-internal wiring is damaged.

Correction 1. 2. 3.

If one of the errors TCU 178 (B2) or 179 (B3) is also active (short to plus / short to ground), the elimination of these errors should be given priority. Check the wiring of the four wheel valve to the TCU for a faulty connection (loose, bent, or corroded contacts) and damage. The TCU must be replaced if no measure is effective.

20-362

Calibrations and electronic diagnosis

Fig. 534 - Solenoid valve four wheel drive

20-363

Calibrations and electronic diagnosis

Fig. 534 - Wiring diagram TCU

Transmission alarm 178 Description Solenoid valve four wheel drive - short to plus. Cause A short to plus (supply voltage) for the four wheel drive control solenoid valve is diagnosed in the TCU. l l

Transmission-internal wiring is damaged. TCU has an internal defect.

Correction The cause of the faulty valve control should be located. 1. 2.

Check the plug connection on the four wheel drive control solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage. Dismantle the TCU and check plug connection A21/5 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage.

20-364

Calibrations and electronic diagnosis 3. 4.

Ensure that plug connection A21/5 is disconnected from the TCU. With the ignition switched ON, use a voltmeter to measure the voltage between both pins on the solenoid valve connector on the wiring harness side. The transmission-internal wiring must be checked for a short to plus and, where necessary, replaced if voltage is applied between the pins. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 534 - Solenoid valve four wheel drive

20-365

Calibrations and electronic diagnosis

Fig. 534 - Wiring diagram TCU

Transmission alarm 179 Description Solenoid valve four wheel drive - short circuit or short to ground. Cause A short circuit or a short to ground for the four wheel drive control solenoid valve is diagnosed in the TCU. l l l

Transmission-internal wiring is damaged. Solenoid valve has an internal defect. TCU has an internal defect.

Correction The cause of the faulty valve control should be located. 1. 2.

Check the plug connection on the four wheel drive control solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage. Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 2.5 Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations.

20-366

Calibrations and electronic diagnosis 3. 4.

Dismantle the TCU and check plug connection A21/5 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 534 - Solenoid valve four wheel drive

20-367

Calibrations and electronic diagnosis

Fig. 534 - Wiring diagram TCU

Transmission alarm 184 Description Solenoid valve clutch forward - interruption of control. Cause A line open circuit for the direction clutch forward solenoid valve is diagnosed in the TCU. The transmission is switched into neutral during forward travel as an error response. l l l l

The plug connection belonging to the solenoid valve on the TCU is loose or has a poor contact. Solenoid valve has an internal defect. TCU has an internal defect. Transmission-internal wiring is damaged or interrupted.

Correction The cause of the faulty valve control should be located. 1.

Check the plug connection on the direction clutch forward solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage.

20-368

Calibrations and electronic diagnosis 2. 3. 4.

Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 2.5 Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations. Dismantle the TCU and check plug connection A21/3 (see) as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 535 - Solenoid valve KV

20-369

Calibrations and electronic diagnosis

Fig. 535 - Wiring diagram TCU

Transmission alarm 185 Description Solenoid valve clutch forward - faulty PWM signal. Cause The PWM control of the direction clutch forward solenoid valve is incorrect. The transmission is switched into neutral during forward travel as an error response. l l

TCU has an internal defect. Transmission-internal wiring is damaged.

Correction 1. 2. 3.

If one of the errors TCU 186 (BAh) or 187 (BBh) is also active (short to plus / short to ground), the elimination of these errors should be given priority. Check the wiring of the solenoid valve to the TCU for a faulty connection (loose, bent, or corroded contacts) and damage. The TCU should be replaced if no measure is effective.

20-370

Calibrations and electronic diagnosis

Fig. 535 - Solenoid valve KV

20-371

Calibrations and electronic diagnosis

Fig. 535 - Wiring diagram TCU

Transmission alarm 186 Description Solenoid valve clutch forward - short to plus. Cause A short to plus (supply voltage) for the direction clutch forward solenoid valve is diagnosed in the TCU. The switch of the transmission to neutral and the deactivation of the valve output stage master switch takes place as an error response. l l

Transmission-internal wiring is damaged. TCU has an internal defect.

Correction The cause of the faulty valve control should be located. 1. 2.

Check the plug connection on the direction clutch forward solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage. Dismantle the TCU and check plug connection A21/3 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage.

20-372

Calibrations and electronic diagnosis 3. 4.

Ensure that plug connector A21/3 is disconnected from the TCU. With the ignition switched ON, use a voltmeter to measure the voltage between both pins on the solenoid valve connector on the wiring harness side. The transmission-internal wiring must be checked for a short to plus and, where necessary, replaced if voltage is applied between the pins. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 535 - Solenoid valve KV

20-373

Calibrations and electronic diagnosis

Fig. 535 - Wiring diagram TCU

Transmission alarm 187 Description Solenoid valve clutch forward - short circuit or short to ground. Cause A short circuit or a short to ground for the direction clutch forward solenoid valve is diagnosed in the TCU. The transmission is switched into neutral during forward travel as an error response. l l l

Transmission-internal wiring is damaged. Solenoid valve has an internal defect. TCU has an internal defect.

Correction The cause of the faulty valve control should be located. 1.

Check the plug connection on the direction clutch forward solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage.

20-374

Calibrations and electronic diagnosis 2. 3. 4.

Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 2.5 Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations. Dismantle the TCU and check plug connection A21/3 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 535 - Solenoid valve KV

20-375

Calibrations and electronic diagnosis

Fig. 535 - Wiring diagram TCU

Transmission alarm 188 Description Solenoid valve clutch forward - clutch does not open. Cause The clutch does not open although the direction clutch forward solenoid valve is not actuated by the TCU. The transmission is switched into neutral as an error response. l l l

Short-term clutch malfunction. The hydraulic section of the solenoid valve is defective. Clutch defect.

l

Correction The cause of the faulty clutch control should be located. 1.

If one of the errors TCU 184 (B8h) to 187 (BBh) is also active (electric error), the elimination of these errors should be given priority.

20-376

Calibrations and electronic diagnosis 2.

3.

Keep in mind that additional TCU errors (line open circuit errors) occur in the following step due to the disassembly of the connectors; these are not relevant with regard to troubleshooting and should be deleted following repair. Dismantle the connector from the direction clutch forward solenoid valve. Connect a manometer to the designated „KV“ measuring connection and check the pressure with the engine running. The solenoid valve should be replaced if pressure is measured on the measuring point. Keep possible consequential damage to the dog clutches in mind. An inspection of the shifting drum - particularly that belonging to clutch forward - for mechanical damage should be performed. If no pressure is measurable check clutch KV for mechanical damage.

Fig. 535 - Solenoid valve KV

20-377

Calibrations and electronic diagnosis

Fig. 535 - Wiring diagram TCU

Transmission alarm 189 Description Solenoid valve clutch forward - clutch does not close Cause The clutch does not close although the direction clutch forward solenoid valve is not actuated by the TCU. The transmission is switched into neutral during forward travel as an error response. l l l

Short-term clutch malfunction. The hydraulic section of the solenoid valve is defective. Clutch defect.

Correction The cause of the faulty clutch control should be located. 1.

If one of the errors TCU 184 (B8h) to 187 (BBh) is also active (electric error), the elimination of these errors should be given priority.

20-378

Calibrations and electronic diagnosis 2. 3.

Assemble a manometer on the designated „KV“ measuring connection and check the pressure when the engine is running (selected direction of travel is forward) . The solenoid valve direction clutch forward should be replaced if no pressure is measured on the measuring point. Keep possible consequential damage to the dog clutch in mind. If no measures are effective, an inspection of the shifting drum - particularly that belonging to clutch forward - for leakages should be performed.

Fig. 535 - Solenoid valve KV

20-379

Calibrations and electronic diagnosis

Fig. 535 - Wiring diagram TCU

Transmission alarm 190 Description Solenoid valve clutch forward - differential speed too high, clutch slipping. Cause The clutch unintentionally opens although the direction clutch forward solenoid valve is not actuated by the TCU (clutch was already closed). The transmission is switched into neutral during forward travel as an error response. l l l

Short-term clutch malfunction. The hydraulic section of the solenoid valve is defective. Clutch defect.

Correction The cause of the faulty clutch control should be located. 1. 2. 3.

If one of the errors TCU 184 (B8h) to 187 (BBh) is also active (electric error), the elimination of these errors is given priority. Replace the direction clutch forward solenoid valve. Keep possible consequential damage to the dog clutches in mind. If no measures are effective, an inspection of the shifting drum - particularly that belonging to clutch forward - for leakages should be performed.

20-380

Calibrations and electronic diagnosis

Fig. 535 - Solenoid valve KV

20-381

Calibrations and electronic diagnosis

Fig. 535 - Wiring diagram TCU

Transmission alarm 192 Description Solenoid valve clutch reverse - interruption of the control. Cause A line open circuit for the direction clutch reverse solenoid valve is diagnosed in the TCU. The transmission is switched into neutral during reverse travel as an error response. l l l l

The plug connection belonging to the solenoid valve on the TCU is loose or has a poor contact. Solenoid valve has an internal defect. TCU has an internal defect. Transmission-internal wiring is damaged or interrupted.

Correction The cause of the faulty valve control should be located. 1.

Check the plug connection on the direction clutch reverse solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage.

20-382

Calibrations and electronic diagnosis 2. 3. 4.

Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 2.5 Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations. Dismantle the TCU and check plug connection A21/3 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 536 - Solenoid valve KR

20-383

Calibrations and electronic diagnosis

Fig. 536 - Wiring diagram TCU

Transmission alarm 193 Description Solenoid valve clutch reverse - faulty PWM signal. Cause The PWM control of the direction clutch reverse solenoid valve is false. The transmission is switched into neutral during reverse travel as an error response. l l

TCU has an internal defect. Transmission-internal wiring is damaged.

Correction 1. 2. 3.

If one of the errors TCU 194 (C2h) or 195 (C3h) is also active (short to plus / short to ground), the elimination of these errors should be given priority. Check the wiring of the solenoid valve to the TCU for a faulty connection (loose, bent, or corroded contacts) and damage. The TCU should be replaced if no measure is effective.

20-384

Calibrations and electronic diagnosis

Fig. 536 - Solenoid valve KR

20-385

Calibrations and electronic diagnosis

Fig. 536 - Wiring diagram TCU

Transmission alarm 194 Description Solenoid valve clutch reverse - short to plus. Cause A short to plus (supply voltage) for the direction clutch reverse solenoid valve is diagnosed in the TCU. The switch of the transmission to neutral and the deactivation of the valve output stage master switch takes place as an error response. l l

Transmission-internal wiring is damaged. TCU has an internal defect.

Correction The cause of the faulty valve control should be located. 1. 2.

Check the plug connection on the direction clutch reverse solenoid valve (see installation drawing solenoid valve clutch reverse) for a faulty connection (loose, bent, or corroded contacts) and damage Dismantle the TCU (see installation drawing TCU) and check plug connections A21/3 (see TCU pin assignment) as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage.

20-386

Calibrations and electronic diagnosis 3. 4.

Ensure that plug connector A21/3 is disconnected from the TCU. With the ignition switched ON, use a voltmeter to measure the voltage between both pins on the solenoid valve connector on the wiring harness side. The transmission-internal wiring must be checked for a short to plus and, where necessary, replaced if voltage is applied between the pins. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 536 - Solenoid valve KR

20-387

Calibrations and electronic diagnosis

Fig. 536 - Wiring diagram TCU

Transmission alarm 195 Description Solenoid valve clutch reverse - short circuit or short to ground. Cause A short circuit or a short to ground for the direction clutch reverse solenoid valve is diagnosed in the TCU. The transmission is switched into neutral during reverse travel as an error response. l l l

Transmission-internal wiring is damaged. Solenoid valve has an internal defect. TCU has an internal defect.

Correction The cause of the faulty valve control should be located. 1.

Check the plug connection on the direction clutch reverse solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage.

20-388

Calibrations and electronic diagnosis 2. 3. 4.

Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 2.5 Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations. Dismantle the TCU and check plug connection A21/3 (see) as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 536 - Solenoid valve KR

20-389

Calibrations and electronic diagnosis

Fig. 536 - Wiring diagram TCU

Transmission alarm 196 Description Clutch reverse solenoid valve – clutch does not open. Cause The clutch does not open although the direction clutch reverse solenoid valve is not actuated by the TCU. The transmission is switched into neutral as an error response. l l l

Short-term clutch malfunction. The hydraulic section of the solenoid valve is defective. Clutch defect.

Correction The cause of the faulty clutch control should be located. 1.

If one of the errors TCU 192 (C0h) to 195 (C3h) is also active (electric errors), the elimination of these errors should be given priority.

20-390

Calibrations and electronic diagnosis 2.

3.

Keep in mind that additional TCU errors (line open circuit errors) occur in the following step due to the disassembly of the connectors; these are not relevant with regard to troubleshooting and should be deleted following repair. Dismantle the connector from the direction clutch reverse solenoid valve. Assemble a manometer on the designated „KR“ measuring connection and check the pressure when the engine is running. The solenoid valve should be replaced if pressure is measured on the measuring point. Keep possible consequential damage to the dog clutch in mind. An inspection of the shifting drum - particularly that belonging to clutch reverse - for mechanical damage should be performed. If no pressure is measurable check clutch KR for mechanical damage

Fig. 536 - Solenoid valve KR

20-391

Calibrations and electronic diagnosis

Fig. 536 - Wiring diagram TCU

Transmission alarm 197 Description Clutch reverse solenoid valve – clutch does not close. Cause The clutch does not close although the direction clutch reverse solenoid valve is not actuated by the TCU. The transmission is switched into neutral during reverse travel as an error response. l l l

Short-term clutch malfunction. The hydraulic section of the solenoid valve is defective. Clutch defect.

Correction The cause of the faulty clutch control should be located. 1.

If one of the errors TCU 192 (C0h) to 195 (C3h) is also active (electric errors), the elimination of these errors should be given priority.

20-392

Calibrations and electronic diagnosis 2. 3.

Assemble a manometer on the designated „KR“ measuring connection and check the pressure when the engine is running (the selected direction of travel is reverse). The solenoid valve direction clutch reverse should be replaced if no pressure is measured on the measuring point. Keep possible consequential damage to the dog clutches in mind. If no measures are effective, an inspection of the shifting drum - particularly that belonging to clutch reverse - for leakages should be performed.

Fig. 536 - Solenoid valve KR

20-393

Calibrations and electronic diagnosis

Fig. 536 - Wiring diagram TCU

Transmission alarm 198 Description Solenoid valve clutch reverse - differential speed too high, clutch slipping. Cause The clutch unintentionally opens although the direction clutch reverse solenoid valve is not actuated by the TCU (clutch was already closed). The transmission is switched into neutral during reverse travel as an error response. l l l

Short-term clutch malfunction. The hydraulic section of the solenoid valve is defective. Clutch defect.

Correction The cause of the faulty clutch control should be located. 1. 2.

If one of the errors TCU 192 (C0h) to 195 (C3h) is also active (electric errors), the elimination of these errors should be given priority. Replace the direction clutch reverse solenoid valve. Keep possible consequential damage to the dog clutches in mind.

20-394

Calibrations and electronic diagnosis 3.

If no measures are effective, an inspection of the shifting drum - particularly that belonging to clutch reverse - for leakages should be performed.

Fig. 536 - Solenoid valve KR

20-395

Calibrations and electronic diagnosis

Fig. 536 - Wiring diagram TCU

Transmission alarm 200 Description Solenoid valve clutch 1 - interruption of control Cause A line open circuit for the range clutch 1 solenoid valve is diagnosed in the TCU. The transmission is switched into neutral as an error response. l l l l

The plug connection belonging to the solenoid valve on the TCU is loose or has a poor contact. Solenoid valve has an internal defect. TCU has an internal defect. Transmission-internal wiring is damaged or interrupted.

Correction The cause of the faulty valve control should be located. 1.

Check the plug connection on the range clutch 1 solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage.

20-396

Calibrations and electronic diagnosis 2. 3. 4.

Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 2.5 Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations. Dismantle the TCU and check plug connection A21/3 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 537 - Solenoid valve K1

20-397

Calibrations and electronic diagnosis

Fig. 537 - Wiring diagram TCU

Transmission alarm 201 Description Solenoid valve clutch 1 - faulty signal PWM Cause The PWM control of the range clutch 1 solenoid valve is incorrect. The transmission is switched into neutral as an error response. l l

TCU has an internal defect. The transmission-internal wiring is damaged.

Correction 1. 2. 3.

If one of the errors TCU 202 (CAh) or 203 (CBh) is also active (short to plus / short to ground), the elimination of these errors should be given priority. Check the wiring of the solenoid valve to the TCU for a faulty connection (loose, bent, or corroded contacts) and damage. The TCU should be replaced if no measure is effective.

20-398

Calibrations and electronic diagnosis

Fig. 537 - Solenoid valve K1

20-399

Calibrations and electronic diagnosis

Fig. 537 - Wiring diagram TCU

Transmission alarm 202 Description Solenoid valve clutch 1 - short to plus. Cause A short to plus (supply voltage) for the range clutch 1 solenoid valve is diagnosed in the TCU. The switch of the transmission to neutral and the deactivation of the valve output stage master switch takes place as an error response. l l

Transmission-internal wiring is damaged. TCU has an internal defect.

Correction The cause of the faulty valve control should be located 1. 2.

Check the plug connection on the range clutch 1 solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage. Dismantle the TCU and check plug connection A21/3 (see) as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage.

20-400

Calibrations and electronic diagnosis 3. 4.

Ensure that plug connector A21/3 is disconnected from the TCU. With the ignition switched ON, use a voltmeter to measure the voltage between both pins on the solenoid valve connector on the wiring harness side. The transmission-internal wiring must be checked for a short to plus and, where necessary, replaced if voltage is applied between the pins. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 537 - Solenoid valve K1

20-401

Calibrations and electronic diagnosis

Fig. 537 - Wiring diagram TCU

Transmission alarm 203 Description Solenoid valve clutch 1 - short circuit or short to ground. Cause A short circuit or a short to ground for the range clutch 1 solenoid valve is diagnosed in the TCU. The transmission is switched into neutral as an error response. l l l

Transmission-internal wiring is damaged. Solenoid valve has an internal defect. TCU has an internal defect.

Correction The cause of the faulty valve control should be located. 1.

Check the plug connection on the range clutch 1 solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage.

20-402

Calibrations and electronic diagnosis 2. 3. 4.

Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 2.5 Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations. Dismantle the TCU and check plug connection A21/3 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 537 - Solenoid valve K1

20-403

Calibrations and electronic diagnosis

Fig. 537 - Wiring diagram TCU

Transmission alarm 204 Description Clutch 1 solenoid valve – clutch does not open. Cause The clutch does not open although the range clutch 1 solenoid valve is not actuated by the TCU. The transmission is switched into neutral as an error response. l l l

Short-term clutch malfunction. The hydraulic section of the solenoid valve is defective. Clutch defect.

Correction The cause of the faulty clutch control should be located. 1.

If one of the errors TCU 200 (C8h) to 203 (CBh) is also active (electric error), the elimination of these errors should be given priority.

20-404

Calibrations and electronic diagnosis 2.

Keep in mind that additional TCU errors (line open circuit error) occur in the following step due to the disassembly of the connectors; these are not relevant with regard to troubleshooting and should be deleted following repair. Dismantle the connector from the range clutch 1 solenoid valve. Assemble a manometer on the designated „K1“ measuring connection and check the pressure when the engine is running. The solenoid valve should be replaced if pressure is measured on the measuring point. Keep possible consequential damage to the dog clutches in mind. An inspection of the shifting drum - particularly that belonging to clutch 1 - for mechanical damage must be performed. If no pressure is measurable check clutch K1 for mechanical damage.

3.

Fig. 537 - Solenoid valve K1

Transmission alarm 205 Description Clutch 1 solenoid valve – clutch does not close. Cause The clutch does not close although the range clutch 1 solenoid valve is not actuated by the TCU. The transmission is switched into neutral as an error response. l l l

Short-term clutch malfunction. The hydraulic section of the solenoid valve is defective. Clutch defect.

Correction The cause of the faulty clutch control should be located. 1. 2. 3.

If one of the errors TCU 200 (C8h) to 203 (CBh) is also active (electric error), the elimination of these errors should be given priority. Assemble a manometer on the designated „K1“ measuring connection and check the pressure when the engine is running (the selected direction of travel is forward or reverse). The solenoid valve range clutch 1 should be replaced if no pressure is measured on the measuring point. Keep possible consequential damage to the dog clutches in mind. If no measures are effective, an inspection of the shifting drum - particularly that belonging to clutch 1 - for leakages must be performed.

20-405

Calibrations and electronic diagnosis

Fig. 537 - Solenoid valve K1

Transmission alarm 206 Description Solenoid valve clutch 1 - differential speed too high, clutch slipping. Cause The clutch unintentionally opens although the range clutch 1 solenoid valve is not actuated by the TCU (clutch was already closed). The transmission is switched into neutral as an error response. l l l

Short-term clutch malfunction. The hydraulic section of the solenoid valve is defective. Clutch defect.

Correction The cause of the faulty clutch control should be located. 1. 2. 3.

If one of the errors TCU 200 (C8h) to 203 (CBh) is also active (electric errors), the elimination of these errors should be given priority. Replace range clutch 1 solenoid valve. Keep possible consequential damage to the dog clutches in mind. If no measures are effective, an inspection of the shifting drum - particularly that belonging to clutch 1 - for leakages must be performed.

20-406

Calibrations and electronic diagnosis

Fig. 537 - Solenoid valve K1

Transmission alarm 208 Description Solenoid valve clutch 2 - interruption of control. Cause A line open circuit for the range clutch 2 solenoid valve is diagnosed in the TCU. The restriction to the first speed range takes place as an error response. l l l l

The plug connection belonging to the solenoid valve on the TCU is loose or has a poor contact. Solenoid valve has an internal defect. TCU has an internal defect. Transmission-internal wiring is damaged or interrupted.

Correction The cause of the faulty valve control should be located. 1. 2. 3. 4.

Check the plug connection on the range clutch 2 solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage. Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 2.5 Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations. Dismantle the TCU and check plug connection A21/3 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

20-407

Calibrations and electronic diagnosis

Fig. 538 - Solenoid valve K2

20-408

Calibrations and electronic diagnosis

Fig. 538 - Wiring diagram TCU

Transmission alarm 209 Description Solenoid valve clutch 2 - faulty signal PWM. Cause The PWM control of the range clutch 2 solenoid valve is incorrect. The restriction to the first speed range takes place as an error response. l l

TCU has an internal defect. Transmission-internal wiring is damaged.

Correction 1. 2. 3.

If one of the errors TCU 210 (D2h) or 211 (D3h) is also active (short to plus / short to ground), the elimination of these errors should be given priority. Check the wiring of the solenoid valve to the TCU for a faulty connection (loose, bent, or corroded contacts) and damage. The TCU should be replaced if no measure is effective.

20-409

Calibrations and electronic diagnosis

Fig. 538 - Solenoid valve K2

20-410

Calibrations and electronic diagnosis

Fig. 538 - Wiring diagram TCU

Transmission alarm 210 Description Solenoid valve clutch 2 - short to plus. Cause A short to plus (supply voltage) for the range clutch 2 solenoid valve is diagnosed in the TCU. The switch of the transmission to neutral and the deactivation of the valve output stage master switch takes place as an error response. l l

Transmission-internal wiring is damaged. TCU has an internal defect.

Correction The cause of the faulty valve control should be located. 1. 2.

Check the plug connection on the range clutch 2 solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage. Dismantle the TCU and check plug connection A21/3 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage.

20-411

Calibrations and electronic diagnosis 3. 4.

Ensure that plug connector A21/3 is disconnected from the TCU. With the ignition switched ON, use a voltmeter to measure the voltage between both pins on the solenoid valve connector on the wiring harness side. The transmission-internal wiring must be checked for a short to plus and, where necessary, replaced if voltage is applied between the pins. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 538 - Solenoid valve K2

20-412

Calibrations and electronic diagnosis

Fig. 538 - Wiring diagram TCU

Transmission alarm 211 Description Solenoid valve clutch 2 - short circuit or short to ground. Cause A short circuit or a short to ground for the range clutch 2 solenoid valve is diagnosed in the TCU. The restriction to the first speed range takes place as an error response. l l l

Transmission-internal wiring is damaged. Solenoid valve has an internal defect. TCU has an internal defect.

Correction The cause of the faulty valve control should be located. 1.

Check the plug connection on the range clutch 2 solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage.

20-413

Calibrations and electronic diagnosis 2. 3. 4.

Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 2.5 Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations. Dismantle the TCU and check plug connection A21/3 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 538 - Solenoid valve K2

20-414

Calibrations and electronic diagnosis

Fig. 538 - Wiring diagram TCU

Transmission alarm 212 Description Clutch 2 solenoid valve – clutch does not open. Cause The clutch does not open although the range clutch 2 solenoid valve is not actuated by the TCU. The transmission is switched into neutral as an error response. l l l

Short-term clutch malfunction. The hydraulic section of the solenoid valve is defective. Clutch defect.

Correction The cause of the faulty clutch control should be located. 1.

If one of the errors TCU 208 (C0h) to 211 (C3h) is also active (electric errors), the elimination of these errors should be given priority.

20-415

Calibrations and electronic diagnosis 2.

Keep in mind that additional TCU errors (line open circuit error) occur in the following step due to the disassembly of the connectors; these are not relevant with regard to troubleshooting and should be deleted following repair! Disassemble the connector from the range clutch 2 solenoid valve. Connect a manometer to the designated „K2“ measuring connection and check the pressure when the engine is running. The solenoid valve should be replaced if pressure is measured on the measuring point. Keep possible consequential damage to the dog clutches in mind. An inspection of the shifting drum - particularly that belonging to clutch 2 - for mechanical damage should be performed. If no pressure is measurable check clutch K2 for mechanical damage.

3.

Fig. 538 - Solenoid valve K2

Transmission alarm 213 Description Clutch 2 solenoid valve – clutch does not close. Cause The clutch does not close although the range clutch 2 solenoid valve is not actuated by the TCU. The restriction to the first speed range takes place as an error response. l l l

Short-term clutch malfunction. The hydraulic section of the solenoid valve is defective. Clutch defect.

Correction The cause of the faulty clutch control should be located. 1. 2. 3.

If one of the errors TCU 208 (C0h) to 211 (C3h) is also active (electric errors), the elimination of these errors should be given priority. Connect a manometer to the designated „K2“ measuring connection and check the pressure when the engine is running (driving forward in the range K2). The solenoid valve range clutch 2 should be replaced if no pressure is measured on the measuring point. Keep possible consequential damage to the dog clutches in mind. If no measures are effective, an inspection of the shifting drum - particularly that belonging to clutch 2 - for leakages should be performed.

20-416

Calibrations and electronic diagnosis

Fig. 538 - Solenoid valve K2

Transmission alarm 214 Description Solenoid valve clutch 2 - differential speed too high, clutch slipping. Cause The clutch unintentionally opens although the range clutch 2 solenoid valve is not actuated by the TCU (clutch was already closed). The restriction to the first speed range takes place as an error response. l l l

Short-term clutch malfunction. The hydraulic section of the solenoid valve is defective. Clutch defect.

Correction The cause of the faulty clutch control should be located. 1. 2. 3.

If one of the errors TCU 208 (C0h) to 211 (C3h) is also active (electric errors), the elimination of these errors should be given priority. Replace range clutch 2 solenoid valve. Keep possible consequential damage to the dog clutches in mind. If no measures are effective, an inspection of the shifting drum - particularly that belonging to clutch 2 - for leakages should be performed.

20-417

Calibrations and electronic diagnosis

Fig. 538 - Solenoid valve K2

Transmission alarm 216 Description Solenoid valve clutch 3 - interruption of control. Cause A line open circuit for the range clutch 3 solenoid valve is diagnosed in the TCU. The restriction to the first two speed ranges takes place as an error response. l l l l

The plug connection belonging to the solenoid valve on the TCU is loose or has a poor contact. Solenoid valve has an internal defect. TCU has an internal defect. Transmission-internal wiring is damaged or interrupted.

Correction The cause of the faulty valve control should be located. 1. 2. 3. 4.

Check the plug connection on the range clutch 3 solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage. Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 2.5 Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations. Dismantle the TCU and check plug connection A21/3 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

20-418

Calibrations and electronic diagnosis

Fig. 539 - Solenoid valve K3

20-419

Calibrations and electronic diagnosis

Fig. 539 - Wiring diagram TCU

Transmission alarm 217 Description Solenoid valve clutch 3 - faulty signal PWM. Cause The PWM control of the range clutch 3 solenoid valve is incorrect. The restriction to the first two speed ranges takes place as an error response. l l

TCU has an internal defect. Transmission-internal wiring is damaged.

Correction 1. 2. 3.

If one of the errors TCU 218 (DAh) or 219 (DBh) is also active (short to plus / short to ground), the elimination of these errors should be given priority. Check the wiring of the solenoid valve to the TCU for a faulty connection (loose, bent, or corroded contacts) and damage. The TCU must be replaced if no measure is effective.

20-420

Calibrations and electronic diagnosis

Fig. 539 - Solenoid valve K3

20-421

Calibrations and electronic diagnosis

Fig. 539 - Wiring diagram TCU

Transmission alarm 218 Description Solenoid valve clutch 3 - short to plus. Cause A short to plus (supply voltage) for the range clutch 3 solenoid valve is diagnosed in the TCU. The switch of the transmission to neutral and the deactivation of the valve output stage master switch takes place as an error response. l l

Transmission-internal wiring is damaged. TCU has an internal defect.

Correction The cause of the faulty valve control should be located. 1. 2.

Check the plug connection on the range clutch 3 solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage. Dismantle the TCU and check plug connection A21/3 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage.

20-422

Calibrations and electronic diagnosis 3. 4.

Ensure that plug connector A21/3 is disconnected from the TCU. With the ignition switched ON, use a voltmeter to measure the voltage between both pins on the solenoid valve connector on the wiring harness side. The transmission-internal wiring must be checked for a short to plus and, where necessary, replaced if voltage is applied between the pins. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 539 - Solenoid valve K3

20-423

Calibrations and electronic diagnosis

Fig. 539 - Wiring diagram TCU

Transmission alarm 219 Description Solenoid valve clutch 3 - short circuit or short to ground. Cause A short circuit or a short to ground for the range clutch 3 solenoid valve is diagnosed in the TCU. The restriction to the first two speed ranges takes place as an error response. l l l

Transmission-internal wiring is damaged. Solenoid valve has an internal defect. TCU has an internal defect.

Correction The cause of the faulty valve control should be located. 1.

Check the plug connection on the range clutch 3 solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage.

20-424

Calibrations and electronic diagnosis 2. 3. 4.

Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 2.5 Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations. Dismantle the TCU and check plug connection A21/3 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 539 - Solenoid valve K3

20-425

Calibrations and electronic diagnosis

Fig. 539 - Wiring diagram TCU

Transmission alarm 220 Description Clutch 3 solenoid valve – clutch does not open. Cause The clutch does not open although the range clutch 3 solenoid valve is not actuated by the TCU. The transmission is switched into neutral as an error response. l l l

Short-term clutch malfunction. The hydraulic section of the solenoid valve is defective. Clutch defect.

l

Correction The cause of the faulty clutch control should be located. 1.

If one of the errors TCU 216 (D8h) to 219 (DBh) is also active (electric errors), the elimination of these errors should be given priority.

20-426

Calibrations and electronic diagnosis 2.

Keep in mind that additional TCU errors (line open circuit error) occur in the following step due to the disassembly of the connectors; these are not relevant with regard to troubleshooting and should be deleted following repair. Dismantle the connector from the range clutch 3 solenoid valve. Assemble a manometer on the designated „K3“ measuring connection and check the pressure when the engine is running. The solenoid valve should be replaced if pressure is measured on the measuring point. Keep possible consequential damage to the dog clutches in mind. An inspection of the shifting drum - particularly that belonging to clutch 3 - for mechanical damage should be performed. If no pressure is measurable check clutch K3 for mechanical damage.

3.

Fig. 539 - Solenoid valve K3

Transmission alarm 221 Description Clutch 3 solenoid valve – clutch does not close. Cause The clutch does not close although the range clutch 3 solenoid valve is not actuated by the TCU. The restriction to the first two speed ranges takes place as an error response. l l l

Short-term clutch malfunction. The hydraulic section of the solenoid valve is defective. Clutch defect.

Correction The cause of the faulty clutch control should be located. 1. 2. 3.

If one of the errors TCU 216 (D8h) to 219 (DBh) is also active (electric errors), the elimination of these errors should be given priority. Connect a manometer to the designated „K3“ measuring connection and check the pressure when the engine is running (driving forward in the range K3). The solenoid valve range clutch 3 should be replaced if no pressure is measured on the measuring point. Keep possible consequential damage to the dog clutches in mind. If no measures are effective, an inspection of the shifting drum - particularly that belonging to clutch 3 - for leakages should be performed.

20-427

Calibrations and electronic diagnosis

Fig. 539 - Solenoid valve K3

Transmission alarm 222 Description Solenoid valve clutch 3 - differential speed too high, clutch slipping. Cause The clutch unintentionally opens although the range clutch 3 solenoid valve is not actuated by the TCU (clutch was already closed). The restriction to the first two speed ranges takes place as an error response. l l l

Short-term clutch malfunction. The hydraulic section of the solenoid valve is defective. Clutch defect.

Correction The cause of the faulty clutch control should be located. 1. 2. 3.

If one of the errors TCU 216 (D8h) to 219 (DBh) is also active (electric errors), the elimination of these errors should be given priority. Replace range clutch 3 solenoid valve. Keep possible consequential damage to the dog clutches in mind. If no measures are effective, an inspection of the shifting drum - particularly that belonging to clutch 3 - for leakages should be performed.

20-428

Calibrations and electronic diagnosis

Fig. 539 - Solenoid valve K3

Transmission alarm 224 Description Solenoid valve clutch 4 - interruption of control. Cause A line open circuit for the range clutch 4 solenoid valve is diagnosed in the TCU. The restriction to the first three speed ranges takes place as an error response. l l l l

The plug connection belonging to the solenoid valve on the TCU is loose or has a poor contact. Solenoid valve has an internal defect. TCU has an internal defect. Transmission-internal wiring is damaged or interrupted.

Correction The cause of the faulty valve control should be located. 1. 2. 3. 4.

Check the plug connection on the range clutch 4 solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage. Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 2.5Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations. Dismantle the TCU and check plug connection A21/3 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

20-429

Calibrations and electronic diagnosis

Fig. 540 - Solenoid valve K4

20-430

Calibrations and electronic diagnosis

Fig. 540 - Wiring diagram TCU

Transmission alarm 225 Description Solenoid valve clutch 4 - faulty signal PWM. Cause The PWM control of the range clutch 4 solenoid valve is incorrect. The restriction to the first three speed ranges takes place as an error response. l l

TCU has an internal defect. Transmission-internal wiring is damaged.

Correction 1. 2. 3.

If one of the errors TCU 226 (E2h) or 227 (E3h) is also active (short to plus / short to ground), the elimination of these errors should be given priority. Check the wiring of the solenoid valve to the TCU for a faulty connection (loose, bent, or corroded contacts) and damage. The TCU should be replaced if no measure is effective.

20-431

Calibrations and electronic diagnosis

Fig. 540 - Solenoid valve K4

20-432

Calibrations and electronic diagnosis

Fig. 540 - Wiring diagram TCU

Transmission alarm 226 Description Solenoid valve clutch 4 - short to plus. Cause A short to plus (supply voltage) for the range clutch 4 solenoid valve is diagnosed in the TCU. The switch of the transmission to neutral and the deactivation of the valve output stage master switch takes place as an error response. l l

Transmission-internal wiring is damaged. TCU has an internal defect.

Correction The cause of the faulty valve control should be located. 1. 2.

Check the plug connection on the range clutch 4 solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage. Dismantle the TCU and check plug connection A21/3 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage.

20-433

Calibrations and electronic diagnosis 3. 4.

Ensure that plug connector A21/3 is disconnected from the TCU. With the ignition switched ON, use a voltmeter to measure the voltage between both pins on the solenoid valve connector on the wiring harness side. The transmission-internal wiring must be checked for a short to plus and, where necessary, replaced if voltage is applied between the pins. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 540 - Solenoid valve K4

20-434

Calibrations and electronic diagnosis

Fig. 540 - Wiring diagram TCU

Transmission alarm 227 Description Solenoid valve clutch 4 - short circuit or short to ground. Cause A short circuit or a short to ground for the range clutch 4 solenoid valve is diagnosed in the TCU. The restriction to the first three speed ranges takes place as an error response. l l l

Transmission-internal wiring is damaged. Solenoid valve has an internal defect. TCU has an internal defect.

Correction The cause of the faulty valve control should be located. 1.

Check the plug connection on the range clutch 4 solenoid valve for a faulty connection (loose, bent, or corroded contacts) and damage.

20-435

Calibrations and electronic diagnosis 2. 3. 4.

Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 2.5 Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations. Dismantle the TCU and check plug connection A21/3 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 540 - Solenoid valve K4

20-436

Calibrations and electronic diagnosis

Fig. 540 - Wiring diagram TCU

Transmission alarm 228 Description Clutch 4 solenoid valve – clutch does not open. Cause The clutch does not open although the range clutch 4 solenoid valve is not actuated by the TCU. The transmission is switched into neutral as an error response. l l l

Short-term clutch malfunction. The hydraulic section of the solenoid valve is defective. Clutch defect.

Correction The cause of the faulty clutch control should be located. 1.

If one of the errors TCU 224 (E0h) to 227 (E3h) is also active (electric error), the elimination of these errors should be given priority.

20-437

Calibrations and electronic diagnosis 2.

Keep in mind that additional TCU errors (line open circuit error) occur in the following step due to the disassembly of the connectors; these are not relevant with regard to troubleshooting and should be deleted following repair! Dismantle the connector from the range clutch 4 solenoid valve. Assemble a manometer on the designated „K4“ measuring connection and check the pressure with the engine running. The solenoid valve should be replaced if pressure is measured on the measuring point. Keep possible consequential damage to the dog clutches in mind. An inspection of the shifting drum - particularly that belonging to clutch 4 - for mechanical damage should be performed. If no pressure is measurable check clutch K4 for mechanical damage.

3.

Fig. 540 - Solenoid valve K4

Transmission alarm 229 Description Clutch 4 solenoid valve – clutch does not close. Cause The clutch does not close although the range clutch 4 solenoid valve is not actuated by the TCU. The restriction to the first three speed ranges takes place as an error response. l l l

Short-term clutch malfunction. The hydraulic section of the solenoid valve is defective. Clutch defect.

Correction The cause of the faulty clutch control should be located. 1. 2. 3.

If one of the errors TCU 224 (E0h) to 227 (E3h) is also active (electric errors), the elimination of these errors should be given priority. Connect a manometer to the designated „K4“ measuring connection and check the pressure when the engine is running (driving forward in the range K4). The solenoid valve range clutch 4 should be replaced if no pressure is measured on the measuring point. Keep possible consequential damage to the dog clutches in mind. If no measures are effective, an inspection of the shifting drum - particularly that belonging to clutch 4 - for leakages must be performed.

20-438

Calibrations and electronic diagnosis

Fig. 540 - Solenoid valve K4

Transmission alarm 230 Description Solenoid valve clutch 4 - differential speed too high, clutch slipping Cause The clutch unintentionally opens although the range clutch 4 solenoid valve is not actuated by the TCU (clutch was already closed). The restriction to the first three speed ranges takes place as an error response. l l l

Short-term clutch malfunction. The hydraulic section of the solenoid valve is defective. Clutch defect.

Correction The cause of the faulty clutch control should be located. 1. 2. 3.

If one of the errors TCU 224 (E0h) to 227 (E3h) is also active (electric errors), the elimination of these errors should be given priority. Replace range clutch 4 solenoid valve. Keep possible consequential damage to the dog clutches in mind. If no measures are effective, an inspection of the shifting drum - particularly that belonging to clutch 4 - for leakages must be performed

20-439

Calibrations and electronic diagnosis

Fig. 540 - Solenoid valve K4

Transmission alarm 232 Description Solenoid valve parking lock ON - interruption of control. Cause A line open circuit for the solenoid valve for engaging the parking lock is diagnosed in the TCU. l l l l

The plug connection belonging to the solenoid valve on the TCU is loose or has a poor contact. Solenoid valve has an internal defect. TCU has an internal defect. The wiring is damaged or interrupted.

Correction The cause of the faulty valve control should be located. 1. 2. 3. 4.

Check the plug connection on the solenoid valve for the engagement of the parking lock for a faulty connection (loose, bent, or corroded contacts) and damage. Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 2.5 Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations. Dismantle the TCU and check plug connection A21/5 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

20-440

Calibrations and electronic diagnosis

Fig. 541 - Solenoid valve parking lock

20-441

Calibrations and electronic diagnosis

Fig. 541 - Wiring diagram TCU

Transmission alarm 232 (SDF S240 / SDF S180+) Description Solenoid valve brake oil cooling - interruption of control. Cause A line open circuit for the solenoid valve for brake oil cooling is diagnosed in the TCU. l l l l

The plug connection belonging to the solenoid valve on the TCU is loose or has a poor contact. Solenoid valve has an internal defect. TCU has an internal defect. The wiring is damaged or interrupted.

Correction The cause of the faulty valve control should be located. 1.

Check the plug connection on the solenoid valve for brake oil cooling for a faulty connection (loose, bent, or corroded contacts) and damage.

20-442

Calibrations and electronic diagnosis 2.

Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 8.0 Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations. Dismantle the TCU and check plug connection A21/5 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

3. 4.

Fig. 541 - Wiring diagram TCU

Transmission alarm 234 Description Solenoid valve parking lock ON - short to plus. Cause A short to plus (supply voltage) for the solenoid valve for engaging the parking lock is diagnosed in the TCU. l l

Transmission-internal wiring is damaged. TCU has an internal defect.

20-443

Calibrations and electronic diagnosis Correction The cause of the faulty valve control should be located. 1. 2. 3. 4.

Check the plug connection on the solenoid valve for the engagement of the parking lock for a faulty connection (loose, bent, or corroded contacts) and damage. Dismantle the TCU and check plug connection A21/5 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. Ensure that plug connector A21/3 is disconnected from the TCU. With the ignition switched ON, use a voltmeter to measure the voltage between both pins on the solenoid valve connector on the wiring harness side. The transmission-internal wiring must be checked for a short to plus and, where necessary, replaced if voltage is applied between the pins. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 541 - Solenoid valve parking lock

20-444

Calibrations and electronic diagnosis

Fig. 541 - Wiring diagram TCU

Transmission alarm 234 (SDF S240 / SDF S180+) Description Solenoid valve brake oil cooling - short circuit to plus. Cause A short to plus (supply voltage) for the solenoid valve for engaging the parking lock is diagnosed in the TCU. l l

Transmission-internal wiring is damaged. TCU has an internal defect.

Correction The cause of the faulty valve control should be located. 1. 2.

Check the plug connection on the solenoid valve of brake cooling for a faulty connection (loose, bent, or corroded contacts) and damage. Dismantle the TCU and check plug connection A21/5 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage.

20-445

Calibrations and electronic diagnosis 3.

Ensure that plug connector A21/3 is disconnected from the TCU. With the ignition switched ON, use a voltmeter to measure the voltage between both pins on the solenoid valve connector on the wiring harness side. The transmission-internal wiring must be checked for a short to plus and, where necessary, replaced if voltage is applied between the pins. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

4.

Fig. 541 - Wiring diagram TCU

Transmission alarm 235 Description Solenoid valve parking lock ON - short or short to ground. Cause In the TCU a short circuit or a short to ground is diagnosed for the solenoid valve to engage the parking lock. l l l

Transmission-internal wiring is damaged. Solenoid valve has an internal defect. TCU has an internal defect.

Correction The cause of the faulty valve control should be located. 20-446

Calibrations and electronic diagnosis 1. 2. 3. 4.

Check the plug connection on the solenoid valve for the engagement of the parking lock for a faulty connection (loose, bent, or corroded contacts) and damage. Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 2.5 Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations. Dismantle the TCU and check plug connection A21/5 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 541 - Solenoid valve parking lock

20-447

Calibrations and electronic diagnosis

Fig. 541 - Wiring diagram TCU

Transmission alarm 235 (SDF S240 / SDF S180+) Description Solenoid valve brake oil cooling - short to ground. Cause In the TCU a short circuit or short to ground is diagnosed for the solenoid valve for brake oil cooling. l l l

Transmission-internal wiring is damaged. Solenoid valve has an internal defect. TCU has an internal defect.

Correction The cause of the faulty valve control should be located. 1. 2.

Check the plug connection on the solenoid valve for the engagement of the parking lock for a faulty connection (loose, bent, or corroded contacts) and damage. Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 2.5 Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations.

20-448

Calibrations and electronic diagnosis 3.

Dismantle the TCU and check plug connection A21/5 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

4.

Fig. 541 - Wiring diagram TCU

Transmission alarm 236 Description Solenoid valve parking lock ON - parking lock not engageable. Cause The engagement of the parking lock failed. l l l l

Parking lock is mechanically unlocked (emergency release). Short-term parking lock on solenoid valve malfunction. Defective solenoid valve. Parking lock mechanical defect.

Correction The cause of the faulty clutch control should be located. 20-449

Calibrations and electronic diagnosis 1.

If one of the errors TCU 232 (E8h), 234 (EAh), 235 (EBh) or 240 (F0h) is also active (electric error „PS ON“), the elimination of these errors should be given priority. Check the parking lock emergency release, it should be fully released. Assemble a manometer on the designated „PSU“ measuring connection and check the pressure during a parking lock engagement process when the engine is running. The solenoid valve should be replaced if no pressure is measured on the measuring point at any time. Assemble a manometer on the designated „PSA“ measuring connection and check the pressure during a parking lock engagement process when the engine is running. Do not apply any pressure during the engagement process and afterwards. If this is not the case, replace the solenoid valve PSA. If no measures are effective, an inspection of the parking lock for mechanical damage should be performed.

2. 3. 4. 5.

Transmission alarm 237 Description Solenoid valve parking lock ON - parking lock engaged but open again. Cause A diagnosis is made that the vehicle is rolling although the parking lock was properly engaged. l l l

Parking lock was mechanically unlocked (emergency release). Short-term malfunction caused by load changes on the output or on the PTO shaft. Parking lock mechanical defect.

Correction 1.

If one of the errors TCU 232 (E8h), 234 (EAh), 235 (EBh), 236 (ECh) or 240 (F0h) is also active (electric errors), the elimination of these errors should be given priority. Check the parking lock emergency release, it should be fully released. If the error occurs when the vehicle was repeatedly exposed to jerks with engaged parking lock, no further measures are necessary. An inspection of the parking lock for mechanical damage should be performed should the error continue to occur.

2. 3. 4.

Transmission alarm 240 Description Solenoid valve parking lock OFF - interruption of control. Cause A line open circuit for the solenoid valve to release the parking lock is diagnosed in the TCU. l l l l

The plug connection belonging to the solenoid valve on the TCU is loose or has a poor contact. Solenoid valve has an internal defect. TCU has an internal defect. The wiring is damaged or interrupted.

Correction The cause of the faulty valve control should be located. 1. 2. 3. 4.

Check the plug connection on the solenoid valve for the release of the parking lock for a faulty connection (loose, bent, or corroded contacts) and damage. Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 20 °C, the resistance value should approximately amount to 2.5 Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations. Dismantle the TCU and check plug connection A21/5 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

20-450

Calibrations and electronic diagnosis

Fig. 541 - Solenoid valve parking lock

20-451

Calibrations and electronic diagnosis

Fig. 541 - Wiring diagram TCU

Transmission alarm 242 Description Solenoid valve parking lock OFF - short to plus. Cause A short to plus (supply voltage) for the solenoid valve to release the parking lock is diagnosed in the TCU. l l

Transmission-internal wiring is damaged. TCU has an internal defect.

Correction The cause of the faulty valve control should be located. 1. 2.

Check the plug connection on the solenoid valve for the release of the parking lock for a faulty connection (loose, bent, or corroded contacts) and damage. Dismantle the TCU and check plug connection A21/5 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage.

20-452

Calibrations and electronic diagnosis 3. 4.

Ensure that plug connectors A21/5 is disconnected from the TCU. With the ignition switched ON, use a voltmeter to measure the voltage between both pins on the solenoid valve connector on the wiring harness side. The transmission-internal wiring must be checked for a short to plus and, where necessary, replaced if voltage is applied between the pins. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 541 - Solenoid valve parking lock

20-453

Calibrations and electronic diagnosis

Fig. 541 - Wiring diagram TCU

Transmission alarm 243 Description Solenoid valve parking lock OFF - short circuit or short to ground. Cause A short circuit or a short to ground for the solenoid valve for the release of the parking lock is diagnosed in the TCU. l l l

Transmission-internal wiring is damaged. Solenoid valve has an internal defect. TCU has an internal defect.

Correction The cause of the faulty valve control should be located. 1. 2.

Check the plug connection on the solenoid valve for the release of the parking lock for a faulty connection (loose, bent, or corroded contacts) and damage. Check the resistance of the solenoid valve. For this purpose, determine the resistance between the two pins on the valvesided connector using an ohmmeter with the solenoid valve unplugged. At 25 °C, the resistance value should approximately amount to 2.5 Ω. The solenoid valve should be replaced in the event of damage or resistance value deviations.

20-454

Calibrations and electronic diagnosis 3. 4.

Dismantle the TCU and check plug connection A21/5 as well as the wiring harness for a faulty connection (loose, bent, or corroded contacts) and damage. With the solenoid valve connected, delete the error, switch the ignition OFF, wait at least 10 seconds, and then start the engine. The TCU has to be replaced should the error occur again.

Fig. 541 - Solenoid valve parking lock

20-455

Calibrations and electronic diagnosis

Fig. 541 - Wiring diagram TCU

20-456

Calibrations and electronic diagnosis TCU pin assignment Table 217 A21/1

Pin no.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Signal

CAN_H1 CAN_L1 31 TEST A0.+ A0.S A0. – ER CAN_G1 GND 30 30 15 EV ISO K LED

Use

Mod.

Use

Mod.

CAN High transmission CAN Low transmission Terminal 31 n.c. n.c. Clutch 75% (BOC) n.c. Emergency operation switch reverse CAN Gnd transmission Emergency operation switch Gnd n.c. Terminal 30 Terminal 15 Emergency operation switch forward n.c. n.c.

Table 218 A21/2

Pin no.

1 2 3 4 5 6 7 8 9 10 11 12

Signal

CAN_L1 CAN_G1 TEMP+ SD.+ OD.S SD.S SD. – OD.– GND TEMP– OD.+ CAN_H1

n.c. n.c. Sensor transmission oil temperature Vers. + sensor system pressure Signal sensor lubrication pressure Signal sensor system pressure Vers. – sensor System pressure Vers. – sensor lubrication pressure n.c. Sensor Transmission oil temperature Vers. + sensor lubrication pressure n.c.

E

Table 219 A21/3

Pin no.

1 2 3 4 5 6 7 8 9 10 11 12

Signal

KR+ KV+ K4+ K3+ K2+ K1+ K1– K2– K3– K4– KV– KR–

Use

Valve clutch reverse + Valve clutch forward + Valve clutch 4 + Valve clutch 3 + Valve clutch 2 + Valve clutch 1 + Valve clutch 1 – Valve clutch 2 – Valve clutch 3 – Valve clutch 4 – Valve clutch forward – Valve clutch reverse –

Mod.

20-457

Calibrations and electronic diagnosis Table 220 A21/4

Pin no.

1 2 3 4 5 6 7 8 9 10 11 12

Signal

HP2.+ SF DF HP2.S HP1.S HP1.+ HP1. – HP2. – DF GND SF GND HYDIST HYDSOLL

Use

Mod.

Use

Mod.

Use

Mod.

Use

Mod.

Use

Mod.

Use

Mod.

Use

Mod.

Supply HP sensor 2 n.c. Maintenance switch Pressure filter Signal HP sensor 2 Signal HP sensor 1 Supply HP sensor 1 Ground HP sensor 1 Ground HP sensor 2 Maintenance switch pressure filter n.c. Hydrostatic unit actual position Hydrostatic unit nominal position

Table 221 A21/5

Pin no.

1 2 3 4 5 6 7 8 9 10 11 12

Signal

HYD– HYD+ HYDV+ PSE+ PSA+ KA+ KA– GND HYDV– MTSR MRST SCLK

Ground parking lock valve PSA n.c. Vers. + stepping motor elect. MGV parking lock on + MGV parking lock off + MGV four wheel drive + MGV four wheel drive – Ground parking lock valve PSE Vers. – stepping motor elect. n.c. n.c. n.c.

Table 222 A21/6

Pin no.

1 2

Signal

DZST1.+ DZST1. –

Speed ridge 1 Speed ridge 1

Table 223 A21/7

Pin no.

1 2

Signal

DZMOZ.+ DZMOT. –

Speed engine Speed engine

Table 224 A21/8

Pin no.

1 2

Signal

DZS23.+ DZS23. –

Speed sun 2 / sun 3 Speed sun 2 / sun 3

Table 225 A21/9

Pin no.

1 2

Signal

DZAB2.+ DZAB2. –

Speed output 2 Speed output 2

Table 226 A21/10

20-458

Pin no.

1 2

Signal

DZAB1.+ DZAB1. –

Speed output 1 Speed output 1

Calibrations and electronic diagnosis

A21/2

A21/6

A21/4

A21/7

A21/8

A21/10

A21/9

1

1

12

7

12

7

gruen

grau

grau

braun

1

1

1 12

7

7

1 12

6.

6.

braun

schwarz

schwarz

1

1

6.

6.

1 A21/1

gruen

A21/3

A21/5

Fig. 542

20.5.3 - Armrest alarms

PLA_2 Armrest Alarms List Digital Input

Table 227 Cod. ART Spn

Instrument panel display error

Severity

Component

Fault

Trasmission Neutral push button Rear PTO Out 1 lever Rear PTO Out 2 lever “ASM” Activation push button Differential Lock activation push button Transmission Mode: (AUTO, MANUAL, etc...) Hydraulic Enable F1 joystck push button F2 joystck push button

1001 1002 1003 1004 1005 1006 1007

Armrest error: 1001 Armrest error: 1002 Armrest error: 1003 Armrest error: 1004 Armrest error: 1005 Armrest error: 1006 Armrest error: 1007

Medium Medium Medium Medium Medium Medium Medium

0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX

1008 1009 1010

Armrest error: 1008 Armrest error: 1009 Armrest error: 1010

Medium Low Low

0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX

20-459

Calibrations and electronic diagnosis Cod. ART Spn

Instrument panel display error

Severity

Component

Fault

1011 1012

Armrest error: 1011 Armrest error: 1012

Low Low

0.019.2557.4/XX 0.019.2557.4/XX

1013 1014

Armrest error: 1013 Armrest error: 1014

Low Low

0.019.2557.4/XX 0.019.2557.4/XX

1015

Armrest error: 1015

Low

0.019.2557.4/XX

1016

Armrest error: 1016

Low

0.019.2557.4/XX

1017 1018 1019 1020 1021 1022 1024 1025 1026 1027 1028 1029

Armrest error: 1017 Armrest error: 1018 Armrest error: 1019 Armrest error: 1020 Armrest error: 1021 Armrest error: 1022 Armrest error: 1024 Armrest error: 1025 Armrest error: 1026 Armrest error: 1027 Armrest error: 1028 Armrest error: 1029

Low Low Low Low Low Low Medium Low Low Medium Medium Low

0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX

F3 joystck push button Distributor max flow setting push button Distributor mode setting push button Front Axle suspension activation push button “EPB Smart” Function activation push button Auto PTO function activation push button Instrument cluster ESC push button Instrument cluster M+ push button Instrument cluster M- push button Instrument cluster RET push button “Agrosky” Activation push button “Trailer Stretch” push button Front PTO out 2 lever Third Point Activation push button 1 Third Point Activation push button 2 Rear Lift unlock push button “ABS” System activaion push button “MMI” push button

Severity

Component

Fault

-

0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX

Digital spare input 1 Digital spare input 2 Digital spare input 3 Digital spare input 4

Severity

Component

Fault

Medium Medium Medium Medium Medium Low Low Low Medium

0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX

Rear Lift UP command Rear Lift STOP command Rear Lift DOWN command Forward Direction command Backward Direction command “SDS” push button “Cruise” 1 push button “Cruise” 2 push button Safety (CONS) push button

Severity

Component

Fault

Armrest error: 1043 Armrest error: 1044 Armrest error: 1045

Low Low Low

0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX

Tumb Wheel Distributor 1 Tumb Wheel Distributor 2 Power Commander ENCODER

Instrument panel display error

Severity

Component

Fault

Low

0.019.2557.4/XX

Mini MMI ENCODER

Digital Spare

Table 228 Cod. ART Spn

1030 1031 1032 1033

Instrument panel display error

Armrest error: 1030 Armrest error: 1031 Armrest error: 1032 Armrest error: 1033

Power Commander Digital Input

Table 229 Cod. ART Spn

1034 1035 1036 1037 1038 1039 1040 1041 1042

Instrument panel display error

Armrest error: 1034 Armrest error: 1035 Armrest error: 1036 Armrest error: 1037 Armrest error: 1038 Armrest error: 1039 Armrest error: 1040 Armrest error: 1041 Armrest error: 1042

Power Command Analog Input

Table 230 Cod. ART Spn

1043 1044 1045

Instrument panel display error

Mini MMI

Table 231 Cod. ART Spn

1046

20-460

Armrest error: 1046

Calibrations and electronic diagnosis Cod. ART Spn

1047 1048

Instrument panel display error

Armrest error: 1047 Armrest error: 1048

Severity

Component

Fault

Low Low

0.019.2557.4/XX 0.019.2557.4/XX

Mini MMI ENCODER push button Mini MMI ESC push button

Severity

Component

Fault

PLA_2 Analog Input

Table 232 Cod. ART Spn

Instrument panel display error

1049 1050 1051 1052 1018 1054 1055 1056 1057 1058 1059 1060 1061 1062 1063

Armrest error: 1049 Armrest error: 1050 Armrest error: 1051 Armrest error: 1052 Armrest error: 1018 Armrest error: 1054 Armrest error: 1055 Armrest error: 1056 Armrest error: 1057 Armrest error: 1058 Armrest error: 1059 Armrest error: 1060 Armrest error: 1061 Armrest error: 1062 Armrest error: 1063

Medium Medium Medium Low Low Low Low Low Low Low Low Low Medium Low Low

0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX

1064

Armrest error: 1064

Low

0.019.2557.4/XX

1065

Armrest error: 1065

Low

0.019.2557.4/XX

1066 1067 1068

Armrest error: 1066 Armrest error: 1067 Armrest error: 1068

Low Low Low

0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX

1069

Armrest error: 1069

Low

0.019.2557.4/XX

Potentiometer virtual GROUND 12V internal power supply 12V battery External sensors power supply Internal sensors power supply HW release analog value JOY STICK Distributor 3 JOY STICK Distributor 4 Rear Lift Slipping Set Potentiometer Rear Lift Speed “Down” Potentiometer Rear Lift “Intermix Set”Potentiometer Rear Lift MAX High Potentiometer Rear Lift “Set Point” Potentiometer Power Commander position Transmission Performance (ECOPOWER) Potentiometer Transmission Acceleration setting Potentiometer Power Commander Right Left position (not used) Distributor 5 Command Distributor 6- Front Lift Command Distributor 7- “Confort Pack” Command Front Lift Set Point Potentiometer

Severity

Component

Fault

Low -

0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX

Spare 5 Analog input Spare 6 Analog input PTO Brake activation push button Spare 8 Analog input

Severity

Component

Fault

-

0.019.2557.4/XX

Power Command Digital Spare Input

Severity

Component

Fault

Low Medium Medium Medium

0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX 0.019.2557.4/XX

EEPROM failure CAN Line 1 (Vehicle CAN) failure CAN Line 2 (Auxiliary CAN) failure CAN Line 3 (Internal CAN: Power Command Mini MMI connection) failure

Analog Spare

Table 233 Cod. ART Spn

1070 1071 1072 1074

Instrument panel display error

Armrest error: 1070 Armrest error: 1071 Armrest error: 1072 Armrest error: 1073

Power Command Digital Spare Input

Table 234 Cod. ART Spn

1074

Instrument panel display error

Armrest error: 1074

CAN + EEPROM

Table 235 Cod. ART Spn

1075 1076 1077 1078

Instrument panel display error

Armrest error: 1075 Armrest error: 1076 Armrest error: 1077 Armrest error: 1078

20-461

Calibrations and electronic diagnosis 20.5.4 - Electrohydraulic control valve alarms Distributor alarms Table 236

Cod. ART Spn Fmi

Severity

Fault

Controls

11 12 13 14 15 16 17

Low Low Low Low Low Low Low

21

Low

22

Low

23 24 25 26 31

Low Low Low Low Low

32

Low

41 42

Medium Medium

43 81

Medium Medium

82 83

Medium Medium

No receive message 1 No receive message 2 Implausible receive message 1 Implausible receive message 2 Potentiometer/PWM fault EEPROM inconsistent No faults, but valve had switched off for > 1...4s and can only switch itself back on when setpoint = neutral has been received Undervoltage < customer value (optional shutdown) Overvoltage > customer value (optional shutdown) Spool deflection too short (optional shutdown) Spool deflection excessive Open centre position not reached Manual operation Undervoltage < 8V, valve shuts off output stage Overvoltage 36...45V, valve shuts off output stage High overvoltage ( > approx. 45V ) Output stage fault (output stage for pilot solenoid valve) Postion transducer fault Valve spool cannot be brought back to neutral position Valve spool not in neutral when switched on Checksum error

Link to system

20.5.5 - HLHP alarms HLHP2 alarm list Table 237

ART code Spn Fmi

51

12

63

2

158

2

20-462

Instru- Severity ment panel display error

HLHP Medium Alarm SPN 51 FMI 12 HLHP Medium Alarm SPN 63 FMI 2 HLHP Medium Alarm SPN 158 FMI 2

Component

Fault

Link to system

Accelerator pedal Invalid accelerator pedal poten- 40-106 position sensor tiometer signal received by engine control unit. Armrest

Direction selector buttons on [LNK] armrest pressed for too long.

Battery

Battery voltage out of 10 -15 [LNK] Volt range

Calibrations and electronic diagnosis ART code Spn Fmi

510

9

511

13

522

2

531

3

4

5

6

11

12

13

540

3

4

Instru- Severity ment panel display error

HLHP Alarm SPN 510 FMI 9 HLHP Alarm SPN 511 FMI 13 HLHP Alarm SPN 522 FMI 2 HLHP Alarm SPN 531 FMI 3 HLHP Alarm SPN 531 FMI 4 HLHP Alarm SPN 531 FMI 5 HLHP Alarm SPN 531 FMI 6 HLHP Alarm SPN 531 FMI 11 HLHP Alarm SPN 531 FMI 12 HLHP Alarm SPN 531 FMI 13 HLHP Alarm SPN 540 FMI 3 HLHP Alarm SPN 540 FMI 4

Component

Fault

Link to system

Medium

EPB device

No CANBUS signal received 40-231 from EPB (Electronic Park 40-250 40-297 Brake) 40-216

Medium

EPB device

Dataset in EPB has not been [LNK] initialised correctly for tractor model.

Low

Brakes circuit pres- Inconsistency between brake 40-480 sure sensor light on sensor and brake pedal 40-321 sensor

Medium

PTO 540E selector Solenoid valve shorting to posi- 40-474 40-309 solenoid valve tive power feed

Medium

PTO 540E selector Solenoid valve shorting to 40-474 40-309 solenoid valve ground

Medium

PTO 540E selector Solenoid valve disconnected solenoid valve

Medium

PTO 540E selector Solenoid valve shorting to 40-474 40-309 solenoid valve ground

Medium

PTO 540E selector Fault not identified solenoid valve

40-474 40-309

Medium

PTO 540E selector Device faulty solenoid valve

40-474 40-309

Medium

PTO 540E selector ECU “Output” channel not cali- 40-474 40-309 solenoid valve brated

Medium

Hitch draft sensor Sensor signal shorting to posi- 40-315 (LH) tive power feed

Medium

Hitch draft sensor Sensor signal (LH) ground.

shorting

40-474 40-309

to 40-315

20-463

Calibrations and electronic diagnosis ART code Spn Fmi

541

3

4

Instru- Severity ment panel display error

Component

Fault

Link to system

HLHP Medium Alarm SPN 541 FMI 3 HLHP Medium Alarm SPN 541 FMI 4

Hitch draft sensor Sensor signal shorting to posi- 40-315 (RH) tive power feed

Instru- Severity ment panel display error

Component

Hitch draft sensor Sensor signal (RH) ground.

shorting

to 40-315

Table 238 ART code Spn Fmi

550

2

3

4

5

11

12

20-464

HLHP Alarm SPN 550 FMI 2 HLHP Alarm SPN 550 FMI 3 HLHP Alarm SPN 550 FMI 4 HLHP Alarm SPN 550 FMI 5 HLHP Alarm SPN 550 FMI 11 HLHP Alarm SPN 550 FMI 12

Fault

Link to system

40-474 40-309

Medium

Rear PTO control Signal not valid solenoid valve

Medium

Rear PTO control Solenoid valve shorting to posi- 40-474 40-309 solenoid valve tive power feed

Medium

Rear PTO control Solenoid valve shorting to 40-474 40-309 solenoid valve ground

Medium

Rear PTO control Solenoid valve disconnected solenoid valve

40-474 40-309

Medium

Rear PTO control Fault not identified solenoid valve

40-474 40-309

Medium

Rear PTO control Device faulty solenoid valve

40-474 40-309

Calibrations and electronic diagnosis ART code Spn Fmi

551

2

3

4

5

11

12

552

2

3

4

5

11

12

560

-

Instru- Severity ment panel display error

HLHP Alarm SPN 551 FMI 2 HLHP Alarm SPN 551 FMI 3 HLHP Alarm SPN 551 FMI 4 HLHP Alarm SPN 551 FMI 5 HLHP Alarm SPN 551 FMI 11 HLHP Alarm SPN 551 FMI 12 HLHP Alarm SPN 522 FMI 2 HLHP Alarm SPN 522 FMI 3 HLHP Alarm SPN 522 FMI 4 HLHP Alarm SPN 522 FMI 5 HLHP Alarm SPN 522 FMI 11 HLHP Alarm SPN 522 FMI 12 HLHP alarm SPN 560 FMI -

Component

Fault

Link to system

40-474 40-309

Medium

Front PTO solenoid Signal not valid valve

Medium

Front PTO solenoid Solenoid valve shorting to posi- 40-474 40-309 valve tive power feed

Medium

Front PTO solenoid Solenoid valve shorting to 40-474 40-309 valve ground

Medium

Front PTO solenoid Solenoid valve disconnected valve

40-474 40-309

Medium

Front PTO solenoid Fault not identified valve

40-474 40-309

Front PTO solenoid Device faulty valve

40-474 40-309

Medium

4WD solenoid valve Signal not valid

[LNK]

Medium

4WD solenoid valve Solenoid valve shorting to posi- [LNK] tive power feed

Medium

4WD solenoid valve Solenoid valve shorting to [LNK] ground

Medium

4WD solenoid valve Solenoid valve disconnected

[LNK]

Medium

4WD solenoid valve Fault not identified

[LNK]

Medium

4WD solenoid valve Device faulty

[LNK]

Medium

Additional external sensor for rear hitch

[LNK]

20-465

Calibrations and electronic diagnosis ART code Spn Fmi

561

12

562

3

4

600

3

4

601

3

4

12

20-466

Instru- Severity ment panel display error

HLHP Alarm SPN 561 FMI 12 HLHP Alarm SPN 562 FMI 3 HLHP Alarm SPN 562 FMI 4 HLHP Alarm SPN 600 FMI 3 HLHP Alarm SPN 600 FMI 4 HLHP Alarm SPN 601 FMI 3 HLHP Alarm SPN 601 FMI 4 HLHP Alarm SPN 601 FMI 12

Component

Fault

Link to system

Medium

Armrest

Hand throttle potentiometer sig- [LNK] nal shorting to ground

Medium

Clutch pedal position Sensor signal shorting to posi- 40-125 sensor tive power feed

Medium

Clutch pedal position Sensor signal sensor ground.

Medium

Rear hitch control Sensor signal shorting to posi- 40-315 lever tive power feed

Medium

Rear hitch control Sensor signal lever ground.

Medium

Rear hitch position Sensor signal shorting to posi- 40-315 sensor tive power feed

Medium

Rear hitch position Sensor signal sensor ground.

Medium

Rear hitch position Fault not identified sensor

shorting

shorting

shorting

to 40-125

to 40-315

to 40-315

40-315

Calibrations and electronic diagnosis Table 239 ART code Spn Fmi

602

3

4

5

6

11

603

3

4

5

6

11

604

3

4

Instru- Severity ment panel display error

HLHP Alarm SPN 602 FMI 3 HLHP Alarm SPN 602 FMI 4 HLHP Alarm SPN 602 FMI 5 HLHP Alarm SPN 602 FMI 6 HLHP Alarm SPN 602 FMI 11 HLHP Alarm SPN 603 FMI 3 HLHP Alarm SPN 603 FMI 4 HLHP Alarm SPN 603 FMI 5 HLHP Alarm SPN 603 FMI 6 HLHP Alarm SPN 603 FMI 11 HLHP Alarm SPN 604 FMI 3 HLHP Alarm SPN 604 FMI 4

Component

Fault

Link to system

Medium

Rear hitch ‘UP’ con- Solenoid valve shorting to posi- 40-315 trol solenoid valve tive power feed

Medium

Rear hitch ‘UP’ con- Solenoid valve shorting to 40-315 trol solenoid valve ground

Medium

Rear hitch ‘UP’ con- Solenoid valve disconnected trol solenoid valve

Medium

Rear hitch ‘UP’ con- Solenoid valve shorting to 40-315 trol solenoid valve ground

Medium

Rear hitch ‘UP’ con- Fault not identified trol solenoid valve

Medium

Rear hitch DOWN Solenoid valve shorting to posi- 40-315 control solenoid tive power feed valve

Medium

Rear hitch DOWN Solenoid valve shorting to 40-315 control solenoid ground valve

Medium

Rear hitch DOWN Solenoid valve disconnected control solenoid valve

Medium

Rear hitch DOWN Solenoid valve shorting to 40-315 control solenoid ground valve

Medium

Rear hitch DOWN Fault not identified control solenoid valve

Medium

Armrest

Depth selector potentiometer [LNK] signal shorting to positive power feed

Medium

Armrest

Depth selector potentiometer [LNK] signal shorting to ground

40-315

40-315

40-315

40-315

20-467

Calibrations and electronic diagnosis ART code Spn Fmi

605

3

4

606

3

4

607

3

4

620

3

4

20-468

Instru- Severity ment panel display error

HLHP Alarm SPN 605 FMI 3 HLHP Alarm SPN 605 FMI 4 HLHP Alarm SPN 606 FMI 3 HLHP Alarm SPN 606 FMI 4 HLHP Alarm SPN 607 FMI 3 HLHP Alarm SPN 607 FMI 4 HLHP Alarm SPN 620 FMI 3 HLHP Alarm SPN 620 FMI 4

Component

Fault

Link to system

Low

Armrest

Maximum height potentiometer [LNK] signal shorting to positive power feed

Low

Armrest

Maximum height potentiometer [LNK] signal shorting to ground

Low

Armrest

Descent speed potentiometer [LNK] signal shorting to positive

Low

Armrest

Descent speed potentiometer [LNK] signal shorting to ground

Low

Armrest

Draft control potentiometer sig- [LNK] nal shorting to positive power feed

Low

Armrest

Draft control potentiometer sig- [LNK] nal shorting to ground

Medium

Front axle suspen- Sensor signal shorting to posi- 40-141 sion position sensor tive power feed

Medium

Front axle suspen- Sensor signal sion position sensor ground.

shorting

to 40-141

Calibrations and electronic diagnosis ART code Spn Fmi

621

2

3

4

5

11

12

622

2

3

4

Instru- Severity ment panel display error

HLHP Alarm SPN 621 FMI 2 HLHP Alarm SPN 621 FMI 3 HLHP Alarm SPN 621 FMI 4 HLHP Alarm SPN 621 FMI 5 HLHP Alarm SPN 621 FMI 11 HLHP Alarm SPN 621 FMI 12 HLHP Alarm SPN 622 FMI 2 HLHP Alarm SPN 622 FMI 3 HLHP Alarm SPN 622 FMI 4

Component

Fault

Link to system

40-141

Medium

Front axle “Up” con- Signal not valid trol coil

Medium

Front axle “Up” con- Solenoid valve shorting to posi- 40-141 trol coil tive power feed

Medium

Front axle “Up” con- Solenoid valve shorting to 40-141 trol coil ground

Medium

Front axle “Up” con- Solenoid valve disconnected trol coil

40-141

Medium

Front axle “Up” con- Fault not identified trol coil

40-141

Medium

Front axle “Up” con- Device faulty trol coil

40-141

Medium

Front axle ‘Down’ Signal not valid control coil

40-141

Medium

Front axle ‘Down’ Solenoid valve shorting to posi- 40-141 control coil tive power feed

Medium

Front axle ‘Down’ Solenoid valve shorting to 40-141 control coil ground

20-469

Calibrations and electronic diagnosis Table 240 ART code Spn Fmi

622

5

11

12

623

2

3

4

5

11

12

624

3

4

625

20-470

13

Instru- Severity ment panel display error

HLHP Alarm SPN 622 FMI 5 HLHP Alarm SPN 622 FMI 11 HLHP Alarm SPN 622 FMI 12 HLHP Alarm SPN 623 FMI 2 HLHP Alarm SPN 623 FMI 3 HLHP Alarm SPN 623 FMI 4 HLHP Alarm SPN 623 FMI 5 HLHP Alarm SPN 623 FMI 11 HLHP Alarm SPN 623 FMI 12 HLHP Alarm SPN 624 FMI 3 HLHP Alarm SPN 624 FMI 4 HLHP Alarm SPN 625 FMI 13

Component

Fault

Link to system

Medium

Front axle ‘Down’ Solenoid valve disconnected control coil

40-141

Medium

Front axle ‘Down’ Fault not identified control coil

40-141

Medium

Front axle ‘Down’ Device faulty control coil

40-141

Medium

Front axle suspen- Signal not valid sion Load Sensing control coil

40-141

Medium

Front axle suspen- Solenoid valve shorting to posi- 40-141 sion Load Sensing tive power feed control coil

Medium

Front axle suspen- Solenoid valve shorting to 40-141 sion Load Sensing ground control coil

Medium

Front axle suspen- Solenoid valve disconnected sion Load Sensing control coil

40-141

Medium

Front axle suspen- Fault not identified sion Load Sensing control coil

40-141

Medium

Front axle suspen- Device faulty sion Load Sensing control coil

40-141

Medium

Brakes circuit pres- Solenoid valve shorting to posi- 40-480 40-321 sure sensor tive power feed

Medium

Brakes circuit pres- Solenoid valve shorting to 40-480 40-321 sure sensor ground

High

Operator sensor

present Sensor signal out of permissible 40-125 range.

Calibrations and electronic diagnosis ART code Spn Fmi

626

11

629

2

3

4

5

11

12

630

-

631

9

632

9

633

9

Instru- Severity ment panel display error

HLHP High Alarm SPN 626 FMI 11 HLHP Alarm SPN 629 FMI 2 HLHP Alarm SPN 629 FMI 3 HLHP Alarm SPN 629 FMI 4 HLHP Alarm SPN 629 FMI 5 HLHP Alarm SPN 629 FMI 11 HLHP Alarm SPN 629 FMI 12 HLHP alarm SPN 630 FMI HLHP Alarm SPN 631 FMI 9 HLHP Alarm SPN 632 FMI 9 HLHP Alarm SPN 633 FMI 9

Medium

Component

Fault

Link to system

present Operator not seated (for 1 sec.) 40-125 with shuttle lever in neutral and parking brake not engaged. Operator not seated (for 10 40-125 sec.) with shuttle lever engaged in forward or reverse drive. Rear PTO brake so- Signal not valid 40-309 lenoid valve

Operator sensor

Medium

Rear PTO brake so- Solenoid valve shorting to posi- 40-474 lenoid valve tive power feed

Medium

Rear PTO brake so- Solenoid valve shorting to 40-309 lenoid valve ground

Medium

Rear PTO brake so- Solenoid valve disconnected lenoid valve

40-474

Medium

Rear PTO brake so- Fault not identified lenoid valve

40-309

Medium

Rear PTO brake so- Device faulty lenoid valve

40-474

Low

Power output device -

[LNK]

Medium

Armrest

High

Transmission control No CANBUS signal from trans- 40-231 40-250 unit mission control unit 40-297 40-216

High

Engine control unit

No CANBUS signal from arm- 40-231 40-250 rest 40-297 40-216

No CANBUS signal from engine 40-231 40-250 control unit 40-297 40-216

20-471

Calibrations and electronic diagnosis ART code Spn Fmi

653

2

3

Instru- Severity ment panel display error

Component

Fault

HLHP Medium Alarm SPN 653 FMI 2 HLHP Medium Alarm SPN 653 FMI 3

Differential lock con- Signal not valid trol solenoid valve

Instru- Severity ment panel display error

Component

Link to system

40-125

Differential lock con- Solenoid valve shorting to posi- 40-125 trol solenoid valve tive power feed

Table 241 ART code Spn Fmi

653

4

5

11

12

654

2

655

2

656

12

657

2

20-472

HLHP Alarm SPN 653 FMI 4 HLHP Alarm SPN 653 FMI 5 HLHP Alarm SPN 653 FMI 11 HLHP Alarm SPN 653 FMI 12 HLHP Alarm SPN 654 FMI 2 HLHP Alarm SPN 655 FMI 2 HLHP Alarm SPN 656 FMI 12 HLHP Alarm SPN 657 FMI 2

Fault

Link to system

Medium

Differential lock con- Solenoid valve shorting to 40-125 trol solenoid valve ground

Medium

Differential lock con- Solenoid valve disconnected trol solenoid valve

40-125

Medium

Differential lock con- Fault not identified trol solenoid valve

40-125

Medium

Differential lock con- Device faulty trol solenoid valve

40-125

Medium

HLHP unit

Problem identified on 8 Volt sensor power feed line

Medium

HLHP unit

Problem identified on 5 Volt [LNK] sensor power feed line

Medium

Radar

Device faulty

Medium

Limp-home signal

input Signal not valid

40-315

[LNK]

Calibrations and electronic diagnosis ART code Spn Fmi

658

3

4

5

6

11

12

13

659

2

4

Instru- Severity ment panel display error

HLHP Alarm SPN 658 FMI 3 HLHP Alarm SPN 658 FMI 4 HLHP Alarm SPN 658 FMI 5 HLHP Alarm SPN 658 FMI 6 HLHP Alarm SPN 658 FMI 11 HLHP Alarm SPN 658 FMI 12 HLHP Alarm SPN 658 FMI 13 HLHP Alarm SPN 659 FMI 2 HLHP Alarm SPN 659 FMI 4

Component

Fault

Link to system

High

Left hand cab sus- Device shorting to positive pow- 40-194 pension er feed

High

Left hand cab sus- Device shorting to ground pension

40-194

High

Left hand cab sus- Device disconnected pension

40-194

High

Left hand cab sus- Device shorting to ground pension

40-194

High

Left hand cab sus- Fault not identified pension

40-194

High

Left hand cab sus- Internal device fault pension

40-194

High

Left hand cab sus- Internal device fault pension

40-194

Medium

Shuttle control lever More than one output signal 40-125 from shuttle lever simultaneously active

Medium

Shuttle control lever Shuttle lever signal not identi- 40-125 fied

20-473

Calibrations and electronic diagnosis ART code Spn Fmi

660

3

4

5

6

11

12

13

20-474

Instru- Severity ment panel display error

HLHP Alarm SPN 660 FMI 3 HLHP Alarm SPN 660 FMI 4 HLHP Alarm SPN 660 FMI 5 HLHP Alarm SPN 660 FMI 6 HLHP Alarm SPN 660 FMI 11 HLHP Alarm SPN 660 FMI 12 HLHP Alarm SPN 660 FMI 13

Component

Fault

Link to system

Medium

PTO 1000N selector Solenoid valve shorting to posi- 40-474 40-309 solenoid valve tive power feed

Medium

PTO 1000N selector Solenoid valve shorting to 40-474 40-309 solenoid valve ground

Medium

PTO 1000N selector Solenoid valve disconnected solenoid valve

Medium

PTO 1000N selector Solenoid valve shorting to 40-474 40-309 solenoid valve ground

Medium

PTO 1000N selector Fault not identified solenoid valve

40-474 40-309

Medium

PTO 1000N selector Device faulty solenoid valve

40-474 40-309

Medium

PTO 1000N selector solenoid valve

40-474 40-309

40-474 40-309

Calibrations and electronic diagnosis Table 242 ART code Spn Fmi

661

8

662

3

664

9

665

11

666

9

667

2

3

4

5

11

12

668

7

Instru- Severity ment panel display error

HLHP Alarm SPN 661 FMI 8 HLHP Alarm SPN 662 FMI 3 HLHP Alarm SPN 664 FMI 9 HLHP Alarm SPN 665 FMI 11 HLHP alarm SPN 666 FMI 9 HLHP Alarm SPN 667 FMI 2 HLHP Alarm SPN 667 FMI 3 HLHP Alarm SPN 667 FMI 4 HLHP Alarm SPN 667 FMI 5 HLHP Alarm SPN 667 FMI 11 HLHP Alarm SPN 667 FMI 12 HLHP Alarm SPN 668 FMI 7

Component

Fault

Link to system

Medium

HLHP unit

ECU parameter read error

[LNK]

Medium

RH rear PTO button Button signal shorting to posi- 40-474 40-309 (on mudguard) tive power feed

Medium

PTO speed sensor

Device malfunction

Medium

Rear PTO

Requested PTO speed cannot [LNK] be engaged because PTO rotation speed is too high

Medium

Front PTO

Speed sensor error

Medium

Front PTO solenoid Signal not valid valve

Medium

Front PTO solenoid Solenoid valve shorting to posi- 40-474 40-309 valve tive power feed

Medium

Front PTO solenoid Solenoid valve shorting to 40-474 40-309 valve ground

Medium

Front PTO solenoid Solenoid valve disconnected valve

40-474 40-309

Medium

Front PTO solenoid Fault not identified valve

40-474 40-309

Medium

Front PTO solenoid Device faulty valve

40-474 40-309

Medium

Front PTO

[LNK]

Front PTO slippage detected

40-474 40-309

[LNK]

40-474 40-309

20-475

Calibrations and electronic diagnosis ART code Spn Fmi

669

7

689

3

4

690

4

691

4

692

4

693

3

4

694

3

695

3

20-476

Instru- Severity ment panel display error

HLHP Alarm SPN 669 FMI 7 HLHP Alarm SPN 689 FMI 3 HLHP Alarm SPN 689 FMI 4 HLHP Alarm SPN 690 FMI 4 HLHP Alarm SPN 691 FMI 4 HLHP Alarm SPN 692 FMI 4 HLHP Alarm SPN 693 FMI 3 HLHP Alarm SPN 693 FMI 4 HLHP Alarm SPN 694 FMI 3 HLHP Alarm SPN 695 FMI 3

Component

Fault

Link to system

Medium

Rear PTO

Rear PTO slippage detected

[LNK]

Medium

Steering angle sen- Sensor signal shorting to posi- 40-125 sor tive power feed

Medium

Steering angle sen- Sensor signal sor ground.

Medium

Armrest

Rear hitch STOP button signal [LNK] shorting to ground

Medium

Armrest

Internal rear hitch up button sig- [LNK] nal shorting to ground

Medium

Armrest

Internal rear hitch down button [LNK] signal shorting to ground

Medium

Armrest

Slippage potentiometer signal [LNK] shorting to positive power feed

Medium

Armrest

Slippage potentiometer signal [LNK] shorting to ground

Medium

I018 - Right hand Button signal shorting to posi- 40-315 rear hitch UP button tive power feed (on mudguard)

Medium

RH rear hitch DOWN Button signal shorting to posi- 40-315 button (on mud- tive power feed guard)

shorting

to 40-125

Calibrations and electronic diagnosis Table 243 ART code Spn Fmi

697

3

698

3

700

4

701

4

702

3

4

5

6

11

12

13

Instru- Severity ment panel display error

HLHP Alarm SPN 697 FMI 3 HLHP Alarm SPN 698 FMI 3 HLHP Alarm SPN 700 FMI 4 HLHP Alarm SPN 701 FMI 4 HLHP Alarm SPN 702 FMI 3 HLHP Alarm SPN 702 FMI 4 HLHP Alarm SPN 702 FMI 5 HLHP Alarm SPN 702 FMI 6 HLHP Alarm SPN 702 FMI 11 HLHP Alarm SPN 702 FMI 12 HLHP Alarm SPN 702 FMI 13

Component

Fault

Link to system

Medium

Armrest

Rear PTO selector button signal 40-315 shorting to positive power feed

Medium

Armrest

Front PTO selector button sig- 40-315 nal shorting to positive power feed

Low

Front hitch UP con- Button signal shorting to ground 40-315 trol pushbutton

Low

Front hitch DOWN Button signal shorting to ground 40-315 control pushbutton

High

Right hand cab sus- Device shorting to positive pow- 40-194 pension er feed

High

Right hand cab sus- Device shorting to ground pension

40-194

High

Right hand cab sus- Device disconnected pension

40-194

High

Right hand cab sus- Device shorting to ground pension

40-194

High

Right hand cab sus- Fault not identified pension

40-194

High

Right hand cab sus- Internal device fault pension

40-194

High

Right hand cab sus- Internal device fault pension

40-194

20-477

Calibrations and electronic diagnosis ART code Spn Fmi

703

3

4

704

3

4

706

3

4

8

707

4

708

4

709

3

4

710

3

4

20-478

Instru- Severity ment panel display error

HLHP Alarm SPN 703 FMI 3 HLHP Alarm SPN 703 FMI 4 HLHP Alarm SPN 704 FMI 3 HLHP Alarm SPN 704 FMI 4 HLHP Alarm SPN 706 FMI 3 HLHP Alarm SPN 706 FMI 4 HLHP Alarm SPN 706 FMI 8 HLHP Alarm SPN 707 FMI 4 HLHP Alarm SPN 708 FMI 4 HLHP Alarm SPN 709 FMI 3 HLHP Alarm SPN 709 FMI 4 HLHP Alarm SPN 710 FMI 3 HLHP Alarm SPN 710 FMI 4

Component

Fault

Link to system

Low

Left hand cab sus- Sensor signal shorting to posi- 40-194 pension tive power feed

Low

Left hand cab sus- Sensor signal pension ground.

Low

Right hand cab sus- Sensor signal shorting to posi- 40-194 pension tive power feed

Low

Right hand cab sus- Sensor signal pension ground.

High

Oil temperature sen- Sensor signal shorting to posi- 40-125 sor tive power feed

High

Oil temperature sen- Sensor signal sor ground.

High

Oil temperature sen- Oil temperature has exceeded 40-125 sor permissible limits

Low

RH distributor Button signal shorting to ground 40-336 DOWN button (on mudguard)

Low

RH distributor UP Button signal shorting to ground 40-336 button (on mudguard)

Low

Armrest

Distributor No. 5 potentiometer [LNK] signal shorting to positive power feed

Low

Armrest

Distributor No. 5 potentiometer [LNK] signal shorting to ground

Low

Armrest

Distributor No. 6 potentiometer [LNK] signal shorting to positive power feed

Low

Armrest

Distributor No. 6 potentiometer [LNK] signal shorting to ground

shorting

shorting

shorting

to 40-194

to 40-194

to 40-125

Calibrations and electronic diagnosis ART code Spn Fmi

711

3

4

712

8

Instru- Severity ment panel display error

Component

Fault

Link to system

HLHP Low Alarm SPN 711 FMI 3 HLHP Low Alarm SPN 711 FMI 4 HLHP High Alarm SPN 712 FMI 8

Armrest

Distributor No. 7 potentiometer [LNK] signal shorting to positive power feed

Armrest

Distributor No. 7 potentiometer [LNK] signal shorting to ground

-

Tractor has exceeded 58 Km/h [LNK] speed limit

Instru- Severity ment panel display error

Component

Fault

Table 244 ART code Spn Fmi

713

8

714

8

715

8

716

9

717

718

8

719

8

720

8

HLHP Alarm SPN 713 FMI 8 HLHP Alarm SPN 714 FMI 8 HLHP Alarm SPN 715 FMI 8 HLHP Alarm SPN 716 FMI 9 HLHP alarm SPN 717 FMI HLHP Alarm SPN 718 FMI 8 HLHP Alarm SPN 719 FMI 8 HLHP Alarm SPN 720 FMI 8

Link to system

40-125

Medium

Front axle speed No sensor signal sensor

Low

4WD clutch

Brief slippage of 4WD clutch [LNK] detected

Medium

4WD clutch

Prolonged slippage of 4WD [LNK] clutch detected

Low

Armrest

Hitch control console discon- [LNK] nected

Low

-

“OnTrac2 enable relay”

Medium

Steering filter sensor Indicates that steering filter sen- [LNK] sor is clogged

Medium

Steering switch

Medium

Booster pump pres- Booster pump oil pressure in- [LNK] sure switch correct

[LNK]

pressure Steering system oil pressure [LNK] incorrect

20-479

Calibrations and electronic diagnosis ART code Spn Fmi

722

2

723

2

724

3

4

725

-

726

9

12

727

9

728

9

729

9

730

9

731

9

732

9

20-480

Instru- Severity ment panel display error

HLHP Alarm SPN 722 FMI 2 HLHP Alarm SPN 723 FMI 2 HLHP Alarm SPN 724 FMI 3 HLHP Alarm SPN 724 FMI 4 HLHP alarm SPN 725 FMI HLHP Alarm SPN 726 FMI 9 HLHP Alarm SPN 726 FMI 12 HLHP Alarm SPN 727 FMI 9 HLHP Alarm SPN 728 FMI 9 HLHP Alarm SPN 729 FMI 9 HLHP Alarm SPN 730 FMI 9 HLHP Alarm SPN 731 FMI 9 HLHP Alarm SPN 732 FMI 9

Component

Fault

Link to system

Medium

5V sensor - Power Off-scale value read by sensor [LNK] feed 2 for 2nd 5V power line

Medium

5V sensor - Power Off-scale value read by sensor [LNK] feed 3 for 3rd 5V power line

Low

“SmartWheel”

Sensor signal shorting to posi- [LNK] tive power feed

Low

“SmartWheel”

Sensor signal ground.

Medium

EPB device

Comfort function of EPB device [LNK] failed

Medium

Front brakes pres- Front brake sensor not detected [LNK] sure switch on CAN Bus line

Medium

HLHP Alarm SPN Front brake pressure too low 726 FMI 9

Low

iMonitor 2.0

Medium

Work Display (WoD) Work Display (WoD) not detect- [LNK] ed on CAN Bus line

Low

Work Light Panel Work Light Panel (WoLP) not [LNK] (WoLP) detected on CAN Bus line

Medium

Power Commander Power Commander not detect- [LNK] ed on CAN Bus line

Low

MMI

MMI not detected on CAN Bus 40-371 line

Low

Auto A/C

Auto A/C not detected on CAN 40-200 Bus line

shorting

to [LNK]

[LNK]

iMonitor 2.0 not detected on 40-371 CAN Bus line

Calibrations and electronic diagnosis ART code Spn Fmi

733

12

734

3

4

735

9

Instru- Severity ment panel display error

Component

Fault

Medium

EPB device

Excessive pad wear detected [LNK] by HLHP

Medium

EPB device

EPB signal => HLHP ECU short [LNK] circuiting to positive power feed

Medium

EPB device

EPB signal => HLHP ECU short [LNK] circuiting to ground or disconnected

Medium

Agrosky

GTECU not detected by vehicle 40-373 CAN line. AG2: No GTECU communication

Instru- Severity ment panel display error

Component

Fault

Link to system

HLHP Medium Alarm SPN 736 FMI 13

Agrosky

Steering angle sensor not calibrated: - Initial installation during construction, - Restore factory default values AG2: WAS calibration not performed “SPOOL of PVED-CL” not calibrated: - Initial installation during construction, - Restore factory default values AG2: SPOOL calibration not performed AGI4 antenna not detected on CAN Bus line AGI4 antenna not detected AGI4 detected by Agrosky, but tractor is configured with EASY STEER only AGI4 antenna configured incorrectly “PVED-CL” not detected on CAN Bus line AGI4 antenna configured incorrectly EPB system has been used as emergency brake with a tractor speed exceeding 30 Km/h.

40-373

HLHP Alarm SPN 733 FMI 12 HLHP Alarm SPN 734 FMI 3 HLHP Alarm SPN 734 FMI 4 HLHP Alarm

Link to system

Table 245 ART code Spn Fmi

736

13

737

13

HLHP Medium Alarm SPN 737 FMI 13

Agrosky

738

9

HLHP Alarm

Medium

Agrosky

739

11

HLHP Medium Alarm SPN 739 FMI 11

Agrosky

740

9

HLHP Alarm

Agrosky

744

7

HLHP Medium Alarm SPN 744 FMI7-

Medium

EPB device

40-373

40-373 40-373

40-373

[LNK]

20-481

Calibrations and electronic diagnosis ART code Spn Fmi

745

13

998

3

4

5

6

11

12

13

20-482

Instru- Severity ment panel display error

HLHP Alarm SPN 745 FMI 13 HLHP Alarm SPN 998 FMI 3 HLHP Alarm SPN 998 FMI 4 HLHP Alarm SPN 998 FMI 5 HLHP Alarm SPN 998 FMI 6 HLHP Alarm SPN 998 FMI 11 HLHP Alarm SPN 998 FMI 12 HLHP Alarm SPN 998 FMI 12

Component

Fault

Link to system

Medium

Rear PTO

Rear PTO not calibrated

40-309 40-474

Low

Lubrication cut-off Solenoid valve shorting to posi- [LNK] solenoid valve 1 tive power feed

Low

Lubrication cut-off Solenoid valve shorting to [LNK] solenoid valve 1 ground

Low

Lubrication cut-off Voltage too low during solenoid [LNK] solenoid valve 1 valve operation

Low

Lubrication cut-off Voltage too high during solenoid [LNK] solenoid valve 1 valve operation

Low

Lubrication cut-off Erroneous voltage while sole- [LNK] solenoid valve 1 noid valve is not in use

Low

Lubrication cut-off Internal ECU error solenoid valve 1

Low

Lubrication cut-off ECU “Output” channel not cali- [LNK] solenoid valve 1 brated

[LNK]

Calibrations and electronic diagnosis ART code Spn Fmi

999

3

4

5

6

11

12

13

Instru- Severity ment panel display error

HLHP Alarm SPN 999 FMI 3 HLHP Alarm SPN 999 FMI 4 HLHP Alarm SPN 999 FMI 5 HLHP Alarm SPN 999 FMI 6 HLHP Alarm SPN 999 FMI 11 HLHP Alarm SPN 999 FMI 12 HLHP Alarm SPN 6999 FMI 12

Component

Fault

Link to system

Low

Lubrication cut-off Solenoid valve shorting to posi- [LNK] solenoid valve 2 tive power feed

Low

Lubrication cut-off Solenoid valve shorting to [LNK] solenoid valve 2 ground

Low

Lubrication cut-off Voltage too low during solenoid [LNK] solenoid valve 2 valve operation

Low

Lubrication cut-off Voltage too high during solenoid [LNK] solenoid valve 2 valve operation

Low

Lubrication cut-off Erroneous voltage while sole- [LNK] solenoid valve 2 noid valve is not in use

Low

Lubrication cut-off Internal ECU error solenoid valve 2

Low

Lubrication cut-off ECU “Output” channel not cali- [LNK] solenoid valve 2 brated

[LNK]

20-483

Calibrations and electronic diagnosis 20.5.6 - AC system alarms

Manual Air Conditioner Alarms Position of the water valve When the control unit switches off the position of the water valve is memorised in the EEPROM. When the control unit switches on the previously memorised position of the water valve is read from the EEPROM. Diagnostics The ECU will manage the following faults: l l l

Short Circuit (S.C.) of one of the valve stepper motor outputs, Open Circuit (O.C.) of one of the valve stepper motor outputs, Closed Circuit (C.C.) of one of the recirculation actuator DC motor outputs,

Only for the air conditioned version l l l l

Evaporator temperature sensor in Open Circuit (O.C.), Evaporator temperature sensor in Short Circuit (S.C.), A/C compressor relay output in Open Circuit (O.C.) or to Battery +, A/C compressor relay output in Short Circuit (S.C.) or to Earth,

The faults will be signalled by a function LED flashing (A/C or recirculation) timed as described below:

Fig. 543

Flashes The first part (flash every 100 msec) indicates that a fault has been detected, whereas the second part indicates the type of fault as indicated in the table below:

Table 246 Priority

1 2 3

Description

Function LED

Valve stepper motor Open Circuit (O.C.) or Short Circuit (S.C.) RECIRCULATION to Earth Valve stepper motor Short Circuit (S.C.) to Battery + RECIRCULATION Recirculation DC motor Short Circuit (S.C.) RECIRCULATION

No. of flashes

1 2 3

Table 247 Only for the air conditioned version Priority Description

1 2 3

20-484

Function LED

Evaporator temperature sensor in Open Circuit (O.C.) A/C Evaporator temperature sensor in Short Circuit (S.C.) A/C A/C compressor relay output in Open Circuit (O.C.) or to Battery + A/C

No. of flashes

1 2 3

Calibrations and electronic diagnosis Only for the air conditioned version Priority Description

4

A/C compressor relay output in Short Circuit (S.C.) or to Earth

Function LED

A/C

No. of flashes

4

WARNING In the event of several simultaneous faults they will be managed through the priority table and therefore the one with the highest priority will be displayed. WARNING Therefore one fault will be managed at a time. When the managed fault is removed the next one in order or priority will be displayed. The following are the fault validation times:

Table 248 Description

Check period (msec)

Validation and Notes de-validation period (msec)

Valve stepper motor Open Circuit (O.C.)

100

Valve stepper motor Short Circuit (S.C.)

100

500

Recirculation DC motor Short Circuit (S.C.)

100

1000

Check period (msec)

Validation and Notes de-validation period (msec)

500

Detected only during valve movement. Detected only during valve movement. Detected only during actuator movement.

Table 249 Only for the air conditioned version Description

A/C compressor relay output in Open Circuit (O.C.)

100

1000

A/C compressor relay output in Short Circuit (S.C.)

100

1000

Evaporator temperature sensor in Open Circuit (O.C.) 100 Evaporator temperature sensor in Short Circuit (S.C.) 100

1000 1000

Detected only if the output is activated. Detected only if the output is activated. -

WARNING Any faults are memorised in the EEPROM. Calibration of the water valve Calibration of the valve consists in rotating the stepper motor for about 30 seconds clockwise (toward the valve closing) in order to have a certain point of reference (zero). The stepper motor stroke applied to the valve is 300° which corresponds to 6,000 steps. Therefore the completely closed valve (0%) corresponds to 0 steps, whereas the completely open valve (100%) corresponds to 6,000 steps. The duration of the valve calibration must be greater than 6,000 steps in order to guarantee certain mechanical stop (consider 6,000 + 100 = 6,100 steps). Considering that the configuration of the stepper motor outputs will be updated every 5 msec (200Hz), the duration of the calibration phase will be: 6,100 x 5 msec = 30.5 seconds.

20-485

Calibrations and electronic diagnosis Automatic Climate control unit alarms list Table 250 ART Code Spn

Name

01

Mixed air temperature sensor Opened sensor. #1 failure.

02

Mixed air temperature sensor Shorted circuit sensor. #1 failure.

03 04

Not used Input from recirculation ac- The signal from the potentituator #2 failure. ometer of recirculation actuator #2 is outside its working limits.

05

Cab air temperature sensor Opened sensor. failure.

06

Cab air temperature sensor Shorted circuit sensor. failure.

07

External air temperature sen- Opened sensor. sor failure.

08

External air temperature sen- Shorted circuit sensor. sor failure.

09

Evaporator temperature sen- Opened sensor. sor failure.

10

Evaporator temperature sen- Shorted circuit sensor. sor failure.

11

Solar sensor failure.

14

Input from recirculation ac- The signal from the potentituator #1 failure. ometer of recirculation actuator #1 is outside its working limits.

15

Reference for potentiometer The potentiometer reference recirculation actuator #1 & #2 is shorted circuit to ground. failure.

20-486

Description

The signal from the solar sensor is outside its limits or given an impossible value.

Qualification

Effect

The signal from mixed air sensor is higher than maximum threshold “TSensMax” [V]. The signal from mixed air sensor is lower than minimum threshold “TSensMin” [V].

• The water valve opening is manually controlled. • The AC is manually controlled. • The water valve opening is manually controlled. • The AC is manually controlled.

The signal from the potentiometer is lower than minimum threshold “TInRicMin” or is higher than maximum threshold “TInRicMax”. The signal from ambient air sensor is higher than maximum threshold “TSensMax” [V]. The signal from ambient air sensor is lower than minimum threshold “TSensMin” [V]. The signal from external air sensor is higher than maximum threshold “TSensMax” [V]. The signal from external air sensor is lower than minimum threshold “TSensMin” [V]. The signal from evaporator sensor is higher than maximum threshold “TSensMax” [V]. The signal from evaporator sensor is lower than minimum threshold “TSensMin” [V]. The signal from the solar sensor is higher than maximum threshold or the reading it is not impossible with the external conditions. The signal from the potentiometer is lower than minimum threshold “TInRicMin” or is higher than maximum threshold “TInRicMax”. The potentiometer reference is lower than minimum threshold [V].

• The recirculation actuator (#1 & #2) is forced in the external air position. • The water valve opening is manually controlled. • The A/C is manually controlled. • The water valve opening is manually controlled. • The A/C is manually controlled. • The water valve opening is manually controlled. • The A/C is manually controlled. • The water valve opening is manually controlled. • The A/C is manually controlled. • The A/C is turned off and cannot cooling. • The A/C is turned off and cannot cooling. • The system takes a default value of 300 W/m2.

• The recirculation actuator (#1 & #2) is forced in the external air position. • The recirculation actuator (#1 & #2) is forced in the external air position.

Calibrations and electronic diagnosis ART Code Spn

16

17 18 19 20 21 22 23 24

25 26

27 28 29 30

Name

Description

Qualification

Input from selected tempera- The signal is outside its work- The signal is lower than miniture potentiometer failure. ing limits. mum threshold or is higher than maximum threshold. Input from selected blower The signal is outside its work- The signal is lower than minispeed potentiometer failure. ing limits. mum threshold or is higher than maximum threshold. Cab sensor fan failure. The fan does not rotate. Shorted circuit to ground or to power supply. Stepper motor output failure The stepper motor doesn’t Phases of stepper motor (Water valve). work correctly. opened or shorted circuit to ground or to power supply. Recirculation actuator motor The recirculation actuator Outputs of the recirculation (#1 & #2) output failure. does not work correctly. actuator shorted circuit to ground or to power supply. A/C relay output failure. The relay does not work cor- Output opened or shorted cirrectly. cuit to power supply. Water pump relay output fail- The relay does not work cor- Output opened or shorted cirure. rectly. cuit to power supply. Not Used. Engine RPM failure. The message from CAN is “CANBUS” failure. not valid.

Not Used. Engine water temperature The message from CAN is “CANBUS” failure. failure. not valid.

Effect

• The system goes in automatic mode with a default selected temperature (+21°C). • The system controls the blower speed automatically. • The recirculation actuator (#1 & #2) motor output is turned off. • The system considers the last value received for 2 consecutive seconds. • If no CAN message are received, after this time, the system takes a default value of 1500 RPM.

• The system considers the last value received for 10 consecutive seconds. • If no CAN message are received, after this time, the system takes a default value of +90°C. Output for blower speed con- The signal is outside its work- Shorted circuit to ground or to troller #1 failure. ing limits. power supply. • The control unit works in deUnder voltage failure. (*) The power supply signal is graded mode. lower than minimum threshold. Over voltage failure. The power supply signal is • The control unit is switched off. higher than maximum threshold. Output for blower speed con- The signal is outside its work- Shorted circuit to ground or to troller #2 failure. ing limits. power supply.

20-487

Calibrations and electronic diagnosis Note: (*) = The setting of the “spn 28” is enable 60 seconds after the control unit power on.

20.5.7 - EPB Alarms EPB alarms list Table 251 ART code Spn

4106

Component Instrument panel display error

N004 - E.P.B.

4108

N004 - E.P.B.

4109

N004 - E.P.B.

4111

K007 - E.P.B.

4112

N004 - E.P.B.

4113

N004 - E.P.B.

4114

N004 - E.P.B. device

EPB_014

Fig. 546

4119 4127 4128 4129 4138 EPB_014

4147

Fig. 546

EPB_003

Fig. 547

20-488

RESPONSE

Controls

Link to system

The EPB is blocked in The EPB must be re- 40-321 40-480 Internal device fault The EPB is blocked in The EPB must be re- 40-321 40-480 Internal device fault The EPB is blocked in Possible poor charge 40-321 40-480 Internal device fault The EPB is blocked in Possible poor charge 40-321 40-480 Pressure sensor signal No limitation of the nor- Check the wiring to the 40-321 40-480 Internal device fault The EPB is blocked in The EPB must be re- 40-321 40-480 Internal device fault The EPB is blocked in The EPB must be re- 40-321 40-480 Internal device fault No limitation of the nor- The EPB must be re- 40-321 mal EPB reaction. placed. The EPB returns 40-480 immediately to SDF.

N004 - E.P.B. Internal device fault

4107

4115

Fault

The EPB is blocked in The EPB must be re- 40-321 40-480 Incongruence between It may not be possible to Checking the ignition in- 40-112 starter key position and control the EPB due to put. (Pin C1) signals. this fault. N004 - E.P.B. Internal device fault The EPB is blocked in The EPB must be re- 40-321 40-480 N004 - E.P.B. Internal device fault The EPB is blocked in The EPB must be re- 40-321 40-480 N004 - E.P.B. Internal device fault The EPB is blocked in The EPB must be re- 40-321 40-480 N004 - E.P.B. Internal device fault No limitation of the nor- The EPB must be re- 40-321 device mal EPB reaction. placed. The EPB returns 40-480 immediately to SDF. N004 - E.P.B. Internal device fault

T001 - Battery Main battery voltage be- The EPB switches to the positive terminal low 10V back-up battery and it keeps it operating. Note: The capacity of the backup battery is limited. It is important to restore the functionality of the main battery, otherwise the EPB may stop functioning.

Check - the charge level of the main battery - the voltage of the battery to the EPB connector (Pin A1 = Batt. +, Pin A8 = Batt. -)

Calibrations and electronic diagnosis Table 252 ART code Spn

4148

Component Instrument panel display error

Fault

RESPONSE

4161

voltage The EPB switches to the back-up battery and it keeps it operating. Note: The capacity of the backup battery is limited. It is important to restore the functionality of the main battery, otherwise the EPB may stop functioning. T001a - Battery Main battery voltage not The EPB switches to the positive terminal within permitted range back-up battery and it keeps it operating. Note: The capacity of the backup battery is limited. It is important to restore the functionality of the main battery, otherwise the EPB may stop functioning. N004 - E.P.B. Internal device fault No limitation of the EPB

4163

N004 - E.P.B. Internal device fault

No limitation of the EPB

4167

N004 - E.P.B. Internal device fault device

No limitation of the EPB function

4169

N004 - E.P.B. Internal device fault device

No limitation of the EPB function

4177

T004 - Auxiliary Auxiliary battery volt- No limitation of the norbattery positive age not within permitted mal EPB reaction. Note: terminal range The fault must be eliminated immediately in order to re-establish the correct reaction of the EPB. T004 - Auxiliary Auxiliary battery charge No limitation of the norbattery positive level invalid mal EPB reaction. Note: terminal The fault must be eliminated immediately in order to re-establish the correct reaction of the EPB.

EPB_003

Fig. 547

4149 EPB_003

Fig. 547

EPB_005

Fig. 549

4178 EPB_005

Fig. 549

T001a - Battery Main battery positive terminal above 16V

Controls

Link to system

Check - the charge level of the main battery - the voltage of the battery to the EPB connector (Pin A1 = Batt. +, Pin A8 = Batt. -) - the cables

Check - the voltage of the battery to the EPB connector (Pin A1 = Batt. +, Pin A8 = Batt. -) - the 30 A fuse of the main battery for the EPB - the cables

Check - the connection to 40-321 40-480 Check - the connection to 40-321 40-480 Check - the connection 40-321 between EPB (Pin A6) 40-480 and the armrest (Pin V-1) Check - the connection 40-321 between EPB (Pin B6) 40-480 and WOD (Pin 12) Check - the connection of the battery to the EPB (Pin B8 = Batt. +, Pin C8 = Batt. -) - the 30 Amp fuse of the back-up battery for the EPB - the cables Check - the charge level of the back-up battery. The back-up battery is charged by the EPB as soon as the engine starts running.

20-489

Calibrations and electronic diagnosis ART code Spn

4179

Component Instrument panel display error

EPB_005

Fig. 549

4180 EPB_005

Fig. 549

4181 EPB_005

Fig. 549

4182 EPB_012

Fig. 550

4197 EPB_014

Fig. 550

20-490

Fault

RESPONSE

T004 - Auxiliary Auxiliary battery discon- No limitation of the norbattery positive nected mal EPB reaction. Note: terminal The fault must be eliminated immediately in order to re-establish the correct reaction of the EPB. T004 - Auxiliary Auxiliary battery test cy- No limitation of the norbattery positive cle failed mal EPB reaction. Note: terminal The fault must be eliminated immediately in order to re-establish the correct reaction of the EPB. T004 - Auxiliary Auxiliary battery voltage No limitation of the norbattery positive too high mal EPB reaction. Note: terminal The fault must be eliminated immediately in order to re-establish the correct reaction of the EPB. Problems with both bat- The EPB is blocked in teries the last position. If a command is given while the fault is being checked. The EPB opens and closes again immediately until the alarm reappears Travel speed signal not No limitation of the norwithin permitted range mal EPB reaction. Note: The fault must be eliminated immediately in order to re-establish the correct reaction of the EPB.

Controls

Check - the connection of the battery to the EPB (Pin B8 = Batt. +, Pin C8 = Batt. -) - the 30 Amp fuse of the back-up battery for the EPB - the cables Check - the charge level of the back-up battery - the battery acid level. Charge or replace the battery Check - the connection of the battery to the EPB (Pin B8 = Batt. +, Pin C8 = Batt. -) - the cables

Check - the voltage of the main battery on the male connector of the EPB (Pin A1 = Batt. +, Pin A8 = Batt. -) - the voltage of the back-up battery to the EPB (Pin B8 = Batt. +, Pin C8 = Batt. -) - the cables - the EPB fuses Check - the cable connection between Pin B4 EPB and Pin 84 HLHP2. This is a PWM signal with a 0-12 Volt square wave, 100 Hz frequency and 5-95% utilisation rate

Link to system

Calibrations and electronic diagnosis ART code Spn

4227

Component Instrument panel display error

Fault

RESPONSE

Controls

Link to system

CANBUS line discon- The parking brake renected mains efficient. There is a direct connection of the sensors and the HLHP2. The comfort functions are no longer available. Automatic brake engagement when the engine is turned off is still active. Note: The fault must be eliminated immediately in order to re-establish the correct reaction of the EPB.

Check - the connection 40-231 between EPB and HLHP 40-297 2 (CAN H: Pin C2 EPB 40-216 - Pin 32 HLHP2) (CAN L: Pin C3 EPB - Pin 30 HLHP2)

Fault

Controls

Table 253 ART code Spn

4228

4229

Component Instrument panel display error

RESPONSE

CANBUS line not trans- The parking brake remitting data mains efficient. There is a direct connection of the sensors and the HLHP2. The comfort functions are no longer available. Automatic brake engagement when the engine is turned off is still active. Note: The fault must be eliminated immediately in order to re-establish the correct reaction of the EPB. Problems with CANBUS The parking brake mainline tains complete functionality with the following limitations: - it is possible to release the parking brake without the driver’s seat being occupied. The pressure of the two brake pedals permits opening. Note: The fault must be eliminated immediately in order to re-establish the correct reaction of the EPB.

Link to system

Check - the connection 40-231 between EPB and HLHP 40-297 2 (CAN H: Pin C2 EPB 40-216 - Pin 32 HLHP2) (CAN L: Pin C3 EPB - Pin 30 HLHP2)

Check - the connection 40-231 between EPB and HLHP 40-297 2 (CAN H: Pin C2 EPB 40-216 - Pin 32 HLHP2) (CAN L: Pin C3 EPB - Pin 30 HLHP2) - the condition of HLHP2 (must be engaged when the EPB is engaged)

20-491

Calibrations and electronic diagnosis ART code Spn

4230

Component Instrument panel display error

Fault

RESPONSE

Problems with engine The parking brake maincontrol unit CANBUS line tains complete functionality. Attention: The fault must be eliminated immediately in order to re-establish the correct reaction of the EPB.

4231

Line problems due to sig- The parking brake mainnal loss tains complete functionality. Attention: The fault must be eliminated immediately in order to re-establish the correct reaction of the EPB.

4232

Problems with transmis- The parking brake mainsion control unit CAN- tains complete funcBUS line tionality. Attention: The fault must be eliminated immediately in order to re-establish the correct reaction of the EPB.

4233

Problems with transmis- The parking brake mainsion control unit CAN- tains complete functionality. Attention: The BUS line fault must be eliminated immediately in order to re-establish the correct reaction of the EPB.

4237

Line problems due to sig- The parking brake mainnal loss tains complete functionality Travel direction signal The parking brake maintransmitted via CAN- tains complete functionBUS not within permitted ality range Travel speed signal The parking brake maintransmitted via CAN- tains complete functionBUS not within permitted ality range Line problems due to sig- The parking brake mainnal loss tains complete functionality

4238

4239

4240

20-492

Controls

Link to system

Check - the connection between EPB and HLHP 2 (CAN H: Pin C2 EPB - Pin 32 HLHP2) (CAN L: Pin C3 EPB - Pin 30 HLHP2) - the condition of HLHP2 (must be engaged when the EPB is engaged) Check - the connection between EPB and HLHP 2 (CAN H: Pin C2 EPB - Pin 32 HLHP2) (CAN L: Pin C3 EPB - Pin 30 HLHP2) - the condition of HLHP2 (must be engaged when the EPB is engaged) Check - the connection between EPB and HLHP 2 (CAN H: Pin C2 EPB - Pin 32 HLHP2) (CAN L: Pin C3 EPB - Pin 30 HLHP2) - the condition of HLHP2 (must be engaged when the EPB is engaged) Check - the connection between EPB and HLHP 2 (CAN H: Pin C2 EPB - Pin 32 HLHP2) (CAN L: Pin C3 EPB - Pin 30 HLHP2) - the condition of HLHP2 (must be engaged when the EPB is engaged)

40-231 40-297 40-216

40-231 40-297 40-216

40-231 40-297 40-216

40-231 40-297 40-216

40-231 40-297 40-216 40-231 40-297 40-216 40-231 40-297 40-216 40-231 40-297 40-216

Calibrations and electronic diagnosis Table 254 ART code Spn

4241

Component Instrument panel display error

4242

4246 EPB_014

4248

Fig. 550

4251

4255 4257 EPB_014

4258 4267 4277 4278 4279 4280

Fig. 550

Fault

RESPONSE

Controls

Line problems due to sig- The parking brake mainnal loss tains complete functionality Engine speed signal The parking brake maintransmitted via CAN- tains complete functionBUS not within permitted ality range N004 - E.P.B. Internal device fault No limitation of the nor- The EPB must be redevice mal EPB reaction. placed. The EPB returns immediately to SDF.

Operator present sensor signal transmitted via CANBUS not within permitted range H001 - Armrest E.P.B. control lever signal transmitted via CANBUS not within permitted range

The parking brake maintains complete functionality

Link to system

40-231 40-297 40-216 40-231 40-297 40-216 40-321 40-480 40-231 40-297 40-216

The parking brake main40-480 40-321 tains complete functionality. The manual opening of the parking brake is accepted even if the driver is not in his seat N004 - E.P.B. Internal device fault The EPB is blocked in Reset the Eeprom to re- 40-480 40-321 N004 - E.P.B. Device temperature too No limitation of the nor- The EPB must be re- 40-321 device high mal EPB reaction. placed. The EPB returns 40-480 immediately to SDF. N004 - E.P.B. Power stage temperature The EPB is blocked in Check - the temperature 40-321 40-480 N004 - E.P.B. Brake cable disconnect- The EPB is blocked in Check - the condition of 40-321 40-480 N004 - E.P.B. Incongruent travel speed No limitation of the nor- Check - the CAN con- 40-321 40-480 N004 - E.P.B. Internal device fault The EPB is blocked in The EPB must be re- 40-321 40-480 N004 - E.P.B. Internal device fault The EPB is blocked in Check - the wear to the 40-321 40-480 N004 - E.P.B. Internal device fault The EPB is blocked in Check for any mechani- 40-321 40-480

20-493

Calibrations and electronic diagnosis Table 255 ART code Spn

4281

Component Instrument panel display error

N004 - E.P.B. Internal device fault

4282 EPB_011

4283

Fig. 552

4284 EPB_011

4286

Fig. 553

EPB_009

4287

Fig. 554

EPB_007

Fig. 554

4288 EPB_007

Fig. 554

20-494

Fault

N004 - E.P.B. Internal device fault device N004 - E.P.B. Internal device fault N004 - E.P.B. Internal device fault device N004 - E.P.B. Internal device fault device

RESPONSE

Controls

Link to system

The EPB is blocked in Check the condition of 40-321 40-480 The EPB is blocked in Wait until the alarm dis- 40-321 40-480 the engaged condition appears until the alarm stops. The wear limit of the Check - the brake linings 40-321 40-480 The EPB remains closed Wait a few minutes until 40-321 40-480 until the alarm is deacti- the alarm disappears vated. The EPB operates with- Adjust the brake control 40-321 out limitations and wait for the error to 40-480 deactivate.

H001 - Armrest E.P.B. control lever pow- The EPB operates norer not within permitted mally with the redundant range lever that is connected to the supervisor in the ECU. Note: The fault must be eliminated immediately in order to reestablish the correct reaction of the EPB. H001 - Armrest E.P.B. control lever sig- The EPB operates nornals not within permitted mally with the redundant range lever that is connected to the supervisor in the ECU. Note: The fault must be eliminated immediately in order to reestablish the correct reaction of the EPB.

Check - the power voltage: There must be 5V power on Pin B1 of the EPB - check the cables between Pin B1 of the EPB and Pin V4 of the armrest Check - the cables between Pin B1 of the EPB and Pin V4 of the armrest (there must be voltage equal to 5V) - the cables between Pin C6 of the EPB and Pin V5 of the armrest (there must be voltage equal to 0.5 - 4.5) - the cables between Pin A5 of the EPB and Pin V6 of the armrest (ground connection)

Calibrations and electronic diagnosis

20-495

Calibrations and electronic diagnosis ART code Spn

4290

Component Instrument panel display error

EPB_001

Fig. 554

4292 EPB_009

4308 4310

20-496

Fig. 554

Fault

RESPONSE

Controls

Link to system

H001 - Armrest Incongruent E.P.B. con- The EPB system does trol lever signals not accept the driver’s commands. The behaviour of the EPB is as follows: - if the fault is detected during safety braking, the EPB closes (Apply position) - if the fault is detected while the EPB is engaged, the EPB remains engaged if the fault is recognised in the released position, the EPB remains deactivated. EPB closes automatically as soon as the vehicle stops. All comfort functions remain active

N004 - E.P.B. Internal device fault device

On the main lever: Check: - the cables between Pin B1 of the EPB and Pin V4 of the armrest (there must be a signal of 5V) - the cables between Pin C6 of the EPB and Pin V5 of the armrest (there must be voltage equal to 0.5 and 4.5 Volt) - the cables between Pin A5 of the EPB and Pin V6 of the armrest (ground connection) On the secondary lever: Check: the cables between Pin 72 of the HLHP and Pin V18 of the armrest (there must be a signal of 5V) the cables between Pin 40 of the HLHP and Pin V17 of the armrest (there must be voltage between 0.5 and 4.5 Volt) - the cables between Pin 9 of the HLHP and Pin V16 of the armrest (ground) The EPB system func- Stop incorrect use and 40-321 tions normally wait for the alarm to dis- 40-480 appear

Line problems due to sig- The EPB system funcnal loss or invalid signal tions normally Line problems due to sig- The EPB system funcnal loss or invalid signal tions normally. The comfort functions are not available. Automatic activation after switching on remains active

40-231 40-297 40-216 40-231 40-297 40-216

Calibrations and electronic diagnosis 20.5.8 - Electronic battery master switch alarms Alarm List, Electronic Battery Master Switch Table of errors

Table 256 No. of flashes

Type

Error Identification

01 02

X COM

03

COM

Not used. Short circuit to positive in command signal reading channels. Interrupted command signal reading channels.

04

MCO

05

AUX

06

MCO

07

COM

08

COM

09

COM

Conditions of occurrence

Not used. Both command signal reading channels (CH1 and CH2) at same voltage as battery positive. Both command signal reading channels (CH1 and CH2) interrupted. Close or open manoeuvre failure. Device does not detect main contact state requested by user after 4 repetitions of manoeuvre following initial attempt (for a total of 5 attempts). Short circuit to ground of AUX line Short circuit to ground detected in AUX line, causing interruption in electric power delivered through AUX line itself. This condition is ONLY detectable during activation of line itself. Unexpected contact state. Undesired aperture of main contact detected during activation. Short circuit to negative in command signal read- Both command signal reading channels (CH1 ing channels. and CH2) at same voltage as battery negative. First unexpected state of command signal read- Command signal reading channel CH1 disconing channels. nected and channel CH2 shorted to negative, or vice versa. Second unexpected state of command signal Command signal reading channel CH1 disconreading channels. nected and channel CH2 shorted to positive, or vice versa.

20-497

Calibrations and electronic diagnosis

PAGE LEFT INTENTIONALLY BLANK

20-498

30 - Method of intervention

30-1

Method of intervention 30.1 - Index Repair instructions (7210 TTV Agrotron ->WSXW830400LD50010) 30.1.1 - Repair level III

ZF S-Matic 180 - Continuously variable transmission Table 257 Removal No.

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17

Link

30-236 30-241 30-242 30-245 30-247 30-249 30-250 30-251 30-252 30-253 30-254 30-254 30-258 30-262 30-263 30-267 See para. 30.6.25 - Disassembly of filter ... - page 30-268

Table 258 Removal No.

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Link

30-268 30-269 30-269 30-271 30-274 30-278 30-281 30-283 30-283 30-289 30-290 30-298 30-302 30-302 30-304 30-306 30-308 See para. 30.6.52 - Disassembly of drive s... - page 30-310

Table 259 Installation No.

01 02 03 04 05 06 07 08 09 10 11

30-2

Link

30-349 30-350 30-353 30-355 30-359 30-363 30-372 30-373 30-374 30-376 30-377

Method of intervention Installation No.

12 13 14 15 16 17

Link

30-380 30-381 30-383 30-386 30-386 See para. 30.6.85 - Reassembly of filter h... - page 30-387

Table 260 Installation No.

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Link

30-285 30-388 30-390 30-391 30-393 30-394 30-397 30-399 30-400 30-403 30-403 30-406 30-408 30-409 30-419 30-419 30-422 30-426 30-431 See para. 30.6.105 - Reinstallation of cart... - page 30-437

ZF S-Matic 180 - Rear axle Table 261 Removal No.

01 02 03 04 05 06 07

Link

30-513 30-514 30-517 30-519 30-522 30-528 See para. 30.7.21 - Lifting Unit - Disasse... - page 30-529

Table 262 Assembly No.

01 02 03 04 05 06 07 08

Link

30-530 30-533 30-536 30-550 30-555 30-558 30-564 See para. 30.7.30 - Procedure for checking... - page 30-565

30-3

Method of intervention 30.2 - Index Repair instructions (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 30.2.1 - Repair level III

ZF S-Matic 240 - Continuously variable transmission Table 263 Removal No.

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Link

30-235 30-238 30-241 30-242 30-245 30-247 30-249 30-250 30-251 30-252 30-253 30-254 30-256 30-260 30-262 30-265 30-267 30-276 30-279 30-282 30-287 30-289 30-291 30-307 30-309 See para. 30.6.53 - Disassembly of Drive S... - page 30-312

Table 264 Installation No.

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

30-4

Link

30-313 30-314 30-317 30-319 30-331 30-333 30-334 30-334 30-336 30-337 30-339 30-343 30-345 30-346 30-349 30-403 30-406 30-408 30-414 30-419 30-419 30-422 30-426 30-431

Method of intervention Installation No.

25 26 27

Link

30-440 30-444 See para. 30.6.108 - Pipes and closing comp... - page 30-445

ZF S-Matic 240 - Rear axle Table 265 Removal No.

01 02 03 04 05 06

Link

30-446 30-449 30-451 30-454 30-466 See para. 30.7.6 - Removing the lifter (7... - page 30-467

Table 266 Assembly No.

01 02 03 04 05 06 07 08 09

Link

30-468 30-468 30-471 30-473 30-473 30-500 30-504 30-507 See para. 30.7.31 - Procedure to check EPB... - page 30-578

30-5

Method of intervention 30.3 - Installation of solenoid valves and cartridge valves 30.3.1 - Installation 1. 2.

3. 4.

Remove packaging and protective coverings from solenoid valve bodies and cartridge valves only at the moment of installation, so as to minimize the risk of contamination. Lubricate all O-rings fitted to solenoid valves and valve cartridges using a suitable mineral oil or grease compatible with AKROS oil. Contamination of lubricating fluid must be no higher than level 18/15, as specified in ISO 4406. For further information on contamination, refer to SAME specification 92349 Containers of lubricating fluids must be closed and fitted with the specific dispensing nozzle. The use of open containers or brushes is not permissible. Screw the solenoid valves and cartridge valves into the relative seats by hand, engaging at least one turn of the thread. Power drivers must not be used at this stage. Complete the tightening operation, applying torques as specified in the table of headings 3 and 4.

30.3.2 - Solenoid valve tightening torques Table 267

Type of solenoid valve

Fig. 555

Threads

p/n

7/8”-14 UNF

2.3719.750.0/XX 2.3729.410.0/XX 2.3729.610.0/XX

15-20

5-8

7/8”-14 UNF

2.3729.250.0/XX 2.3729.270.0/XX 2.3729.290.0/XX 2.3729.300.0/XX 2.3729.697.0/XX 2.3729.600.0/XX 2.3729.330.0/XX 2.3729.340.0/XX 2.3729.400.0/XX

15-20

5±0.5

15-20 15-20

5-8 5±0.5

7/8”-14 UNF

2.3729.310.0/XX 2.3729.698.0/XX 2.3729.718.0/XX

15-20

5±0.5

3/4”-16 UNF

2.3719.510.0/XX

15-20

20-25

M18X1.5

Fig. 556

Fig. 557

Fig. 558

30-6

Tightening torque A (Nm) B (Nm)

Method of intervention Type of solenoid valve

Threads

p/n

Tightening torque A (Nm) B (Nm)

M33X2

2.3729.709.0/XX

45-50

Threads

p/n

M18X1.5

2.3729.686.0/XX 2.3719.760.0/XX

Tightening torque A (Nm)

35-40

3/4”-16 UNF

2.3729.691.0/XX

35-40

M22X1.5 M18X1.5

2.3729.692.0/XX 2.3719.630.0/XX

45-50 35-40

7/8”-14 UNF

0.006.6161.4/XX 0.015.5426.4/XX

45-50 45-50

5-8

Fig. 559

30.3.3 - Cartridge valve tightening torques Table 268

Type of valve

Fig. 560

Fig. 561

Fig. 562

Fig. 563

30-7

Method of intervention 30.4 - B0 - Engine

30.4.1 - Removal and refitting of the crankcase breather Special tools:

Tool 5.9035.245.0 (Removal tool)

Removal of the crankcase breather 1.

Components: m m m m m m m m m m m m m m

2.

m m m m

(4) Hex head screw (5) Gasket (6) Crankcase breather (7) Hex head screw (8) Oil return pipe (9) Seal (10) Banjo bolt (11) Pipe retaining clip (12) Hose (13) Hose clamp (14) Seal (15) Return check valve (16) Hex head screw (18) Hose clamp

Fig. 564

Open up hose clamp (1) using the special pliers. Withdraw hose (2). Unscrew screws (3). Remove crankcase breather (4).

Fig. 565

3.

m

Remove gasket (1) using the removal tool.

Fig. 566

30-8

Method of intervention 1.

m m m

Withdraw screw (1). Unscrew screw (2). Unscrew banjo bolt (3). WARNING Keep the banjo bolt in the hose end fitting.

m m

Withdraw seals (4). Withdraw oil return line (5). Fig. 567

2.

m m

Unscrew check valve (1). Remove seal (2).

Fig. 568

Removal of the crankcase breather 1.

m m

Clean the sealing surfaces. Fit a new gasket (1).

Fig. 569

2.

m m

Locate crankcase breather (1). Tighten screws (2). n Tightening torque: 10 Nm

Fig. 570

30-9

Method of intervention 3.

m m

Fit seal (1). Tighten check valve (2). n Tightening torque: 80 Nm

Fig. 570

4.

WARNING Caution! Be careful not to lose the banjo bolt.

m m m m

m m

5.

m m m

Insert banjo bolt (5) and seal (4) in the hose end fitting. Fit oil return pipe (1). Locate pipe retaining clips (2). Tighten screw (3). n Tightening torque: 30 Nm Fit new seals (4). Tighten banjo bolt (5). n Tightening torque: 29 Nm

Fig. 571

Fit hose (1). Locate hose clip (2). Fix the hose clamp using the special pliers.

Fig. 572

30-10

Method of intervention Technical data Tightening torque:

Table 269 Designation

Type of tractor

Crankcase breather in correspondence with the cylin- M8x30-10.9 der head cover Oil return to gearbox M8x40-10.9 M8x50-10.9 Check valve on oil sump M22x1.5 Hose end fitting M12x1.5 Banjo bolt

Notes:

Value

-

10 Nm

Pipe retaining clip

30 Nm

-

80 Nm

-

29 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.2 - Removal and refitting of the crankcase breather Special tools:

Tool 5.9035.245.0 (Removal tool)

Removal of the crankcase breather 1.

Components: m m m m m m m m m m m m m m m m

2.

m m m m

(4) Hex head screw (5) Gasket (6) Crankcase breather (7) Hex head screw (8) Oil return pipe (9) Seal (10) Banjo bolt (11) Pipe retaining clip. (12) Flexible pipe (13) Hose clip (14) Seal (15) Check valve on return line (16) Hex head screw (17) Hose clip (18) Hose clip (950) Plug

Fig. 573

Loosen hose clip (1) with the special pliers. Withdraw flexible pipe (2). Unscrew screws (3) Remove crankcase breather (4).

Fig. 574

30-11

Method of intervention 3.

m

Remove gasket (1) using the removal tool.

Fig. 575

4.

m m m

Remove screw (1). Unscrew screw (2) Unscrew banjo bolt (3) WARNING Keep the banjo bolt in the hose end fitting.

m m

Remove seals (4). Remove oil return pipe (5) Fig. 576

5.

m m

Unscrew check valve (1); Remove seal (2)

Fig. 577

30-12

Method of intervention Refitting the crankcase breather 1.

m m

Clean the mating surfaces. Fit a new gasket (1).

Fig. 578

2.

m m

Locate crankcase breather (1). Tighten screws (2). n Tightening torque: 10 Nm

Fig. 579

3.

m m

Fit seal (1) Tighten check valve (2); n Tightening torque: 80 Nm

Fig. 580

4.

m

Insert banjo bolt (5) and seal (4) in the hose end fitting. WARNING Caution! Be careful with the banjo bolt.

m m m

m m

Fit oil return pipe (1) Locate pipe retaining clips (2) Tighten screw (3) n Tightening torque: 30 Nm Fit new seals (4). Tighten banjo bolt (5). n Tightening torque: 29 Nm

Fig. 581

30-13

Method of intervention 5.

m m m

Fit flexible pipe (1). Locate hose clip (2). Secure the hose clip with the special pliers.

Fig. 582

Technical data Tightening torque:

Table 270 Designation

Screw type

Crankcase breather on cylinder head cov- M8x30-10.9 er. Oil return pipe on gearbox M8x40-10.9 M8x50-10.9 Check valve on lube oil sump M22x1.5 Hose end fitting - Banjo bolt M12x1.5 -

Note:

Value

-

10 Nm

Pipe retaining clip

30 Nm

-

80 Nm

-

29 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.3 - Renewal of the crankshaft oil seal Special tools:

Tool 5.9035.138.0 (Lever) Self-tapping screw Washer

Removal of the crankshaft oil seal 1.

Components: m m m

(1) Front cover (2) Crankshaft oil seal (3) Self-tapping screw

Fig. 583

30-14

Method of intervention 2.

m

m

Remove the torsional vibration damper n See para. 30.5.21 - Installation and remov... - page 30-231 Using a bradawl, make a hole about 3 mm in diameter in the old crankshaft oil seal. WARNING Caution! Be careful not to damage the front cover or the crankshaft.

Fig. 584

3.

m m

Screw a self-tapping screw, fitted with a washer, into the hole. Extract the crankshaft oil seal using the lever. WARNING Be careful not to damage the crankshaft.

m

Carefully examine the sealing surfaces on the crankshaft journal.

Fig. 585

Installation of the crankshaft oil seal 1.

m

Remove bush (1).

Fig. 586

2.

m

Fit guide bush (1). WARNING Check that locating dowel (2) is aligned with hole (3).

Fig. 587

30-15

Method of intervention 3.

m

Tighten screws (1).

Fig. 588

4.

m m

Lightly oil the lip of the crankshaft oil seal. Carefully place the crankshaft oil seal on the crankshaft journal. WARNING The seal lip must face the engine block.

Fig. 589

5.

m m

Fit spacer (1). If the crankshaft flange has an entry groove, the oil seal can be installed at three different depths: n First assembly = 2 shims n 1st overhaul - installation depth - 1 shims n 2nd overhaul - installation depth - 0 shims

Fig. 590

6.

m m

Fit guide bush (1). Push the crankshaft oil seal into its seating.

Fig. 591

30-16

Method of intervention 7.

m m

Fit bearing (1). Tighten nut (2).

Fig. 592

8.

m

Tighten the nut until it seats against installation bush (1). WARNING The crankshaft oil seal is now installed at the correct depth. Insert bush (1) fully.

m

Removal assembly tool.

Fig. 593

9.

m

Fit the torsional vibration damper. n See para. 30.5.21 - Installation and remov... - page 30-231

Fig. 594

30-17

Method of intervention 30.4.4 - Changing the crankshaft ring gasket (flywheel side) Special tools:

Tool 5.9035.139.0 (Assembly tool)

Removal of crankshaft ring gasket 1.

Components: m m m m m

(1) Gearbox (2) Hex screw (3) Hex screw (4) Crankshaft ring gasket (234) Sealant

Fig. 595

2.

m

m

Remove the flywheel. n See para. 30.4.9 - Removal and refitting ... - page 30-30 n See para. 30.4.10 - Removal and refitting ... - page 30-31 n See para. 30.4.11 - Removal and refitting ... - page 30-33 Using an awl, make a hole approximately 3 mm in diameter the crankshaft ring gasket. WARNING Caution! Take care not to damage the gearbox cover and the crankshaft. Fig. 596

3.

m

Insert a self-tapping screw (1) with washer.

Fig. 597

4.

m m

Remove crankshaft ring gasket with the assembly pry bar. Inspect sliding surface of crankshaft ring gasket.

Fig. 598

30-18

Method of intervention Fit crankshaft ring gasket 1.

m m

Fit guide bush (1). Tighten screws (2). WARNING The holes in the guide bush must be aligned with the threaded holes of the crankshaft flange.

Fig. 599

2.

m m

Lightly oil the sealing lip of the crankshaft ring gasket. Gently place the crankshaft ring gasket on the sliding surface. WARNING The sealing lip must be facing the crankcase.

Fig. 600

3.

m

Fit spacer disc (1). WARNING If the crankshaft flange features an entry channel the crankshaft ring gasket can be fitted at three different depths: First assembly = 2 washers, 1st repair - assembly level = 1 washer, 2nd repair - assembly level = 0 washers.

Fig. 601

4.

m m

Fit assembly bush (1). Push crankshaft ring gasket until it is pressed fully home.

Fig. 602

30-19

Method of intervention 5.

m m

Fit bearing (1). Tighten nut (2).

Fig. 603

6.

m

Tighten nut until it locates against assembly bush (1). WARNING The crankshaft ring gasket is now at the chosen installation depth.

m m

Remove the assembly tool. Fit the flywheel. n See para. 30.4.11 - Removal and refitting ... - page 30-33 n See para. 30.4.10 - Removal and refitting ... - page 30-31 n See para. 30.4.9 - Removal and refitting ... - page 30-30 Fig. 604

30.4.5 - Installation and removal of the crankshaft sleeve Special tools: -

Installation of the crankshaft wear sleeve 1.

m

Remove the crankshaft oil seal. n See para. 30.4.1 - Removal and refitting ... - page 30-8 n See para. 30.4.2 - Removal and refitting ... - page 30-11 n See para. 30.4.3 - Renewal of the cranksh... - page 30-14

Fig. 605

2.

m m

Carry out a visual inspection of the crankshaft journal. Thoroughly clean the crankshaft journal. WARNING Any irregularities, such as scoring, wear grooves or particularly rough surfaces can result in oil leaking between the crankshaft and the sleeve.

m m

Correct any irregularities with sealant. Remove bush (1). Fig. 606

30-20

Method of intervention 3.

WARNING Caution! Be careful not to damage the sealing surfaces.

m m

Assemble installation tool (1) over crankshaft wear sleeve (2). Locate the crankshaft sleeve assembly centrally with shoulder (3) facing the crankshaft.

Fig. 607

4.

m

m

Gently tap the centre of installation tool (1) with a mallet to drive in the wear sleeve until the installation tool seats against the crankshaft. Drive the crankshaft sleeve forward square. WARNING The installation depth is determined by the length of the installation tool. WARNING The wear sleeve should cover all signs of wear on the crankshaft journal.

5.

Fig. 608

WARNING After installing the crankshaft wear sleeve, check that there are no grooves or ridges on the crankshaft journal. m

Lightly oil the crankshaft journal. WARNING To avoid possible contamination with dust and dirt, do not soak the crankshaft oil seal, which contains nonwoven fabric, in lubricating oil. WARNING

Fig. 609

A lubricating wax is applied to the seal lip by the manufacturer. m

Install a new crankshaft oil seal. n See para. 30.4.1 - Removal and refitting ... - page 30-8 n See para. 30.4.2 - Removal and refitting ... - page 30-11 n See para. 30.4.3 - Renewal of the cranksh... - page 30-14

30-21

Method of intervention Removal of the crankshaft wear sleeve 1.

m m

Remove the crankshaft oil seal. Remove the oil suction pipe. n See para. 30.4.3 - Renewal of the cranksh... - page 30-14 n See para. 30.4.2 - Removal and refitting ... - page 30-11 n See para. 30.4.1 - Removal and refitting ... - page 30-8

Fig. 610

2.

m

Apply two levers to the sides (arrowed) of the front cover casting. WARNING Caution! Be careful not to damage the mating surfaces.

Fig. 611

3.

m m

Withdraw the crankshaft wear sleeve Remove the front cover.

Fig. 612

4.

m m m

m

Refit the front cover. Refit the oil suction pipe. Install a new crankshaft oil seal. n See para. 30.4.3 - Renewal of the cranksh... - page 30-14 n See para. 30.4.2 - Removal and refitting ... - page 30-11 n See para. 30.4.1 - Removal and refitting ... - page 30-8 Fit bush (1).

Fig. 613

30-22

Method of intervention 30.4.6 - Removal and refitting of the front cover (fixing elements) Special tools: -

Removal of the front cover 1.

Components: m m m

(1) Hex head screw (2) Gasket (3) Bush

Fig. 614

2.

m

m

m m m m m m

Remove the torsional vibration damper n See para. 30.4.10 - Removal and refitting ... - page 30-31 Remove the crankshaft speed sensor. n See para. 30.5.18 - Removal and refitting ... - page 30-226 Remove the oil suction pipe. Remove screws (1). Apply two levers to the sides (arrowed) of the front cover casting. Remove front cover (2). Remove the gasket. Carry out a visual inspection of the components. Fig. 615

3.

m

Remove crankshaft seal (1). WARNING Caution! Be careful not to damage the sealing surfaces during removal.

m

Clean the mating surfaces of the front cover and the engine block.

Fig. 616

Refitting the front cover 1.

WARNING Use a gasket with steel reinforcement ribs. WARNING Consult the documentation supplied with the replacement parts. m m

Fit bush (1). Locate new gasket (2) on engine block. Fig. 617

30-23

Method of intervention 2.

m

Fill the oil pump housing with lubricating oil.

Fig. 618

3.

m

Position the internal rotor relative to the crankshaft. WARNING The machining on the crankshaft and on the rotor guides must coincide. WARNING The internal rotor can only be fitted to the crankshaft in one position. Fig. 619

4.

m m

Fit front cover (1). Fit screws (2). WARNING Do not tighten the screws at this stage.

Fig. 620

5.

m

Push the front cover upwards and align it with the mating surface of the oil sump pan (arrowed).

Fig. 621

30-24

Method of intervention 6.

m

Tighten the screws in the sequence indicated. n Stage 1, Tightening torque: 5 Nm n Stage 2, Tightening torque: 21 Nm

Fig. 622

7.

WARNING Caution! Do not trim off the protruding part of the gasket (arrowed). m m

m

m

Refit the oil suction pipe. Fit the crankshaft speed sensor. n See para. 30.5.18 - Removal and refitting ... - page 30-226 Fit the crankshaft oil seal (opposite end to flywheel) n See para. 30.4.3 - Renewal of the cranksh... - page 30-14 Fit the torsional vibration damper. n See para. 30.4.10 - Removal and refitting ... - page 30-31

Fig. 623

Technical data Tightening torque

Table 271 Designation

Screw type

Front cover to engine block

-

Front cover to engine block

M8x35-10.9 -

Note:

Value

Stage 1: 5 Nm Observe the tightening sequence indicated. Stage 2: 21 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.7 - Removal and refitting of the oil sump pan Special tools:

Tool 5.9035.245.0 (Removal tool) WARNING Collect used service products in suitable containers and dispose of them in accordance with the applicable regulations. WARNING The draining and replenishing of engine fluids and lubricants must be carried out in accordance with the instructions given in the documentation provided by the manufacturer of the vehicle/appliance.

30-25

Method of intervention Removal of the oil sump pan 1.

Components: m m m m m m m m

(1) Oil sump pan (2) Plug (3) Seal (4) Plug (5) Seal (6) Hex head screw (7) O-ring (243) Sealant

Fig. 624

2.

m m m

m

Do not fully unscrew drain plug (1). Remove the seal. Drain, collect and dispose of the used oil in accordance with the applicable regulations. Remove the filler neck. n See para. 30.4.8 - Removal and refitting ... - page 30-28

Fig. 625

3.

m m

m

Remove all the screws (1). Fit the screws in threaded holes (2). n 2xM8 Tighten the screws alternately. WARNING The sump pan is separated from the mating surface.

m m m

4.

m

Prise off the sump pan by using a lever in the apertures (arrowed). Remove the the oil sump pan. Carry out a visual inspection of the components.

Fig. 626

Remove seal (1) using the removal tool.

Fig. 627

30-26

Method of intervention Refitting the oil sump pan 1.

m

Clean the mating surfaces. WARNING The mating surfaces must be free of grease and dirt.

m

Fit new seals (1).

Fig. 628

2.

m

Apply sealant (1) evenly to the mating surface. WARNING Apply a bead of sealant approx. 3.5 mm wide. WARNING The illustration shows a detail of how the sealant is to be applied. WARNING Apply sealant to the rest of the mating surface in the same way.

Fig. 629

WARNING Caution! Make sure that no sealant enters the oil way (2). 3.

m

m

To align the sump pan, screw four stud bolts in a diagonal pattern into the crankcase holes. Fit the oil sump pan. WARNING Be careful not to dislodge the sealant when fitting the oil sump pan.

m

Tighten all screws (1).

Fig. 630

4.

m

Tighten the screws in the sequence indicated. n Tightening torque: 30 Nm

Fig. 631

30-27

Method of intervention 5.

m

m m

m

Fit the oil filler neck. n See para. 30.4.8 - Removal and refitting ... - page 30-28 Fit the new seal. Tighten plug (1). n Tightening torque: 55 Nm Top up the lubricating oil as described in the instructions.

Fig. 632

Technical data Tightening torque

Table 272 Designation

Screw type

Oil sump pan (cast) on engine crankcase. M8x25-10.9 Plug in oil sump pan. M18x1.5 -

Note:

Value

Observe the indicated tightening se- 30 Nm quence! Renew seal. 55 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.8 - Removal and refitting of the oil filler pipe Special tools:

Tool 5.9035.245.0 (Removal tool) WARNING Collect used service products in suitable containers and dispose of them in accordance with the applicable regulations.

Removal of the oil filler neck 1.

Components: m m m

(1) Oil filler neck (2) Hex head screw (3) O-ring

Fig. 633

30-28

Method of intervention 2.

m m

Remove screws (1). Remove oil filler neck (2).

Fig. 634

3.

m

Remove O-ring (1) using the removal tool.

Fig. 635

Refitting the oil filler neck 1.

m m m

Clean the sealing surfaces. Fit new seals (1). Apply a thin smear of assembly product to the O-ring.

Fig. 636

2.

m m

Fit oil filler neck (1). Tighten screws (2). n Tightening torque: 22 Nm

Fig. 637

30-29

Method of intervention Technical data Tightening torque:

Table 273 Designation

Oil filler neck, support to engine block.

Type of tractor

M8x16-10.9 -

Note:

-

Value

22 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.9 - Removal and refitting of the V-belt pulley Special tools:

Tool 5.9035.335.0 (Rotation device)

Removal of the lubricating oil pipe 1.

Removal of the V-belt pulley m m m m m m

(1) Torx screw (2) Tightening bush (3) Spring pin (4) Torsional vibration damper (5) V-belt pulley (6) Fillister-head screw

Fig. 638

2.

m m m

Slacken off the ribbed V-belt at the chain tensioner. Remove the ribbed V-belt. Apply rotation device (1). WARNING Use the rotation device to hold the pulley against rotation.

m m m

Remove screws (2). Remove V-belt pulley (3). Visually inspect the component. Fig. 639

Refitting the V-belt pulley 1.

m m

Locate V-belt pulley (1). Fit screws (2) using thread locking agent. WARNING Use the rotation device to hold the pulley against rotation.

m

m m

Tighten screws (2). n Tightening torque: 170 Nm Remove rotation device (3). Fit the ribbed V-belt. Fig. 640

30-30

Method of intervention Technical data Tightening torque:

Table 274 Designation

Screw type

V-belt pulley to V-belt pulley/torsional vibra- M14x35-10.9 tion damper

Note:

Use DEUTZ DW72 thread locking agent.

Value

170 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.10 - Removal and refitting of the torsional vibration damper Special tools:

Tool 5.9035.142.0 (Counterhead)

Removal of the torsional vibration damper 1.

Components: m m m m m m

(1) Torx screw (2) Bush (3) Spring pin (4) Torsional vibration damper (5) V-belt pulley (6) Fillister-head screw

Fig. 641

2.

m m m

m

m m

Slacken off the V-belt at the tensioner. Remove the V-belt. Remove the belt tensioner. n See para. 30.4.26 - Removing and installin... - page 30-81 n See para. 30.4.27 - Removing and installin... - page 30-82 n See para. 30.5.12 - Removal and refitting ... - page 30-214 n See para. 30.5.13 - Removal and assembly o... - page 30215 Remove the V-belt pulley. n See para. 30.4.9 - Removal and refitting ... - page 30-30 n See para. 30.4.11 - Removal and refitting ... - page 30-33 Fit locking device (1). Tighten screws (2).

Fig. 642

30-31

Method of intervention Refitting the torsional vibration damper. 1.

m

Fit torsional vibration damper (1). WARNING Spring pin (2) must be inserted in hole (3). WARNING Bush (4) must be inserted in hole (5).

Fig. 644

2.

m m m

Fit new screws (1). Fit counterhead (2). Tighten screw (3)

Fig. 645

3.

m

Tighten the new screws (1) using the long reach socket and the rotation angle gauge. n Stage 1, Tightening torque 40 Nm n Stage 2, Angle: 60° n Stage 3, Angle: 60° WARNING Caution! The screws must be renewed each time they are disturbed. Fig. 646

4.

m m m

m

m

30-32

Remove screws (1). Remove counterhead (2). Fit the V-belt pulley. n See para. 30.4.11 - Removal and refitting ... - page 30-33 n See para. 30.4.9 - Removal and refitting ... - page 30-30 Fit the belt tensioner. n See para. 30.5.13 - Removal and assembly o... - page 30215 n See para. 30.5.12 - Removal and refitting ... - page 30-214 n See para. 30.4.27 - Removing and installin... - page 30-82 n See para. 30.4.26 - Removing and installin... - page 30-81 Fit the ribbed V-belt, taking into account the direction of rotation.

Fig. 647

Method of intervention Technical data Tightening torque:

Table 275 Designation

V-belt pulley/torsional vibration damper on crankshaft. V-belt pulley/torsional vibration damper on crankshaft. V-belt pulley/torsional vibration damper on crankshaft.

Screw type

M16x80-10.9 -

Note:

Value

Stage 1: Use new screws Stage 2:

40 Nm 60°

Stage 3:

60°

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.11 - Removal and refitting of the flywheel (fixing elements) Special tools:

Tool 5.9035.335.0 (Rotation device)

Removal of the flywheel 1.

Components: m

(1) Hex head screw

Fig. 648

2.

m

Fit rotation device (1).

Fig. 649

30-33

Method of intervention 3.

m m m m m

Fit service screws (1). Counterhold the crankshaft using the rotation device. Remove screws (2). Remove the flywheel using the service screws. Carry out a visual inspection of the components.

Fig. 650

Refitting the flywheel 1.

m

Insert the shop made guide bolt (arrowed). WARNING The holes in the flywheel must coincide with the threaded hole in the V-belt pulley.

m

Fit the flywheel using the service screws.

Fig. 651

2.

m m

Fit rotation device (1). Counterhold the crankshaft using the rotation device.

Fig. 652

3.

DANGER Caution! The screws must be renewed each time they are disturbed. m

m

m m

30-34

Tighten the screws alternately. n Stage 1, Tightening torque 30 Nm Tighten the screws using the rotation angle gauge. n Stage 2, Angle: 60° n Stage 3, Angle: 60° Withdraw locating dowel “A”. Unscrew the service screws.

Fig. 653

Method of intervention 4.

m

Remove rotation device (1).

Fig. 654

5.

CAUTION For part numbers, see replacement parts documentation.

m

Screw plugs fully into the threaded holes (arrowed).

Fig. 655

Technical data Tightening torque:

Table 276 Designation

Flywheel to engine

Flywheel to engine Flywheel to engine

Screw type

M10x35-12.9 M10x40-12.9 M10x45-12.9 M10x50-12.9 M10x55-12.9 M10x70-12.9 M10x75-12.9 M10x80-12.9 M10x85-12.9 -

Note:

Stage 1:

Value

30 Nm

Use new screws

Stage 2:

60°

Stage 3:

60°

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.12 - Compression test Special tools:

Tool 5.3095.XXX.0 (Union)

30-35

Method of intervention Compression test 1.

m

m

m

m

Check the valve clearances and adjust if necessary. n See para. 30.4.14 - Check and adjust valve... - page 30-40 Remove all the injectors. n See para. 30.4.20 - Removal and refitting ... - page 30-58 Remove the fuel lift pump. n See para. 30.5.1 - Removal and installati... - page 30-185 n See para. 30.5.2 - Removal and installati... - page 30-187 Fit union (1). WARNING Use the injector seal.

2.

m m m

Fig. 656

Rest retaining bracket (1) on the convex surface of union (2). Fit union (3) together with retaining bracket (1). Tighten the screw. n Tightening torque: 20 Nm

Fig. 657

3.

m

Connect adapter (1) to the union.

Fig. 658

4.

m m

Connect compression tester (1) to union (2). Crank the engine with the starter.

Fig. 659

30-36

Method of intervention 5.

WARNING The pressure reading will depend on the number of starter revolutions during the testing process and on the altitude at which the test is performed. The limit values therefore cannot be defined precisely. We recommend that that the readings obtained are used solely for comparison between the different cylinders. A difference between cylinders of over 15% should be investigated by dismantling the cylinder giving the low reading. Fig. 660

6.

m m m m

m

Remove the compression tester and adapter (1). Remove the union. Remove the seal. Fit the injectors. n See para. 30.4.20 - Removal and refitting ... - page 30-58 Fit the fuel lift pump. n See para. 30.5.2 - Removal and installati... - page 30-187 n See para. 30.5.1 - Removal and installati... - page 30-185

Fig. 661

Technical data Tightening torque:

Table 277 Designation

Screw type

Union on cylinder head, retaining bracket -

Notes:

-

Value

20 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.13 - Removal and refitting of the cylinder head cover Special tools: -

Removal of the cylinder head cover 1.

Components: m m m m m m

(1) Cylinder head cover (2) Shoulder screw (3) Cover gasket (4) Plug (7) Cover bar (8) Seal

Fig. 662

30-37

Method of intervention 2.

m

m m

Remove the crankcase breather. n See para. 30.4.1 - Removal and refitting ... - page 30-8 n See para. 30.4.2 - Removal and refitting ... - page 30-11 Press lightly on cover bar (1) at pressure points (2). Prise up cover bar (1) applying leverage at points (3).

Fig. 663

3.

m m m

Remove screws (1). Remove cable duct (2). Move cable duct (2) to one side.

Fig. 664

4.

m m m

Remove screws (1). Remove cylinder head cover (2). Be careful not to damage seal (3).

Fig. 665

5.

m m m

Remove screws (1). Unscrew all the nuts (2). Remove cover gasket (3).

Fig. 666

30-38

Method of intervention Refitting the cylinder head cover 1.

m m m

m

Clean the mating surfaces. Fit cover gasket (1). Tighten screws (2). n Tightening torque: 1.5 Nm Tighten nuts (3). n Tightening torque: 1.5 Nm

Fig. 667

2.

m m

m

Fit cylinder head cover (1). Tighten screws (2) alternately. n Tightening torque: 8.5 Nm Fit seal (3).

Fig. 668

3.

m m

m m m

Fit cable duct (1). Tighten screws (2). n Tightening torque: 8.5 Nm Fit cover bar (3). Press down by hand on cover bar (3). Fit the crankcase breather. n See para. 30.4.2 - Removal and refitting ... - page 30-11 n See para. 30.4.1 - Removal and refitting ... - page 30-8

Fig. 669

Technical data Tightening torque:

Table 278 Designation

Cylinder head cover to cylinder head Cable duct on cylinder head cover Cable clamp on injector

Screw type

M6x12-10.9 -

Note:

Value

-

8.5 Nm

-

8.5 Nm

-

1.5 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30-39

Method of intervention 30.4.14 - Check and adjust valve clearances Special tools: WARNING Pay attention to the direction of rotation of the engine - see instruction manual. WARNING Before adjusting valve clearance, allow engine to cool for at least 30 minutes. Engine oil temperature < 80°C. WARNING For this procedure it is not necessary to remove the cover gasket.

Adjustment of valve clearance 1.

m

Remove the cylinder head cover. n See para. 30.4.12 - Compression test - page 30-35 n See para. 30.4.13 - Removal and refitting ... - page 30-37 WARNING For this procedure it is not necessary to remove the cover gasket.

m

2.

m

m

Fit the rotation tool. n See para. 30.5.20 - Installation and remov... - page 30-229 n See para. 30.5.21 - Installation and remov... - page 30-231

Fig. 670

Depending on the assembly conditions, use the suitable tool as an extension for the rotation device (1). Turn the crankshaft in the engine rotation direction using the rotation device until reaching the cylinder 1 valve overlap angle. WARNING Valve overlap angle: Exhaust valve not yet closed, intake valve starts to open. WARNING Firing order: 1, 5, 3, 6, 2, 4.

Fig. 670

Table 279 Valves

Cylinder

Adjust on overlap 1 Angle 6

30-40

5 2

3 4

6 1

2 5

4 3

Method of intervention 3.

m m m m

Secure rotation angle disc magnet to cylinder head. Position rotation angle disc with screwdriver insert on adjuster screw. Fit crank handle (1). Disengage locknut (2). WARNING Hold with handle. WARNING Do not move the adjuster screw.

Fig. 671

Check 1.

m m m

Hold adjustment screw. Bring rotation angle disc to “0” . Lock adjuster screw with screwdriver insert (1).

Fig. 672

2.

m

Tighten adjusted screw with screwdriver insert (1) in the direction shown by the arrow until the adjuster screw has no more free travel. WARNING If the adjuster screw already has no more free travel, this means that the valve has no more clearance. WARNING Eliminate the causes.

m

Read the rotation angle value on the relative disk.

Fig. 673

Adjustment 1.

m

Tighten adjusted screw with screwdriver insert (1) in the direction shown by the arrow until the adjuster screw has no more play.

Fig. 674

30-41

Method of intervention 2.

m m

Bring rotation angle disc to “0” . Lock adjuster screw with screwdriver insert (1).

Fig. 675

3.

m

m

m

Tighten the adjuster screw with screwdriver (1) until reaching the specified rotation angle. Intake valve n Angle: 75° Exhaust valve n Angle: 120°

Fig. 676

4.

m

Fit crank handle (1). WARNING Hold with handle. WARNING Do not move the adjuster screw.

m

Tighten locknut (2) using the open-ended wrench. n Tightening torque: 20 Nm WARNING Adjust all the other valves in accordance with the valves adjustment diagram.

m

m

30-42

Remove the rotation tool. n See para. 30.5.21 - Installation and remov... - page 30-231 n See para. 30.5.20 - Installation and remov... - page 30-229 Fit the cylinder head cover. n See para. 30.4.13 - Removal and refitting ... - page 30-37 n See para. 30.4.12 - Compression test - page 30-35

Fig. 677

Method of intervention Technical data Test and adjustment data

Table 280 Designation

Valve clearance (intake) with rotation angle disc Valve clearance (exhaust) with rotation angle disc

Screws type

-

Note:

Value

-

75°

-

120°

Tightening torque prescriptions

Table 281 Designation

Locknut, valve clearance adjuster screw

Screws type

-

Note:

-

Value

20 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30.4.15 - Removal and refitting of oil cooler (auxiliary services) Special tools:

Tool 5.9035.245.0 (Removal tool) DEUTZ AP1908 assembly product WARNING Collect used service products in suitable containers and dispose of them in accordance with the applicable regulations. WARNING The engine oil should be drained and replenished following the instructions given in the operation manual.

Removal of the oil cooler 1.

Components: m m m

(1) Gasket (2) Lube oil cooler (3) Hex head screw

Fig. 678

30-43

Method of intervention 2.

m m

Remove all the screws (1). Remove oil cooler (2). WARNING Collect used lubricating oil and dispose of it in accordance with the applicable regulations.

m m

Remove the seals using the removal tool. Carry out a visual inspection of the components.

Fig. 679

Refitting the oil cooler 1.

m m m

Clean the mating surfaces. Apply assembly product to the new seals. Fit new seals (1).

Fig. 680

2.

m

Fit oil cooler. WARNING Pins (1) should locate in holes (2).

Fig. 681

3.

m m

Fit screws (1). Tighten all the screws (1) in the sequence indicated. n Tightening torque: 22 Nm

Technical data Tightening torque:

Table 282 Designation

Lube oil cooler on oil cooler housing

Screw type

M8x20-10.9 -

Note:

Value

Observe the indicated tightening se- 22 Nm quence.

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30-44

Method of intervention 30.4.16 - Removal and refitting of the lube oil cooler housing Special tools: WARNING Collect used service products in suitable containers and dispose of them in accordance with the applicable regulations. WARNING To drain and replenish the engine oil, follow the instructions provided.

Removal of the lube oil cooler housing 1.

Components: m m m m m m m m m m m m m m m m m m m m m

2.

m

m

m

m m m m m m

(1) Lube oil cooler housing (2) Flange (3) O-ring (4) Hex head screw (5) Plug (6) Seal (7) O-ring (8) Plug (9) Seal (10) Seal (11) Temperature sender (12) Pressure transducer (13) Drain valve (14) Plug (15) Seal 16) Oil filter (17) Housing (18) Pedestal (19) Bypass valve (30) Hex head screw (31) Hex head screw Remove the fuel filter support. n See para. 30.5.1 - Removal and installati... - page 30-185 Fit the fuel pipe support n See para. 30.5.3 - Removal and refitting ... - page 30-189 n See para. 30.5.4 - Removal and refitting ... - page 30-193 n See para. 30.5.5 - Removal and refitting ... - page 30-195 n See para. 30.5.6 - Removal and refitting ... - page 30-198 Remove the oil cooler. n See para. 30.4.15 - Removal and refitting ... - page 30-43 Remove the lube oil filter. Remove cable tie. Unlock and disconnect the wiring connectors. Remove all the screws (1). Remove lube oil cooler housing (2). Remove the gasket.

Fig. 682

Fig. 683

30-45

Method of intervention Refitting the lube oil cooler housing 1.

m m m

m

Carry out a visual inspection of the components. Clean the mating surfaces. Fit screws (arrowed). n M8x50-10.9 Fix the new gasket (1) and screws to the base of the oil cooler.

Fig. 684

2.

m m m

m

Fit the lube oil cooler housing. Tighten the screws alternately Fit screws (1). n M8x25-10.9 Fit screws (2). n M8x50-10.9

Fig. 685

3.

m

m m m

m

m

30-46

Tighten the screws in the sequence indicated. n Tightening torque: 30 Nm Connect and lock the wiring connector. Fix the cable tie. Fit oil cooler. n See para. 30.4.15 - Removal and refitting ... - page 30-43 Fit the lube oil filter. n See para. 30.5.1 - Removal and installati... - page 30-185 Fit the fuel pipe support n See para. 30.5.6 - Removal and refitting ... - page 30-198 n See para. 30.5.5 - Removal and refitting ... - page 30-195 n See para. 30.5.4 - Removal and refitting ... - page 30-193 n See para. 30.5.3 - Removal and refitting ... - page 30-189

Fig. 686

Method of intervention Technical data Tightening torque

Table 283 Designation

Oil cooler housing on engine block

Screw type

M8x20-10.9 M8x25-10.9 M8x50-10.9 Threaded plug on oil cooler housing M33X2 Threaded plug on oil cooler housing M16x1.5 Threaded plug on oil cooler housing M26x1.5 Blank flange on oil cooler housing M8x20-10.9 Oil pressure switch connected to oil cooler housing Blank flange on oil cooler housing -

Note:

Value

-

30 Nm

Use a new seal.

110 Nm

Use a new seal.

42 Nm

Use a new seal.

90 Nm

-

20 Nm

-

30 Nm

-

25 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.17 - Removal and refitting of the pilot block Special tools:

Tool 5.9035.095.0 (Plugs and caps) DANGER Danger! Do not work on the fuel system when the engine is running. The fuel system is under high pressure. Danger of death! The pressure in the fuel system may still be as high as several hundred bar, even after the engine has been switched off. In this case, the fuel pressure can only be reduced by opening the fuel system to allow fuel to escape. WARNING Caution! Maximum cleanliness is essential when working on the fuel system. Carefully clean the area around the components to be worked on. Dry wet areas with a compressed air jet. WARNING When handling fuels, observe safety standards and all applicable local regulations. WARNING All fuel lines and fittings should be closed immediately after opening using new, clean plugs or caps. Plugs or caps should only be removed immediately prior to assembly. WARNING Collect used service products in suitable containers and dispose of them in accordance with the applicable regulations. WARNING Always bleed the fuel system after every intervention.

30-47

Method of intervention Removal of the pilot block 1.

Components: m

(1) Hex head screw

Fig. 687

2.

m m m

m m m

Release the cable connector. Withdraw the connector. Remove the fuel pipes. n See para. 30.5.3 - Removal and refitting ... - page 30-189 n See para. 30.5.4 - Removal and refitting ... - page 30-193 n See para. 30.5.5 - Removal and refitting ... - page 30-195 n See para. 30.5.6 - Removal and refitting ... - page 30-198 Withdraw screw (1). Unscrew screw (2). Remove pilot block (3). Fig. 688

Refitting the pilot block 1.

m m m m

Fit screw (1). Fit screw (2). Fit the pilot block. Fit the screws without tightening them. WARNING Do not tighten the screws.

Fig. 689

30-48

Method of intervention 2.

WARNING Caution! Tighten the screws in the sequence indicated below. m

m

m

m

Tighten screw (1). n Tightening torque: 20 Nm Tighten screw (2). n Tightening torque: 20 Nm Refit the fuel pipes. n See para. 30.5.6 - Removal and refitting ... - page 30-198 n See para. 30.5.5 - Removal and refitting ... - page 30-195 n See para. 30.5.4 - Removal and refitting ... - page 30-193 n See para. 30.5.3 - Removal and refitting ... - page 30-189 Fit the connector.

Fig. 689

WARNING Check that connector is positioned correctly.

m

m

Refit the fuel pipes. n See para. 30.5.6 - Removal and refitting ... - page 30-198 n See para. 30.5.5 - Removal and refitting ... - page 30-195 n See para. 30.5.4 - Removal and refitting ... - page 30-193 n See para. 30.5.3 - Removal and refitting ... - page 30-189 Fit the connector. WARNING Check that the pipes are connected correctly. WARNING Bleed the fuel system using the hand pump on the fuel prefilter.

30-49

Method of intervention Technical data Tightening torque:

Table 284 Designation

Type of tractor

Pilot block in correspondence with engine M8x75-10.9 M8x85-10.9 block.

Note:

Value

Observe the specified tightening sequence. 20 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.18 - Removal and refitting of the high-pressure pump, Installation position A Special tools:

Tool 5.9035.071.0 (Special pliers) Tool 5.9035.072.0 (Special wrench) Tool 5.9035.076.0 (Set of O-ring installation and removal tools) Tools 5.9035.095.0 (Set of blanking plugs and caps) DANGER Never work on the fuel system when the engine is running. The fuel system is under high pressure. Danger of death.

DANGER The pressure in the fuel system may still be as high as several hundred bar even after the engine has been switched off. In this case, the fuel pressure can only be reduced by opening the fuel system to allow fuel to escape. WARNING Maximum cleanliness is essential when working on the fuel system. Carefully clean the area around the components to be worked on. Dry wet areas with a compressed air jet. WARNING When handling fuels, observe safety standards and all applicable local regulations. WARNING All fuel lines and fittings should be closed immediately after opening using new, clean plugs or caps. Plugs or caps should only be removed immediately prior to assembly. WARNING Collect used service products in suitable containers and dispose of them in accordance with the applicable regulations. WARNING Always bleed the fuel system after every intervention.

30-50

Method of intervention Removal of the high-pressure pump. 1.

Components: m

(1) Shoulder screw

Fig. 690

2.

m

m m m

m

3.

m

Remove the fuel control unit. n See para. 30.4.17 - Removal and refitting ... - page 30-47 Remove the injection pipe. Remove the high-pressure line. Remove the fuel lines. n See para. 30.5.3 - Removal and refitting ... - page 30-189 n See para. 30.5.4 - Removal and refitting ... - page 30-193 n See para. 30.5.5 - Removal and refitting ... - page 30-195 n See para. 30.5.6 - Removal and refitting ... - page 30-198 Fit the rotation device. n See para. 30.5.20 - Installation and remov... - page 30-229 n See para. 30.5.21 - Installation and remov... - page 30-231

Fig. 690

Loosen screws (1) gradually and evenly. WARNING Loosen the screws evenly to avoid distortion of the pump flange. WARNING If necessary, turn the crankshaft using the rotation device until you hear the high-pressure pump discharge.

m m

4.

m

Unscrew screws (1) gradually and evenly. Remove high-pressure pump (2).

Fig. 691

Carefully remove O-ring (1) from the high-pressure pump using the removal tool. WARNING Be careful not to damage the high-pressure pump.

Fig. 692

30-51

Method of intervention 5.

WARNING Do not use magnetic tools to remove the roller tappet.

m

Withdraw roller tappet (1) using the special pliers. WARNING Be careful not to damage the tappets!

m

Carry out a visual inspection of the components.

Fig. 693

Refitting the high-pressure pump 1.

m

Turn the crankshaft using the rotation device to bring the pump cam to the base circle position (arrowed). WARNING Roller tappet stroke less than 0.5 mm.

Fig. 694

2.

m

Lightly oil the roller tappet and insert it carefully using the special pliers. WARNING Locating pin (1) on the roller tappet should engage groove (2).

Fig. 695

3.

m m

Slide the O-ring installation tool (1) onto the high-pressure pump. Slide a new O-ring (2) onto the installation tool.

Fig. 696

30-52

Method of intervention 4.

m

Using installation tool (2), slide O-ring (1) into its groove (3).

Fig. 697

5.

m m m

m

Carefully insert the high-pressure pump in the engine block. Lightly oil screws (1). Tighten screws (1) alternately. n Stage 1, Tightening torque 10 Nm Tighten screws (1). n Stage 2, Tightening torque 50 Nm

Fig. 698

6.

m

m m m

m

Fit the fuel control unit. n See para. 30.4.17 - Removal and refitting ... - page 30-47 Fit the high-pressure line. Fit the fuel lines. Fit the injection pipe. n See para. 30.5.6 - Removal and refitting ... - page 30-198 n See para. 30.5.5 - Removal and refitting ... - page 30-195 n See para. 30.5.4 - Removal and refitting ... - page 30-193 n See para. 30.5.3 - Removal and refitting ... - page 30-189 Remove the rotation device. n See para. 30.5.21 - Installation and remov... - page 30-231 n See para. 30.5.20 - Installation and remov... - page 30-229

Fig. 698

30-53

Method of intervention Technical data Tightening torque

Table 285 Designation

High-pressure pump on engine block. High-pressure pump on engine block.

Screw type

M10x30-10.9 M10x30-10.9 -

Note:

Stage 1 Oiled screws Stage 2

Value

10 Nm 50 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.19 - Installation and removal of the high pressure pump, Assembly position B Special tools:

Tool 5.9035.071.0 (Special pliers) Tool 5.9035.072.0 (Special wrench) Tool 5.9035.076.0 (Assembly case with assembly guides and bushes and removal tool) Tool 5.9035.095.0 (Plugs and caps) DANGER Do not work on the fuel system while the engine is running. The fuel system is under high pressure. Risk of death. The fuel pressure can remain at several hundred bar even after the engine has been switched off. In these cases, the fuel pressure may fall only after the fuel distribution system has been opened to allow the fuel to be drained off to the outside of the circuit. WARNING During work on the fuel system always maintain conditions of the maximum cleanliness. Carefully clean the area around the components concerned, time by time. Dry any damp spots with a compressed air jet. WARNING When handling fuel observe the safety directives and specific local regulations. WARNING After opening the circuit, immediately close all the unions with new and clean plugs and caps. Remove plugs and caps only immediately prior to assembly. WARNING Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations. WARNING After all work on the fuel system the circuit must be bled of air.

30-54

Method of intervention Removing the high pressure pump 1.

Components: m

(1) Clearance screw

Fig. 699

2.

m

m m m

m

3.

m

Remove the pilot block. n See para. 30.4.17 - Removal and refitting ... - page 30-47 Remove the injection pipe. Remove the high pressure line. Remove the fuel lines. n See para. 30.5.3 - Removal and refitting ... - page 30-189 n See para. 30.5.4 - Removal and refitting ... - page 30-193 n See para. 30.4.21 - Removal and refitting ... - page 30-66 n See para. 30.5.5 - Removal and refitting ... - page 30-195 n See para. 30.5.6 - Removal and refitting ... - page 30-198 Fit the rotation tool. n See para. 30.5.20 - Installation and remov... - page 30-229 n See para. 30.5.21 - Installation and remov... - page 30-231

Fig. 699

Loosen screws (1) uniformly. WARNING Loosen the screws uniformly to avoid excessive tension of the high pressure pump. WARNING If necessary, turn the crankshaft with the rotation device in the direction of engine rotation until the high pressure pump is unloaded in a perceptible manner.

m m

4.

m

Loosen screws (1) uniformly. Remove high pressure pump (2).

Fig. 700

Carefully detach round O-ring (1) from the high pressure pump using the disassembly tool. WARNING Take care not to damage the high pressure pump.

Fig. 701

30-55

Method of intervention 5.

WARNING To remove the roller tappet do not use magnetic tools.

m

Extract the roller tappet (1) with special pliers. WARNING Do not damage the tappet!

m

Make a visual inspection of the components.

Fig. 702

Installing the high pressure pump 1.

m

Turn the crankshaft with the rotation device until the cam for the high pressure pump is on the basic circle of the cam (arrow). WARNING Stroke of roller tappet less than 0.5 mm.

Fig. 703

2.

m

Lightly oil the roller tappet and fit it carefully using the special pliers. WARNING Guide pin (1) on the roller tappet must engage in groove (2).

Fig. 704

3.

m m

Slide assembly guide (1) onto the high pressure pump. Slide the new round O-ring (2) onto the assembly guide.

Fig. 705

30-56

Method of intervention 4.

m

Slide round O-ring (1) with assembly bush (2) up to groove (3).

Fig. 706

5.

m m m

m

Carefully fit the high pressure pump in the engine crankcase. Slightly oil screws (1). Tighten screws (1) alternately. n Stage 1, Tightening torque: 10 Nm Tighten (1) the screws. n Stage 2, Tightening torque: 50 Nm

Fig. 707

6.

m

m m m

m

Install the pilot block. n See para. 30.4.17 - Removal and refitting ... - page 30-47 Install the high pressure line. Install the fuel lines. Install the injection pipe. n See para. 30.5.3 - Removal and refitting ... - page 30-189 n See para. 30.5.4 - Removal and refitting ... - page 30-193 n See para. 30.4.21 - Removal and refitting ... - page 30-66 n See para. 30.5.5 - Removal and refitting ... - page 30-195 n See para. 30.5.6 - Removal and refitting ... - page 30-198 Remove the rotation tool. n See para. 30.5.20 - Installation and remov... - page 30-229 n See para. 30.5.21 - Installation and remov... - page 30-231

Fig. 707

30-57

Method of intervention Technical data Tightening torque prescriptions

Table 286 Designation

Screws type

High pressure pump to engine crankcase M10x30-10,9 High pressure pump to engine crankcase M10x30-10,9 -

Note:

Class 1: oiled screws Class 2:

Value

10 Nm 50 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30.4.20 - Removal and refitting of the injector Special tools:

Tool 5.9035.072.0 (Special wrench) Tool 5.9035.077.0 (Puller adapter) Tool 5.9035.076.0 (Set of O-ring installation and removal tools) Tool 5.9035.094.0 (Slide hammer puller) Tool 5.9035.095.0 (Set of blanking plugs and caps) Tool 5.9035.105.0 (Pliers) Tool 5.9035.110.0 (Torx screwdriver set) Tool 5.9035.341.0 (Removal pin) Tool 5.9035.XXX.0 (Lever) Tool 5.9035.XXX.0 (Removal tool) SerDia 2010 diagnostic tool DANGER Never work on the fuel system when the engine is running. The fuel system is under high pressure. Danger of death. The pressure in the fuel system may still be as high as several hundred bar even after the engine has been switched off. In this case, the fuel pressure can only be reduced by opening the fuel system to allow fuel to escape. WARNING Maximum cleanliness is essential when working on the fuel system. Before proceeding with the removal operation, remove any paint residue or debris from around the injectors. Carefully clean the area around the components to be worked on. Dry wet areas with a compressed air jet. WARNING When handling fuels, observe safety standards and all applicable local regulations. All fuel lines and fittings should be closed immediately after opening using new, clean plugs or caps. WARNING Plugs or caps should only be removed immediately prior to assembly. WARNING Always bleed the fuel system after every intervention. WARNING

30-58

Method of intervention Removal of the injectors 1.

Components: m m m m m m m m m m m

2.

(1) Screw (2) Retaining bracket (3) Injector (4) O-ring (5) Seal (6) Delivery pipe sleeve (7) Thrust cap (8) O-ring (9) O-ring (10) Swivel nut (11) O-ring

Fig. 708

2000 bar, Injection system WARNING Note that each injector is paired with a specific cylinder.

WARNING Each injector is assigned to its respective cylinder on the basis of its IMA code (1). Fig. 709

WARNING The assignments are saved in the control unit memory.

WARNING Whenever an injector is renewed or swapped over, it must be assigned to its respective cylinders by entering the new IMA code in the control unit memory. 3.

WARNING The procedures for the removal and refitting of the fuel injectors are described in the following paragraphs. WARNING These procedures apply to all the injectors.

m

m m

m

Remove the cylinder head cover. n See para. 30.4.13 - Removal and refitting ... - page 30-37 Remove the injection pipes. Remove the high-pressure lines. n See para. 30.5.3 - Removal and refitting ... - page 30-189 n See para. 30.5.4 - Removal and refitting ... - page 30-193 n See para. 30.4.21 - Removal and refitting ... - page 30-66 n See para. 30.5.5 - Removal and refitting ... - page 30-195 n See para. 30.5.6 - Removal and refitting ... - page 30-198 Remove swivel nuts (1).

Fig. 710

30-59

Method of intervention 4.

m

Remove the sleeves of delivery pipes (1) using removal tool (2)

Fig. 711

5.

m

Fit thrust cap (1).

Fig. 712

6.

m m

Remove O-ring (1) using the removal tool. Remove O-ring (2) using the removal tool.

Fig. 713

7.

m

Remove screw (1).

Fig. 714

30-60

Method of intervention Variant: Threaded retaining bracket 1.

m

Screw removal pin (1) into the retaining bracket.

Fig. 715

2.

m m

Insert lever (1) in the removal pin (2). Unseat the injector by moving lever (1) in the direction of the arrow.

Fig. 716

3.

m m m m

Position crow’s foot wrench (1) under retaining bracket (2). Loosen the injector by moving lever (3) in the direction of the arrow. Unscrew spindle (4). Remove the injector with the retaining bracket. WARNING Note that each injector is paired with a specific cylinder.

Fig. 717

Variant: Retaining bracket without thread 1.

m m

Insert lever (1) in the retaining bracket. Loosen the injector by moving the lever in the direction of the arrow.

Fig. 718

30-61

Method of intervention 2.

m m m

Position crow’s foot wrench (1) under retaining bracket (2). Loosen the injector by moving lever (3) in the direction of the arrow. Remove the injector with the retaining bracket. WARNING Note that each injector is paired with a specific cylinder.

Fig. 719

3.

WARNING Do not attempt to clean the injector nozzle using a brush. WARNING When removing seal (1), take care not to damage the injector nozzle. m

Grip the fixed seal (1) with the special pliers (2) and remove it by twisting it gently. Fig. 720

Removal of the fixed seal in the cylinder head 1.

m

Insert removal tool (1). WARNING The tool (arrowed) must locate in the seal.

Fig. 721

2.

m

Screw in spindle (1) until the seal is seated on the removal tool. WARNING Counterhold the removal tool.

m

Fit adapter (2) to the removal tool.

Fig. 722

30-62

Method of intervention 3.

m m

Fit slide hammer puller (1) to the removal tool. Remove the seal.

Fig. 723

4.

m

Carefully remove the O-ring (1) from the injector using the removal tool. WARNING Be careful not to damage the injector.

Fig. 724

Refitting the injectors 1.

m m

Slide the installation tool (1) onto the injector. Slide a new O-ring (2) onto the installation tool.

Fig. 725

2.

m

Using installation tool (2), slide O-ring (1) into its groove (3).

Fig. 726

30-63

Method of intervention 3.

m

Remove the pre-fitted seal from the injector. WARNING Read the instructions in the documentation supplied with the replacement part. WARNING Replace the pre-fitted copper seal with new steel seal.

m

4.

Fit a new seal (1) to the injector.

Fig. 727

WARNING Before installing the injector, clean any carbon deposits from the injector bore in the cylinder head. WARNING Remove any particles of dirt.

m

Position the injector so that hole (1) is oriented towards the control side. Fig. 728

5.

WARNING Caution! Note that each injector is paired with a specific cylinder. m

Carefully insert injector (1) and retaining bracket (2) in the cylinder head.

Fig. 729

6.

m

m

Tighten screw (1). n Stage 1, Tightening torque 4 Nm Remove any axial loading on the injector by loosening screw (1). WARNING There must be no axial load on the injector. WARNING Check the installation position is correct. Fig. 730

30-64

Method of intervention 7.

m

Fit new O-rings (1).

Fig. 731

8.

m m

Screw on thrust cap (1). Tighten the thrust cap. n Tightening torque: 80 Nm

Fig. 732

9.

WARNING Renew the delivery pipe sleeve. WARNING Position the delivery pipe sleeve and apply pressure to the thrust cap so that balls (1) of the anti-twist connection locate in grooves (2) in the thrust cap. m

10.

m

Insert the delivery pipe sleeve with the new O-ring in the cylinder head.

Fig. 733

Fit screws (1). n Stage 1, Tightening torque: 15 Nm

Fig. 734

30-65

Method of intervention 11.

m

Tighten screw (1). n Stage 2, Tightening torque: 33 Nm (+3 Nm)

Fig. 735

12.

m

m m

m

Secure the delivery pipe sleeve with screw (1). n Stage 2, Tightening torque: 42 Nm Fit the high-pressure lines. Fit the injection pipes. n See para. 30.5.6 - Removal and refitting ... - page 30-198 n See para. 30.5.5 - Removal and refitting ... - page 30-195 n See para. 30.4.21 - Removal and refitting ... - page 30-66 n See para. 30.5.4 - Removal and refitting ... - page 30-193 n See para. 30.5.3 - Removal and refitting ... - page 30-189 Fit the cylinder head cover. n See para. 30.4.13 - Removal and refitting ... - page 30-37

Fig. 736

Technical data Tightening torque

Table 287 Designation

Screw type

Injector in cylinder head, retaining bracket M8x1.25x41 Injector in cylinder head, retaining bracket (steel sealing disc) Swivel nut for delivery pipe sleeves M22x1.5 Swivel nut for delivery pipe sleeves M22x1.5 Thrust cap on cylinder head M20x1.5 -

Note:

Value

Stage 1: Observe the installation sequence. Fit the injector without applying force. Stage 2:

4 Nm

33 Nm (+3)

Observe the tightening indications.

15 Nm

Stage 2:

42 Nm

-

80 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.21 - Removal and refitting of the common rail Special tools:

Tool 5.9035.072.0 (Special wrench) Tool 5.9035.075.0 (Long reach socket) Tool 5.9035.245.0 (Removal tool) Tool 5.9035.095.0 (Set of blanking plugs and caps) Assembly grease

30-66

Method of intervention DANGER Never work on the fuel system when the engine is running. The fuel system is under high pressure. Danger of death!

DANGER The pressure in the fuel system may still be as high as several hundred bar even after the engine has been switched off. In this case, the fuel pressure can only be reduced by opening the fuel system to allow fuel to escape. WARNING Caution! Maximum cleanliness is essential when working on the fuel system. Carefully clean the area around the components to be worked on. Dry wet areas with a compressed air jet. WARNING Do not allow any contaminants to enter the rail system. Ensure maximum cleanliness. In particular, ensure that the threads and the mating surfaces of the rail are clean. WARNING When handling fuels, observe safety standards and all applicable local regulations. All fuel lines and fittings should be closed immediately after opening using new, clean plugs or caps. Plugs or caps should only be removed immediately prior to assembly. WARNING Always bleed the fuel system after every intervention.

Removal of the common rail 1.

Components: m m m m m m m m m m m m m

(1) Rail (2) Spacer (3) Hex head screw (4) Injection pipe (5) Injection pipe (6) Injection pipe (7) Injection pipe (8) Injection pipe (9) Injection pipe (10) High-pressure line (11) High-pressure line (950) Pressure relief valve (951) Pressure sensor

Fig. 737

Removal of the high-pressure lines 1.

m

Unscrew union nuts (1) with the special wrench. WARNING Counterhold the unions on the high-pressure pump.

m m

Unscrew union nuts (2) with the special wrench. Remove the high-pressure lines. WARNING Collect leaked fuel and dispose of it properly. Fig. 738

30-67

Method of intervention Removal of the injection pipes 1.

m m m

Unscrew union nuts (1) with the special wrench. Remove the injection pipes. Remove the fuel return pipe. n See para. 30.5.3 - Removal and refitting ... - page 30-189 n See para. 30.5.4 - Removal and refitting ... - page 30-193 n See para. 30.5.5 - Removal and refitting ... - page 30-195 n See para. 30.5.6 - Removal and refitting ... - page 30-198 WARNING Collect leaked fuel and dispose of it properly. Fig. 739

2.

m m m m m m

Unlock the wiring connector. Disconnect the wiring connector. Remove screws (1). Remove rail (2). Remove spacers (3). Carry out a visual inspection of the components.

Fig. 740

Removal of the pressure sensor 1.

m

Unscrew rail pressure sensor (1) using the long reach socket. WARNING Collect leaked fuel and dispose of it properly.

Fig. 741

2.

WARNING Caution! To avoid electrostatic discharge, do not touch the male connectors of the rail pressure sensor with bare hands. WARNING Ensure that the connection plug is clean.

m

Carry out a visual inspection of the thread and the sealing edge (arrowed) of the rail pressure sensor. Fig. 742

30-68

Method of intervention Refitting the pressure sensor 1.

WARNING Caution! Do not allow any contaminants to enter the rail system. Ensure maximum cleanliness. In particular, ensure that the threads and the mating surfaces of the rail are clean. WARNING Read the instructions in the documentation supplied with the replacement part. WARNING The rail pressure sensor and the pressure relief valve must be renewed together as a pair. m m

2.

Fig. 743

Clean the threads and the mating surfaces of the rail. Apply a thin coating of assembly grease to the threads and around the sealing edge of the rail pressure sensor. WARNING Caution! Tighten the rail pressure sensor by applying the wrench to the hex on the body only.

m m

Screw in rail pressure sensor (1) Tighten rail pressure sensor (1) using the long reach socket. n Tightening torque: 70 Nm

Fig. 744

Removal of the pressure relief valve 1.

m

Unscrew pressure relief valve (1). DANGER Collect leaked fuel and dispose of it properly.

Fig. 745

2.

m

Carry out a visual inspection of the thread and the sealing edge (arrowed) of the rail pressure sensor.

Fig. 746

30-69

Method of intervention 3.

m

Remove the seal the specific removal tool.

Fig. 747

Refitting the pressure relief valve 1.

DANGER Do not allow any contaminants to enter the rail system. Ensure maximum cleanliness. In particular, ensure that the threads and the mating surfaces of the rail are clean. DANGER Read the instructions in the documentation supplied with the replacement part. DANGER The rail pressure sensor and the pressure relief valve must be renewed together as a pair.

2.

m

Fit a new O-ring (1).

m

Apply a thin coating of assembly grease to the threads and around the sealing edge of the pressure relief valve.

Fig. 748

Fig. 749

3.

m m m

Clean the threads and the mating surfaces of the rail. Screw in pressure relief valve (1). Tighten the pressure relief valve. n Tightening torque: 110 Nm

Fig. 750

30-70

Method of intervention Refitting the common rail 1.

m m

Fit rail (1) with spacers (2). Fit rail (1) without tightening screws (3). WARNING Do not tighten the screws at this stage.

Fig. 751

Refitting the injection pipes 1.

WARNING Once disturbed, the injection pipes must be completely renewed. When fitting the injection pipes, ensure they are not under tension. WARNING Make sure the pipes are installed in the correct positions.

m

Fit the new injection pipes (1). Fig. 752

2.

WARNING Check that the injection pipes are aligned correctly. WARNING Do not rest wires in the holes (1) of the swivel nuts£.

m m

Align the injection pipes. Tighten the swivel nuts by hand. Fig. 753

3.

m

Tighten screws (1). n Tightening torque: 30 Nm

Fig. 754

30-71

Method of intervention 4.

m

Tighten the swivel nuts in the sequence indicated using the special wrench. n Start with cylinder No.1 n Stage 1, Tightening torque 10 Nm n Stage 2, Angle: 60° (+15°) WARNING Use the rotation angle gauge.

m

Check that the injection pipes are positioned correctly.

Fig. 755

Refitting the high-pressure lines 1.

WARNING Once disturbed, the high-pressure pipes must be completely renewed. When fitting the high-pressure pipes, ensure they are not under tension. WARNING Make sure the high-pressure pipes are installed in the correct positions. m

Fit new high-pressure pipes (1). Fig. 756

2.

DANGER Check that the high-pressure pipes are aligned correctly.

DANGER Do not rest wires in the holes (1) of the swivel nuts£.

m m

Align the high-pressure pipes. Tighten the swivel nuts by hand. Fig. 757

30-72

Method of intervention 3.

m

Tighten the swivel nuts in the sequence indicated using the special wrench. n Start from the high-pressure pump (installation position A, flywheel end) n Stage 1, Tightening torque 10 Nm n Stage 2, Angle: 60° DANGER Use the rotation angle gauge.

m m

Fig. 758

Check that the high-pressure pipes are positioned correctly. Fit the fuel return pipe. n See para. 30.5.6 - Removal and refitting ... - page 30-198 n See para. 30.5.5 - Removal and refitting ... - page 30-195 n See para. 30.5.4 - Removal and refitting ... - page 30-193 n See para. 30.5.3 - Removal and refitting ... - page 30-189 DANGER Bleed the fuel system following the instructions provided.

m

Connect and lock the wiring connector. WARNING Make sure the connection is made correctly.

Technical data Tightening torque

Table 288 Designation

Screw type

Injection pipe to common rail and delivery Swivel nut line, high-pressure line to high-pressure pump and common rail. Injection pipe to common rail and delivery line, high-pressure line to high-pressure pump and common rail. Common rail on cylinder head M8x40-10.9 M8x45-10.9 M8x50-10.9 Pressure relief valve on common rail Pressure sensor on rail M18x1.5 -

Note:

Stage 1: Observe the installation indications. Use new pipes. Stage 2: Observe the installation indications.

Value

10 Nm 60° 30 Nm

Apply a thin coating of assembly grease to 110 Nm the threads and around the sealing edge. Apply a thin coating of assembly grease to 70 Nm the threads and around the sealing edge.

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30-73

Method of intervention 30.4.22 - Removal and refitting of the charge air duct Special tools: -

Removal of the charge air duct 1.

m m m m m m m m m m m m m m m m m m m m m m

2.

(1) Charge air duct (2) Gasket (3) Hex head screw (4) Gasket (5) Hex head screw (6) Hex head screw (7) Gasket (8) Cover (9) Hex head screw (10) Pressure/temperature sender (11) Cover (12) Hex head screw (13) Charge air manifold (14) Hose fitting (15) Hex head screw (16) Heater (17) Insulation (18) Positive pole (19) O-ring (20) Negative pole (21) Insulation (22) Hex head screw

m

Remove the cylinder head cover. n See para. 30.4.13 - Removal and refitting ... - page 30-37

m

Unlock and disconnect the wiring connectors. Remove the heat shield. Remove the support. Release the cables. n See para. 30.5.18 - Removal and refitting ... - page 30-226 Remove screws (1). Remove charge air duct (2). Remove gaskets (3). Visually inspect the component.

m m m

m m m m

Fig. 759

Fig. 760

Refitting the charge air duct 1.

m m m

Clean the sealing surfaces. Fit new gaskets (1). Insert the screws so that their threads engage the female threads in the gaskets by a few turns. WARNING The gaskets should be held in position by the screw threads. WARNING Check that the gaskets are positioned correctly.

30-74

Fig. 761

Method of intervention 2.

m m

Fit the charge air duct (1). Screw in screws (2). WARNING Ensure the gaskets do not move.

m

m m

Tighten the screws alternately, working from the centre outwards. n Tightening torque: 13 Nm Fit the support. Fit the heat shield. Fig. 762

WARNING Caution! Check that the cables are positioned correctly.

m

m

Re-connect and lock the wiring connectors. n See para. 30.5.18 - Removal and refitting ... - page 30-226 Fit the cylinder head cover. n See para. 30.4.13 - Removal and refitting ... - page 30-37

Technical data Tightening torque:

Table 289 Designation

Type of tractor

Charge air duct connected to cylinder head M6x110-10.9 Cover to charge air duct M6x16-10.9 Cover to charge air duct M8x20-10.9 -

Note:

Value

-

13 Nm

-

13 Nm

-

30 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.23 - Removal and refitting of the charge air manifold Special tools: -

30-75

Method of intervention Removal of the charge air manifold 1.

Components: m m m m m m m m m m m m m m m m m m m m m m

2.

m m m m m

(1) Charge air duct (2) Gasket (3) Hex head screw (4) Gasket (5) Hex head screw (6) Hex head screw (7) Gasket (8) Cover (9) Hex head screw (10) Pressure/temperature sender (11) Cover (12) Hex head screw (13) Charge air manifold (14) Flexible pipe union (15) Hex head screw (16) Heater (17) Insulation (18) Positive terminal (19) O-ring (20) Negative terminal (21) Insulation (22) Hex head screw

Fig. 763

Remove screws (1). Remove screws (2). Remove charge air manifold (3). Remove gasket (4). Carry out a visual inspection of the component.

Fig. 764

30-76

Method of intervention Refitting the charge air manifold 1.

m m m m m m

Clean the mating surfaces. Fit a new O-ring (1). Fit charge air manifold (2). Fit screws (3). Fit screws (4). Tighten the screws alternately. n Tightening torque: 30 Nm

Fig. 765

Technical data Tightening torque

Table 290 Designation

Charge air manifold to charge air duct

Screw type

M8x30-10.9 M8x95-10.9

Note:

-

Value

30 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.24 - Removal and refitting of the air intake pipe Special tools: -

Removal of the air intake pipe 1.

Components: m m m m m m m

(1) Spring clip (2) Flexible pipe (3) Pipe (4) Spring clip (5) Support (6) Pipe retaining clip (7) Hex head screw

Fig. 766

2.

m m m m

Loosen spring clip (1) using the special pliers. Remove screws (2). Remove pipe retaining clip (3). Remove pipe (4) in the direction of the arrow.

Fig. 767

30-77

Method of intervention 3.

m m m

Loosen spring clip (1) using the special pliers. Withdraw pipe (2) in the direction of the arrow. Carry out a visual inspection of the components.

Fig. 768

Refitting the air intake pipe 1.

m m

Insert pipe (1) in the direction of the arrow. Locate spring clip (2) using the special pliers.

Fig. 769

2.

m m m m

Insert pipe (1) in the direction of the arrow. Locate spring clip (2) using the special pliers. Locate hose clips (3). Tighten screws (1). n Tightening torque: 30 Nm

Fig. 770

Technical data Tightening torque

Table 291 Designation

Pipe retaining clips, fixing screw

Screw type

M8x16-10.9 -

Note:

-

Value

30 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30-78

Method of intervention 30.4.25 - Removal and refitting of the water pump Special tools:

Tool 5.9035.245.0 (Removal tool) WARNING Collect used service products in suitable containers and dispose of them in accordance with the applicable regulations. WARNING To drain and replenish the engine fluids and lubricants, follow the instructions provided.

Removal of the water pump 1.

Components: m m m m m m

(1) Connector (2) O-ring (3) Hex head screw (4) Gasket (5) Hex head screw (242) Assembly product

Fig. 771

2.

m m

m m m m m

Remove the V-belt. Remove the belt tensioner (level 1). n See para. 30.4.26 - Removing and installin... - page 30-81 Remove screw (1). Remove screws (2). Remove water pump (3). Remove gasket (4). Carry out a visual inspection of the components.

Fig. 772

3.

m

Remove connection fitting (1).

Fig. 773

30-79

Method of intervention 4.

m m

Remove O-rings (1) with the removal tool. Carry out a visual inspection of the component.

Fig. 774

Refitting the water pump 1.

m m m

Clean the mating surfaces. Apply a light coating of assembly product to the new O-rings. Fit the new O-rings (1).

Fig. 775

2.

m m

Apply assembly product to connection fitting (1). Insert connection fitting (1).

Fig. 776

3.

m m

m

Clean the mating surfaces. Fit the screws (arrowed). n M8x35-10.9 Fix new gasket (1) with the screws to the water pump.

Fig. 777

30-80

Method of intervention 4.

m m m m

m

Clean the mating surfaces. Fit water pump (1). Tighten the screws alternately Fit screws (2). n M8x90-10.9 Fit screws (3). n M8x35-10.9

Fig. 778

5.

m

m

m m

Tighten all screws (1) alternately. n Tightening torque: 30 Nm Fit the belt tensioner (level 1). n See para. 30.4.26 - Removing and installin... - page 30-81 Fit the ribbed V-belt, taking into account the direction of rotation. Fill the cooling system as indicated in the operating instructions.

Fig. 779

Technical data Tightening torque

Table 292 Designation

Water pump to thermostat housing

Screw type

M8x35-10.9 M8x90-10.9

Note:

-

Value

30 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.26 - Removing and installing the belt tensioner (Level 1). Special tools: -

Removing the belt tensioner 1.

Components: m m m m m m m

(1) Support plate (2) Hex screw (3) Belt tensioner (4) Fillister-head screw (5) Stud screw (6) Hex screw (7) Washer

Fig. 780

30-81

Method of intervention 2.

m m m m

Remove the reinforced vee belt Remove screw (1). Remove belt tensioner (2). Make a visual inspection of the component.

Fig. 781

Installing the belt tensioner 1.

m m m

m

Fit belt tensioner (1). Tighten screws (2). Tighten (2) the screw. n Tightening torque: 60 Nm Fit the reinforced vee belt, ensuring you observe the correct direction of run.

Fig. 782

Technical data Tightening torque prescriptions

Table 293 Designation

Belt tensioner to support plate

Screws type

M10x70-10.9 -

Notes:

-

Value

60 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30.4.27 - Removing and installing the support plate (Level 1) Special tools: -

Removing the lubricating oil line 1.

Removing the support plate m m m m m m m

(1) Support plate (2) Hex screw (3) Belt tensioner (4) Fillister-head screw (5) Stud screw (6) Hex screw (7) Washer

Fig. 783

30-82

Method of intervention 2.

m m

m m m m m

Remove the reinforced vee belt Remove the belt tensioner. n See para. 30.4.26 - Removing and installin... - page 30-81 n See para. 30.4.28 - Removing and installin... - page 30-85 Remove screws (1). Remove washers (2). Unscrew nut (3). Remove support plate (4). Make a visual inspection of the component.

Fig. 784

3.

m m

Unscrew nuts (1). Undo stud screw (2) using the disassembly tool.

Fig. 785

4.

m m

Place disassembly tool (1) on the stud screw. Unscrew the stud screw in the direction indicated by the arrow.

Fig. 786

30-83

Method of intervention Installing the support plate 1.

m m

Tighten the new stud screw (1). Fit the assembly tool.

Fig. 787

2.

m

m

Tighten assembly tool (1) in the direction of the arrow on the stud screw. Tighten the stud screw with assembly tool (1). n Tightening torque: 8 Nm

Fig. 788

3.

m m m m

m

m

m

Fit support plate (1). Tighten nut (2) by several turns. Fit washers (3). Tighten (1) the screws. n Tightening torque: 35 Nm Tighten nut (2). n Tightening torque: 35 Nm Install the belt tensioner. n See para. 30.4.28 - Removing and installin... - page 30-85 n See para. 30.4.26 - Removing and installin... - page 30-81 Fit the reinforced vee belt, ensuring you observe the correct direction of run.

Technical data Tightening torque prescriptions

Table 294 Designation

Support plate on crankcase Stud screw on crankcase

Screws type

M8-10 M8x40-10.9 M8 M8x20-10.9

Note:

Value

-

35 Nm

-

8 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30-84

Method of intervention 30.4.28 - Removing and installing the support console (Level 1) Special tools: -

Removing the idle roller 1.

Components: m m m m

(1) Console (2) Idle roller (3) Hex screw (4) Hex screw

Fig. 789

2.

m m

Remove the reinforced vee belt Withdraw the cover (1).

Fig. 790

3.

m m m

Remove screw (1). Remove idle roller (2). Make a visual inspection of the component.

Fig. 791

4.

m m m m

Remove screw (1). Undo screw (2). Remove bracket (3). Make a visual inspection of the component.

Fig. 792

30-85

Method of intervention Installing the idle roller 1.

m

Install console (1). WARNING Note that the screws are different lengths.

m

m

Tighten (2) the screw. n Tightening torque: 30 Nm Tighten screw (3). n Tightening torque: 30 Nm Fig. 793

2.

m m

Fit idle roller (1). Tighten (2) the screw. n Tightening torque: 60 Nm

Fig. 794

3.

m m

Fit cover (1). Fit the reinforced vee belt, ensuring you observe the correct direction of run.

Fig. 795

Technical data Tightening torque prescriptions

Table 295 Designation

Idle roller on the console Console to support console, alternator

Screws type

M10x45-10.9 M10x52-10.9 M10x65-10.9 M8x35-10.9 M8x55-10.9

Note:

Value

-

60 Nm

-

30 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30-86

Method of intervention 30.4.29 - Removal and installation of the exhaust pipe (auxiliaries) Special tools: -

Removing the support plate 1.

Components: m m m m

(1) Gasket (2) Stud screw (3) Spacer bush (4) Hex screw

Fig. 796

2.

m

m m m m

Remove the exhaust gas turbocharger. n See para. 30.4.30 - Removal and refitting ... - page 30-89 n See para. 30.4.31 - Removal and refitting ... - page 30-92 n See para. 30.4.32 - Removal and refitting ... - page 30-94 n See para. 30.4.33 - Removing and installin... - page 30-97 Unscrew all the nuts (1). Remove spacer bushes (2). Remove exhaust pipe (3); Remove gaskets (4).

Fig. 797

3.

m

Undo stud screw (1) using the disassembly tool.

Fig. 798

4.

m m

Place disassembly tool (1) on the stud screw. Unscrew the stud screw in the direction indicated by the arrow.

Fig. 799

30-87

Method of intervention Installing the exhaust pipe 1.

m m m m

Clean the mating surfaces Smear assembly product DEUTZ S1 on the new stud screws. Tighten the new stud screws (1). Fit the assembly tool.

Fig. 800

2.

m

m

Tighten the assembly tool (1) in the direction of the arrow on the stud screws. Tighten stud screws (1) using the assembly tool. n Tightening torque: 10 Nm

Fig. 801

3.

m m m m m

Apply a thin film of assembly product on the stud screws. Fit new gaskets (1). Fit exhaust pipe (2). Install spacer bushes (3). Tighten new nuts (4).

Fig. 802

4.

m

m

Tighten the nuts in accordance with the specific torquing sequence. n Tightening torque: 42 Nm Install the exhaust gas turbocharger. n See para. 30.4.30 - Removal and refitting ... - page 30-89 n See para. 30.4.31 - Removal and refitting ... - page 30-92 n See para. 30.4.32 - Removal and refitting ... - page 30-94 n See para. 30.4.33 - Removing and installin... - page 30-97

Fig. 803

30-88

Method of intervention Technical data Tightening torque prescriptions

Table 296 Designation

Screws type

Exhaust pipe connected to the cylinder M10 nut head Stud screw on cylinder head M10x108 -

Note:

Value

Observe the tightening sequence 42 Nm Use new stud screws and nuts. Use new stud screws. 10 Nm Apply DEUTZ S1 assembly product or equivalent.

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30.4.30 - Removal and refitting of the exhaust gas turbocharger Special tools:

Tool 5.9035.XXX.0 (Removal tool) Tool 5.9035.XXX.0 (Installation tool) WARNING Collect used service products in suitable containers and dispose of them in accordance with the applicable regulations. WARNING To drain and replenish the engine oil, follow the relative instructions.

Removal of the exhaust gas turbocharger 1.

Components: m m m m m

(1) Drain pipe (2) Stud (3) Gasket (4) Hex nut (169) Assembly product

Fig. 804

2.

m

m

m m m

Remove the lubricating oil pipe. n See para. 30.4.31 - Removal and refitting ... - page 30-92 Remove the lubricating oil return pipe. n See para. 30.4.32 - Removal and refitting ... - page 30-94 Unscrew all the nuts (1). Remove exhaust gas turbocharger (2). Remove seal (3).

Fig. 805

30-89

Method of intervention 3.

m m

Unscrew studs (1) using the removal tool. Visually inspect the component.

Fig. 806

4.

m m

Apply removal tool (1) to the stud. Unscrew the stud in the direction indicated by the arrow.

Fig. 807

5.

m m

Unscrew studs (1) using the removal tool. Visually inspect the component.

Fig. 808

6.

m m

Apply removal tool (1) to the stud. Unscrew the stud in the direction indicated by the arrow.

Fig. 809

30-90

Method of intervention Refitting the exhaust gas turbocharger 1.

m m m m

Clean the sealing surfaces. Apply assembly product DEUTZ S1 to the studs. Screw in the new studs (1). Apply the installation tool.

Fig. 810

2.

m m

Screw installation tool (1) onto the studs in the direction of arrow. Tighten studs (1) using the installation tool. n Tightening torque: 10 Nm

Fig. 811

3.

m m m m

Clean the sealing surfaces. Apply assembly product DEUTZ S1 to the studs. Screw in the new studs (1). Apply th assembly tool.

Fig. 812

4.

m m

Screw installation tool (1) onto the studs in the direction of arrow. Tighten studs (1) using the installation tool. n Tightening torque: 10 Nm

Fig. 813

30-91

Method of intervention 5.

m m m m

m

m

Clean the sealing surfaces. Fit a new seal (1). Fit exhaust gas turbocharger (2). Tighten the new nuts (3). n Tightening torque: 63 Nm Fit the lubricating oil pipe. n See para. 30.4.32 - Removal and refitting ... - page 30-94 Fit the lubricating oil return pipe. n See para. 30.4.31 - Removal and refitting ... - page 30-92 Fig. 814

Technical data Tightening torque:

Table 297 Designation

Studs on exhaust pipe

Type of tractor

M10x30 M12x35 Exhaust gas turbocharger connected to ex- M12 haust pipe Studs on turbocharger M10x30 M12x35

Note:

Use new studs. Apply DEUTZ S1 assembly product Use new studs and nuts Use new studs. Apply DEUTZ S1 assembly product

Value

10 Nm 63 Nm 10 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.31 - Removal and refitting of the lubricating oil pipe (exhaust gas turbocharger) Special tools: WARNING Collect used service products in suitable containers and dispose of them in accordance with the applicable regulations. WARNING To drain and replenish the engine oil, follow the relative instructions.

Removal of the lubricating oil pipe 1.

Components: m m m m m m m m m m m m

30-92

(1) Lubricating oil pipe (2) Seal (3) Banjo bolt (4) Oil return pipe (5) O-ring (6) Gasket (7) Hex head screw (8) Hex head screw (9) Support bracket (11) Pipe retaining clip (12) Pipe retaining clip (13) Hex nut

Fig. 815

Method of intervention 2.

m m m m

Restrain screw (1). Unscrew nuts (2). Unscrew banjo bolt (3). Remove seals (4).

Fig. 816

3.

m m m

Unscrew banjo bolt (1). Remove seals (2). Remove lubricating oil pipe (3).

Fig. 817

Refitting the lubricating oil pipe 1.

m m m m

Clean the sealing surfaces. Fit lubricating oil pipe (1). Fit new seals (2). Screw in banjo bolt (3).

Fig. 818

2.

m m m m

Clean the sealing surfaces. Fit lubricating oil pipe (1). Fit new seals (2). Tighten banjo bolt (3). n Tightening torque: 39 Nm WARNING Caution! When fitting the pipe, ensure that it is not under tension. Fig. 819

30-93

Method of intervention 3.

m

Tighten banjo bolt (1). n Tightening torque: 39 Nm WARNING Caution! When fitting the pipe, ensure that it is not under tension.

Fig. 820

4.

m m m

Locate hose clips (1). Restrain screw (2). Tighten nut (3). n [LNK] WARNING Caution! When fitting the pipe, ensure that it is not under tension.

Fig. 821

Technical data Tightening torque:

Table 298 Designation

Lubrication oil pipe in correspondence with the exhaust gas turbocharger/engine block Pipe retaining clips in correspondence with the lubricating oil pipe and lubricating oil return pipe

Type of tractor

Banjo bolt M8 M8x20-10.9

Note:

Value

Fit new seals

39 Nm

-

30 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.32 - Removal and refitting of the lubricating oil return pipe (exhaust gas turbocharger) Special tools:

Tool 5.9035.245.0 (Removal tool) WARNING Collect used service products in suitable containers and dispose of them in accordance with the applicable regulations. WARNING To drain and replenish the engine oil, follow the relative instructions.

30-94

Method of intervention Removal of the lubricating oil pipe 1.

Components: m m m m m m m m m m m m

2.

m m

(1) Lubricating oil pipe (2) Seal (3) Banjo bolt (4) Oil return pipe (5) O-ring (6) Gasket (7) Hex head screw (8) Hex head screw (9) Support bracket (11) Pipe retaining clip (12) Pipe retaining clip (13) Hex nut

Fig. 822

Restrain screw (1). Unscrew nuts (2).

Fig. 823

3.

m m

Remove screws (1). Remove seal (2)

Fig. 824

4.

m m m

Withdraw screw (1). Remove support bracket (2). Withdraw oil return pipe (3) in the direction of the arrow.

Fig. 825

30-95

Method of intervention 5.

m m

Remove O-ring (1) using the removal tool. Visually inspect the component.

Fig. 826

Refitting the oil return pipe 1.

m m m

Clean the sealing surfaces. Fit new O-ring (1). Apply a thin smear of assembly product to the O-ring.

Fig. 827

2.

m m m m m

Clean the sealing surfaces. Fit oil return pipe (1). Insert oil return pipe (1) in the direction of the arrow. Fit support bracket (2). Tighten screw (3). n Tightening torque: 30 Nm

Fig. 828

3.

m m m m

Clean the sealing surfaces. Fit a new seal (1). Fit oil return pipe (2). Tighten screw (3). n Tightening torque: 30 Nm

Fig. 829

30-96

Method of intervention 4.

m m m

Locate hose clips (1). Restrain screw (2). Tighten nut (3). n Tightening torque: 30 Nm

Fig. 830

Technical data Tightening torque:

Table 299 Designation

Type of tractor

Oil return pipe to exhaust gas turbocharger M8x20-10.9 Pipe retaining clip in correspondence with M8 the lubricating oil pipe and oil return pipe M8x20-10.9 Support bracket (oil return pipe) connected M8x16-10.9 to engine block

Note:

Value

-

30 Nm

-

30 Nm

-

30 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.4.33 - Removing and installing the belt tensioner (Level 2) Special tools: -

Removing the belt tensioner 1.

Components: m m m m m m m m m m m m m

(1) Support console (2) Idle roller (3) Belt tensioner (4) Hex screw (5) Hex screw (6) Hex screw (7) Hex screw (8) Alternator (10) Washer (11) Hex screw (12) Conical retaining ring (13) Vee-groove pulley (950) Tension adjuster

Fig. 831

30-97

Method of intervention 2.

m m m m

Extract the reinforced vee belt Extract screw (1). Remove belt tensioner (2). Make a visual inspection of the component.

Fig. 832

Installing the belt tensioner 1.

m m m

m

Fit belt tensioner (1). Tighten screws (2). Tighten (2) the screw. n Tightening torque: 42 Nm Fit the reinforced vee belt, ensuring you observe the correct direction of run.

Fig. 833

Technical data Tightening torque prescriptions

Table 300 Designation

Screws type

Belt tensioner (alternator) to support con- M10x80-8.8 sole

Note:

-

Value

42 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30.4.34 - Removing and installing the vee-groove pulley (#1) Readily available commercial tools: 8 mm hex wrench 27 mm socket wrench, outside diameter of socket 37 mm Offset tubular box wrench with extension

30-98

Method of intervention Removing the vee-groove pulley 1.

Components: m m m m m

(1) Alternator (4) Hex screw (5) Conical retaining ring (6) Vee-groove pulley (950) Tension adjuster

Fig. 834

2.

m

m m m m

Remove the alternator n See para. 30.5.16 - Removal and refitting ... - page 30-223 n See para. 30.5.17 - Removal and refitting ... - page 30-224 Clamp the alternator in a vice. Unscrew nut (1) with special wrench (2) in the direction of the arrow. Hold the alternator shaft with torque wrench (3). Unscrew nuts (1).

Fig. 835

3.

WARNING Place the alternator on a soft surface.

m

Fit the appropriate socket wrench (1)

Fig. 836

4.

WARNING The socket must rest on shoulder (1) of the vee-groove pulley, and not on locking cone (2)!

Fig. 837

30-99

Method of intervention 5.

DANGER Risk of injury!

WARNING Take care not to damage the components

m m

m m m

Slightly raise the vee-groove pulley. Use a rubber mallet to strike socket (1) until detaching the locking cone. Remove the locking cone. Remove vee-groove pulley (2). Make a visual inspection of the components.

Fig. 838

Installing the vee-groove pulley 1.

m m m

Fit vee-groove pulley (1). Fit locking cone (2). Tighten nut (3).

Fig. 839

2.

m m m m

m

Clamp the alternator in a vice. Fit special wrench (1). Hold the alternator shaft with torque wrench (2). Tighten nut (3) with special wrench (1) in the direction of the arrow. n Tightening torque: 75 Nm Fit the alternator. n See para. 30.5.17 - Removal and refitting ... - page 30-224 n See para. 30.5.16 - Removal and refitting ... - page 30-223

Fig. 840

Technical data Tightening torque prescriptions

Table 301 Designation

Screws type

Vee-groove pulley on alternator (reinforced M16x1.5 vee belt)

Note:

-

Value

75 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30-100

Method of intervention 30.4.35 - Removing and installing the vee-groove pulley (#2) Readily available commercial tools: 8 mm hex wrench 27 mm socket wrench, outside diameter of socket 37 mm Offset tubular box wrench with extension

Removing the vee-groove pulley 1.

Components: m m m m m m m m m m m m m

2.

m

m m m m

(1) Support console (2) Idle roller (3) Belt tensioner (4) Hex screw (5) Hex screw (6) Hex screw (7) Hex screw (8) Alternator (10) Washer (11) Hex screw (12) Conical retaining ring (13) Vee-groove pulley (950) Tension adjuster

Fig. 841

Remove the alternator n See para. 30.5.16 - Removal and refitting ... - page 30-223 n See para. 30.5.17 - Removal and refitting ... - page 30-224 Clamp the alternator in a vice. Unscrew nut (1) with special wrench (2) in the direction of the arrow. Hold the alternator shaft with torque wrench (3). Unscrew nuts (1).

Fig. 842

3.

WARNING Place the alternator on a soft surface.

m

Fit the appropriate socket wrench (1)

Fig. 843

30-101

Method of intervention 4.

WARNING The socket must rest on shoulder (1) of the vee-groove pulley, and not on locking cone (2)!

Fig. 844

5.

DANGER Risk of injury!

WARNING Take care not to damage the components

m m

m m m m

Slightly raise the vee-groove pulley. Use a rubber mallet to strike socket (1) until detaching the locking cone. Remove the locking cone. Remove vee-groove pulley (2). Remove the disc. Make a visual inspection of the components.

Fig. 845

Installing the vee-groove pulley 1.

m m m m

Fit washer (1). Fit vee-groove pulley (2). Fit locking cone (3) Tighten nut (4).

Fig. 846

2.

m m m m

m

Clamp the alternator in a vice. Fit special wrench (1). Hold the alternator shaft with torque wrench (2). Tighten nut (3) with special wrench (1) in the direction of the arrow. n Tightening torque: 75 Nm Fit the alternator. n See para. 30.5.17 - Removal and refitting ... - page 30-224 n See para. 30.5.16 - Removal and refitting ... - page 30-223

Fig. 847

30-102

Method of intervention Technical data Tightening torque prescriptions

Table 302 Designation

Screws type

Vee-groove pulley on alternator (reinforced M16x1.5 vee belt)

Note:

-

Value

75 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30.4.36 - Removing and installing the support console (Level 2) Special tools: -

Removing the support console 1.

Components: m m m m m m m m m m m m m

2.

m m m

m m m m

(1) Support console (2) Idle roller (3) Belt tensioner (4) Hex screw (5) Hex screw (6) Hex screw (7) Hex screw (8) Alternator (10) Washer (11) Hex screw (12) Conical retaining ring (13) Vee-groove pulley (950) Tension adjuster

Fig. 848

Remove the belt tensioner (level 2). Remove the alternator (level 2). Remove the idle roller. n See para. 30.4.38 - Removing and installin... - page 30105 Remove screw (1). Remove screws (2). Remove support console (3). Make a visual inspection of the component.

Fig. 849

30-103

Method of intervention Installing the support console

Technical data Tightening torque prescriptions

Table 303 Designation

Screws type

Support console (alternator - exhaust side) M10x35-10.9 M10x60-10.9 to crankcase

Note:

-

Value

60 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30.4.37 - Removing and installing the console (Level 1) Special tools: -

Removing the console 1.

Components: m m m m

(1) Console (2) Suspension plate (3) Hex screw (4) Hex screw

Fig. 851

30-104

Method of intervention 2.

m m

m

m m m m

Remove the reinforced vee belt Remove the alternator (level 1). n See para. 30.5.17 - Removal and refitting ... - page 30-224 Remove the fuel pump n See para. 30.5.2 - Removal and installati... - page 30-187 Remove screws (1). Remove suspension plate (2). Remove bracket (3). Make a visual inspection of the components.

Fig. 852

Installing the console 1.

m m m m

m

m

m

Fit bracket (1). Fit suspension plate (2). Tighten screws (3). Tighten screw (3). n Tightening torque: 60 Nm Install the fuel pump. n See para. 30.5.2 - Removal and installati... - page 30-187 Install the alternator (level 1). n See para. 30.5.17 - Removal and refitting ... - page 30-224 Fit the reinforced vee belt, ensuring you observe the correct direction of run.

Technical data Tightening torque prescriptions

Table 304 Designation

Screws type

Suspension plate/console on cylinder head M10x95-10.9 -

Note:

-

Value

60 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30.4.38 - Removing and installing the support console (Level 2) Special tools: -

Removing the idle roller 1.

Components: m m m m m m m m m m m m m

(1) Support console (2) Idle roller (3) Belt tensioner (4) Hex screw (5) Hex screw (6) Hex screw (7) Hex screw (8) Alternator (10) Washer (11) Hex screw (12) Conical retaining ring (13) Vee-groove pulley (950) Tension adjuster

Fig. 853

30-105

Method of intervention 2.

m m

Remove the reinforced vee belt Withdraw the cover (1).

Fig. 854

3.

m m m

Remove screw (1). Remove idle roller (2). Make a visual inspection of the component.

Fig. 855

Installing the idle roller 1.

m m

Fit idle roller (1). Tighten (2) the screw. n Tightening torque: 60 Nm

Fig. 856

2.

m m

Fit cover (1). Fit the reinforced vee belt, ensuring you observe the correct direction of run.

Fig. 857

30-106

Method of intervention Technical data Tightening torque prescriptions

Table 305 Designation

Screws type

Idle roller on the console

M10x45-10.9 M10x52-10.9 M10x65-10.9

Note:

-

Value

60 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30.4.39 - Assembly and disassembly of the piston cooling nozzles (L3) Disassembly of the piston cooling nozzles 1.

m m

1- Piston cooling nozzle 2- Hex screw

Fig. 858

2.

m

Disassemble the crankshaft. Construction unit 05

m m m

Remove screw (1). Remove the piston cooling nozzle (2). Carry out a visual inspection of the components.

Fig. 859

30-107

Method of intervention Assembly of the piston cooling nozzles 1.

m m m m

Clean the holes for the piston cooling nozzles in the crankcase. Fit the piston cooling nozzle (1). Tighten the screw (2): 21 Nm Assemble the crankshaft. Construction unit 05

Fig. 860

Technical data Tightening torque

Table 306 ID no.

Designation

Screws type

A02 071

Piston cooling nozzle on M8x35-10.9 the crankcase

Information/observa- Value tions

21 Nm

Note When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.4.40 - Assembly and disassembly of the piston cooling nozzles (L3) Disassembly of the piston cooling nozzles 1.

1.1. Piston cooling nozzle

Fig. 861

30-108

Method of intervention 2.

m

Disassemble the crankshaft. Construction unit 05

m m

Push out the piston cooling nozzle (1) using a suitable tool (2). Carry out a visual inspection of the components.

1

2

Fig. 862

Assembly of the piston cooling nozzles 1.

m m m

Clean the holes for the piston cooling nozzles in the crankcase. With the bolt, insert a new piston cooling nozzle (1) to the stop. Assemble the crankshaft. Construction unit 05 1

Fig. 863

30.4.41 - Replacing the starter ring gear on the flywheel (L3) WARNING Risk of accident, do not touch hot components!

Disassembly of the starter ring gear 1.

1.1. Flywheel 1.2. Ring gear

Fig. 864

30-109

Method of intervention 2.

m

Perforate the ring gear. Note Counterhold the flywheel using a suitable tool.

Fig. 865

3.

m m

Remove the starter ring gear with a suitable tool. Clean the flywheel.

Fig. 866

Assembly of the starter ring gear 1.

m m

Heat the starter ring gear to 220 °C. Position the starter ring gear on the flywheel. Note The starter ring gear must rest evenly on the flywheel support flange.

Fig. 867

30.4.42 - Replacing the starter ring gear on the flywheel (L3) DANGER Risk of accident, do not touch hot components!

30-110

Method of intervention Disassembly of the starter ring gear 1.

1.1. Flywheel 1.2. Ring gear

Fig. 868

2.

m

Perforate the ring gear. Note Counterhold the flywheel using a suitable tool.

Fig. 869

3.

m m

Remove the starter ring gear with a suitable tool. Clean the flywheel.

Fig. 870

30-111

Method of intervention Assembly of the starter ring gear 1.

m m

Heat the starter ring gear to 220 °C. Position the starter ring gear on the flywheel. Note The starter ring gear must rest evenly on the flywheel support flange.

Fig. 871

30.4.43 - Fitting and removing counterweight drive system, checking (L3) Readily available commercial tools: l

Torque wrench

Special tools: l

Alignment pins (q.ty 2): 100810

l

Plaster DEUTZ DW 72 mastic

l

Removing counterweight drive system 1.

m m m m m m m m

3 - Mounting pin 4 - Gear wheel 5 - Self-tapping screw 6 - Washer 8 - Hex screw 9 – O-ring 11 - O-ring 12 - Mounting pin

Fig. 872

2.

m

Disassemble the gear case. Construction unit 09

m

Bring cylinder piston 1 to top dead centre. Note The mark (1) on the flange of the crankshaft must line up with the reference mark (2).

Fig. 873

30-112

Method of intervention 3.

m m m m

Remove screw (1). Remove washer (2). Remove the intermediate wheel (3). Remove the bearing pin.

Fig. 874

4.

m m m m

Remove screw (1). Remove lube oil pipe (2). Remove the intermediate wheel (3). Remove the bearing pin.

Fig. 875

Fitting the counterweight drive system 1.

m

Bring cylinder piston 1 to top dead centre. Note The mark (1) on the flange of the crankshaft must line up with the reference mark (2).

Fig. 876

30-113

Method of intervention 2.

m

Do not fully unscrew drain plug (1).

Fig. 877

3.

m m

Insert the centring pins (1). Fasten the mass compensation shaft with the centring pins (1). WARNING Stop rotating the mass compensation shaft.

Fig. 878

4.

m

Apply the reference marks (1) and (2).

Fig. 879

30-114

Method of intervention 5.

m m

Unscrew the centring pins (side A). Turn the mass compensation shaft of the two teeth in the direction of the arrow.

Fig. 880

6.

m

From above, engage the intermediate wheel (1) in the toothing. Note Turn the mass compensation shaft in the direction of the arrow until the reference marks coincide. Centre the intermediate wheel (1) with respect to the threaded hole (2).

Fig. 881

7.

m m

Lightly oil the bearing pins (1). Insert the bearing pins (1).

Fig. 882

30-115

Method of intervention 8.

m

Fit new O-ring (1).

Fig. 883

9.

m m

Fit lube oil pipe (1). Tighten screws (2). Note Insert the screw with DEUTZ DW 72 sealant. Do not tighten the screw at this stage.

Fig. 884

10.

m

Do not fully unscrew drain plug (1).

Fig. 885

30-116

Method of intervention 11.

m m

Insert the centring pins (1). Fasten the mass compensation shaft with the centring pins (1). WARNING Stop rotating the mass compensation shaft.

Fig. 886

12.

m

Assemble the B side intermediate wheel. Note Centre the intermediate wheel (1) with respect to the threaded hole (2). If the sides of the teeth do not coincide with the crankshaft, it can be rotated easily. WARNING Stop rotating the mass compensation shaft.

Fig. 887

13.

m m m m

Lightly oil the bearing pins (1). Insert the bearing pins (1). Fit washer (2). Screw in the screw (3). Note Insert the screw with DEUTZ DW 72 sealant. Do not tighten the screw at this stage.

Fig. 888

30-117

Method of intervention 14.

m

Unscrew the centring pins (1).

Fig. 889

15.

m m

Fit a new seal. Tighten the screw plug (1): 9 Nm

Fig. 890

16.

m

Unscrew the centring pins (1).

Fig. 891

30-118

Method of intervention 17.

m m

Fit a new seal. Tighten the screw plug (1): 9 Nm

Fig. 892

18.

m m

Tighten the screws (1): 22 Nm Assemble the gear case. Construction unit 09

Fig. 893

Technical data Tightening torque

Table 307 ID no.

Designation

A72 001

Screw plug (counterweight shaft) on crankcase Intermediate wheel on crankcase

A72 003

Screws type

Indications/observa- Value tions

9 Nm

Fit with DEUTZ DW 72 2 22 Nm sealant

Note When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30-119

Method of intervention 30.4.44 - Assembly and disassembly of the crankshaft (L3) Disassembly of the crankshaft 1.

m m

1 - Crankshaft 5 - Threaded insert

Fig. 894

2.

m

Disassemble the front cover. Construction unit

2

01

m

09

m

Place the mark of reference (1) on the ring gear of the camshaft. Note The reference mark must be located on a line between the marking (2) and the mid point (3) of the camshaft.

30-120

3

Disassemble the connecting rod drum. Construction unit 06

m

1

Disassemble the gear case cover. Construction unit

Fig. 895

Method of intervention 3.

m

Uniformly rotate the crankshaft until the mark (1) on the flange of the shaft coincides with the auxiliary mark (2) on the camshaft ring gear. Note If the crankshaft flange is aligned, the mark on the camshaft ring gear will be covered.

m

1

Disassemble the crankshaft bearing covers. Construction unit

2

01

m

Disassemble the crankshaft bearings. Construction unit

Fig. 896

05

m

Remove the crankshaft.

Assembly of the crankshaft 1.

m

Check the crankshaft endfloat. Construction unit 05

m m

Position the camshaft. Assemble the crankshaft bearings. Construction unit

1

2

05

m m

Oil the surfaces of the bearings. Delicately insert the crankshaft in the crankcase. Note

Fig. 897

The mark (1) on the flange of the crankshaft must line up with the reference mark (2).

30-121

Method of intervention 2.

m

Assemble the crankshaft bearing covers. Construction unit 01

m

Assemble the connecting rod drum. Construction unit 06

m

Assemble the gear case cover. Construction unit 09

m

Fitting the front cover. Construction unit 01

30.4.45 - Crankshaft check (L3) Readily available commercial tools: l l l l l

Magnetic stand for measurements Palmer Internal bore meter Prisms Hardness tester

Special tools: l

Dial gauge: 100400

Check the hardness of the main journal 1.

m

Apply the hardness tester on the bearing pins.

Fig. 898

30-122

Method of intervention 2.

m

Lift (1) the probe and press the release device (2). Note

1

The probe (1) falls downward, briefly hits the surface and goes up to the measurement value.

2

Fig. 899

3.

m m

Read the value indicated (arrow) by the hardness tester. Nominal, minimum value: 55 HRc Note The measurement values must be converted using the tester table.

Fig. 900

Check the diameter of the main bearing pins 1.

Note Measurement diagram of the main journals on points 1 and 2 in surfaces a and b.

Fig. 901

30-123

Method of intervention 2.

m m

Measure the main bearing pins with the palmer. Nominal value: n Standard: 84(+0,-0.02) mm n Degree of undersizing: 0.25 mm Note Measurement points, see diagram.

Fig. 902

Check the diameter of the connecting rod pins 1.

m m

Measure the main journal with the palmer. Nominal value: n 69,994(+0,-0.02) mm n Degree of undersizing: 0.25 mm Note Measurement points, see diagram.

Fig. 903

Check the coaxiality 1.

m m m m

m m m m

Rest the crankshaft on the prisms. Apply the magnetic stand for measurements. Fit the dial gauge Apply the preloaded probe on the main bearing pins (arrow) and adjust the dial gauge to “0”. Uniformly turn the crankshaft and check the coaxiality. n Nominal value: 0.1 mm Remove the magnetic stand for measurements. Disassemble the dial gauge.

Fig. 904

30-124

Method of intervention Measuring the length of the flanged bearing 1.

m m

Adjust the palmer to 32 mm. Push the internal bore meter between the test surfaces of the palmer and bring to “0”.

Fig. 905

2.

m

m

Measure the width of the flanged bearing using the internal bore meter between the support surfaces of the thrust rings. n Nominal value: 32.2(+0.04,+0) mm n Degree of undersizing: 0.4 mm

Fig. 906

Technical data Test data and settings

Table 308 ID no.

P02 03 P02 04 P02 07 P02 11 P02 12 P02 21 P02 22 P02 23 P02 26

Designation

Main bearing pins, diameter Main bearing pins, diameter

Additional information

Value

Standard 84(+0,-0.02) mm two degrees of undersizing, 0.25 mm each Main bearing pin, manoeuvre 55 HRc pin, surface hardness Guide bearing pin, width Standard 32.2(+0.04,+0) mm Guide bearing pin, width one degree of oversizing 0.4 mm Manoeuvre pins, width 32.08(+0.02,+0) mm Manoeuvre pin, diameter Standard 69.994 (+0 − 0.02) mm Manoeuvre pin, diameter one degree of undersizing 0.25 mm Crankshaft eccentricity maximum permitted deviation 0.1 mm

30.4.46 - Check the endfloat of the crankshaft (L3) Readily available commercial tools: l l l

Magnetic stand for measurements Palmer Internal bore meter

Special tools: l

Dial gauge 100400

30-125

Method of intervention Check the endfloat 1.

m m m m m

Apply the magnetic stand for measurements. Insert the dial gauge. Apply the preloaded probe on the end of the crankshaft. Press the crankshaft towards the arrow. Adjust the dial gauge to “0”.

Fig. 907

2.

m m m

Press the crankshaft towards the arrow. Read the value measured. n Nominal value: 0.1 - 0.28 mm Note If there is a difference in the endfloat, set the permitted value by replacing the halves of the thrust ring.

Fig. 908

3.

m m

m

Measure the wall thickness of the thrust ring halves. n Standard: 2.0 (+0.05,+ 0) mm n Interference: 2.0 (+0.05,+ 0) mm Select the thrust ring halves based on the measured value.

Fig. 909

30-126

Method of intervention 4.

m

Adjust the palmer to 32 mm.

m

Push the internal bore meter between the test surfaces of the palmer and bring to “0”.

Fig. 910

5.

m

Measure the width of the flanged bearing.

m

Make a note of dimension (a).

Fig. 911

6.

m

Apply the thrust ring halves on the flanged bearing cover (arrows).

m

Measure the width with the palmer. Make a note of dimension (b). Determine the endfloat. n Nominal value: 0.1 - 0.28 mm

m m

Table 309 Calculation example:

Target: Data: Measured value: Calculation: Dimension (a) - dimension (b) The results of all this are:

Endfloat (a) = 32.8 mm (b) = 32.7 mm = 0.1 mm

Fig. 912

30-127

Method of intervention 7.

m

m m

Check the crankshaft endfloat. n Nominal value: 0.1 - 0.28 mm Remove the magnetic stand for measurements. Disassemble the dial gauge.

Fig. 913

Technical data Test data and settings

Table 310 ID no.

P02 34 P02 35 P02 36

Designation

Additional information

Value

Crankshaft, permitted endfloat From assembled 0.1 - 0.28 mm Shoulder, wall thickness Standard (upper and lower half) 2.0 (+0.05,+ 0) mm Shoulder, wall thickness Degree of oversizing 2.0 (+0.05,+ 0) mm

30.4.47 - Fitting and removing crankshaft bearings (L3) Removing crankshaft bearings 1.

Table 311 1 2 952 953

Main bearing Thrust Main bearing Thrust

Standard Standard Degree of undersizing Degree of undersizing

Fig. 914

30-128

Method of intervention 2.

m

Disassemble the crankshaft bearing covers. Construction unit 01

m

Disassemble the crankshaft. Construction unit 05

m m m

Remove both the shims (1). Remove all the main bearing shells (2). Note Put the components to one side in the order in which they were removed. Note the cylinder order.

3.

m

Fig. 915

Remove all the main bearing shells (1). Note Put the components to one side in the order in which they were removed. Note the cylinder order.

Fig. 916

30-129

Method of intervention Fitting crankshaft bearings 1.

m

Insert the upper shells of the main bearings. WARNING Take care to couple the bearing shells. The anti-twist safety (1) must enter the groove (2).

m m

Fit the crankshaft. Construction unit 05

Fig. 917

2.

m m

Fit half of the shims in relation to the endfloat measured. Fit half of the shims between the crankshaft and the crankcase (arrows). Note The oil grooves (1) face towards the shoulder disc (2) of the crankshaft.

2

1

Fig. 918

3.

m

m

Insert the lower shells of the main bearings in the relative main bearing covers. Fit the bearing shell, with the anti-twist retainer (1) in the groove (2). WARNING Take care to couple the bearing shells.

Fig. 919

30-130

Method of intervention 4.

m

m

Flanged bearing cover marked with “2”. Use the halves of the thrust ring with the key (arrow). The oil grooves (1) face towards the shoulder disc of the crankshaft. Assemble the crankshaft bearing covers. Construction unit 01

2

m

Fix the two halves of the shims onto the flanged bearing cover with a little grease. Note

1

Fig. 920

30.4.48 - Check the crankshaft bearings (L3) Readily available commercial tools: l l

Palmer Internal bore meter

Check the crankshaft bearings 1.

Table 312 1 2 952 953

Main bearing Thrust Main bearing Thrust

Standard Standard Degree of undersizing Degree of undersizing

Fig. 921

2.

m

m

Measure the thickness of the shoulder wall with the palmer. n Standard: 2.0 (+ 0.05, + 0) mm n

Degree of oversizing: 2.0 (+ 0.05, + 0) mm

Fig. 922

30-131

Method of intervention 3.

m

Measure the diameter of the main bearing using an internal bore meter. n Nominal value: 84.030 (+ 0.042, + 0) mm

Fig. 923

Technical data Test data and settings

Table 313 ID no.

Designation

P02 31

Main bearing shells, internal diameter Main bearing shells, internal diameter Theoretical tip clearance between the main bearing and main bearing pin Shoulder, wall thickness Shoulder, wall thickness

P02 32 P02 33 P02 35 P02 36

Additional information

Value

Standard

84.030 (+ 0.042, + 0) mm

one degree of undersizing

0.25 mm 0.030 -0.092 mm

Standard (upper and lower half) 2.0 (+ 0.0, + 0) mm Degree of oversizing 2.0 (+ 0.0, + 0) mm

30.4.49 - Assembly and disassembly of the connecting rod drum (L3) Readily available commercial tools: l

Rotation angle gauge: 8190

Special tools: l l l

Assembly device: 130490 Piston ring compression collar 130660 (98 mm) Piston ring compression collar 130670 (101 mm) WARNING The allocation of the connecting rod drum and flanged bearing cover must be maintained. If the connecting rod drum and the flanged bearing cover are switched when assembled, the connecting rod drum will not be usable! Do not damage the breaking surfaces of the connecting rod drum and flanged bearing cover!

30-132

Method of intervention Disassembly of the connecting rod drum 1.

Table 314 1 2 3 4 970

Connecting rod drum Connecting rod small end bush Screw Connecting rod bearing Standard Connecting rod bearing Degree of undersizing

Fig. 924

2.

m

Disassemble the cylinder head. Construction unit 08

m

Remove the oil suction pipe. Construction unit 16

m m m m

Move the connecting rod pins to the bottom dead centre. Remove screws (1). Remove flanged bearing cover (2). Remove the bearing shell.

Fig. 925

WARNING Do not place the connecting rod bearing cover on the break section. 3.

Note Put the components to one side in the order in which they were removed. Note the cylinder order.

30-133

Method of intervention 4.

m

Disassemble the piston and connecting rod drum. WARNING The allocation of the connecting rod drum and flanged bearing cover must be maintained. If the connecting rod drum and the flanged bearing cover are switched when assembled, the connecting rod drum will not be usable! Do not damage the breaking surfaces of the connecting rod drum and flanged bearing cover! Note Put the components to one side in the order in which they were removed. Note the cylinder order. Fig. 926

m

Disassemble the pistons. Construction unit 07

WARNING Do not damage the break sections of the connecting rod drum! 5.

m

Tighten the assembly device (1).

m

Insert the protective plug (2).

1

2

Fig. 927

6.

Note To better represent the operation, the assembly of the assembly device (1) and the protective plug (2) is shown on a removed connecting rod drum.

2 1

Fig. 928

30-134

Method of intervention 7.

m m m

Remove the piston making pressure with the assembly device. Disassemble the assembly device and the protective plug. Remove the connecting rod drum and the piston in the correct assembly and placement position. WARNING The allocation of the connecting rod drum and flanged bearing cover must be maintained. If the bearing drum and cover are exchanged during assembly, the drum is unusable! Do not damage the breaking surfaces of the bearing drum or cover!

1

Fig. 929

Assembly of the connecting rod drum 1.

m

Install the piston. Construction unit 07

m

Insert the connecting rod bearing shell into the connecting rod drum. WARNING Take care to couple the bearing shells. The anti-twist safety (1) must enter the groove (2).

Fig. 930

2.

m

Insert the connecting rod bearing shell into the relative flanged bearing cover. WARNING Take care to couple the bearing shells. The anti-twist safety (1) must enter the groove (2).

Fig. 931

30-135

Method of intervention 3.

WARNING The arrow (1) on the connecting rod bearing cover is facing the flywheel. The flywheel/crankshaft symbol (2) is facing the flywheel.

Fig. 932

4.

m

m

Insert the connecting rod bearing shell into the relative flanged bearing cover. Note Ensure that the bearing shells are matched correctly. The anti-twist retainer must locate correctly in the groove (1).

Fig. 933

5.

m m

Insert the protective plug (1) in the connecting rod drum. Install the assembly device on the connecting rod drum.

1

Fig. 934

30-136

Method of intervention 6.

m m

Offset the piston ring joints by: 120°. Spring washer position: 180° Note Never rotate the piston rings.

Fig. 935

7.

m

m

m

Lightly oil the cylinder sliding surface, piston, piston rings and connecting rod pins. n Piston diameter: 98 mm Compress the piston rings with a compression collar (1) 130660. n Piston diameter: 101 mm Compress the piston rings with a compression collar (1) 130670.

Fig. 936

8.

m m

Move the lifting bearing to a lowered position. Insert the piston and connecting rod drum together with the assembly device in the cylinder liner. 1

Fig. 937

30-137

Method of intervention 9.

m

m

Rotate the crankpins to bottom dead centre Note Pay attention to the piston cylinder allocation. Mark the assembly position on the bottom of the piston. The flywheel/crankshaft symbol (1) must be facing the flywheel. The piston ring blocking tape must rest flat on the crankcase. Insert the piston in the cylinder with the connecting rod drum.

Fig. 938

10.

m

m

Use the assembly device (1) to tighten the connecting rod drum until it is aligned with the manoeuvre pin. Disassemble the assembly device and the protective plug. WARNING Do not damage the break sections of the connecting rod drum!

1

Fig. 939

11.

m

Delicately press the connecting rod drum against the connecting rod pins. WARNING Do not bend the connecting rod drum with the crankshaft.

Fig. 940

30-138

Method of intervention Assembly of the flanged bearing cover 1.

WARNING Pay attention to coupling the flanged bearing cover. The numeric marks (1) on the connecting rod drum and on the connecting rod bearing cover must be identical and positioned in front of each other during assembly. WARNING The allocation of the connecting rod drum and flanged bearing cover must be maintained. If the connecting rod drum and the flanged bearing cover are switched when assembled, the connecting rod drum will not be usable! Do not damage the breaking surfaces of the connecting rod drum and flanged bearing cover!

2.

m

Fig. 941

Fit the cover (1) and the connecting rod bearing shell. WARNING The screws must be renewed after being removed.

Fig. 942

3.

m

m

Tighten the new screws (1). n Stage 1: 30 Nm Tighten the new screws using the rotation angle gauge. n Stage 2: 60° Stage 3: 60° Fit the oil suction pipe. Construction unit n

m

16

m

Assemble the cylinder head. Construction unit 08

Fig. 943

Technical data Test data and settings

Table 315 ID no.

P02 95 P02 96

Designation

Additional information

Position of piston ring gaps offset relative to one another Spacing between spring washer gap and piston ring gap, oil scraper ring

Value

120° 180°

30-139

Method of intervention Tightening torque

Table 316 ID no.

Designation

A02 020

Connecting rod bearing cover in correspondence of the connecting rod drum Connecting rod bearing cover in correspondence of the connecting rod drum Connecting rod bearing cover in correspondence of the connecting rod drum

A02 020

A02 020

Screws type

Indications/observa- Value tions

Stage 1: use the new 30 Nm screws. Oil screws Grade 2:

60°

Stage 3:

60°

Note When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.4.50 - Connecting rod drum check (L3) Readily available commercial tools: l l l l

Palmer Rotation angle gauge: 8190 Internal bore meter Connecting rod tester

Special tools: l

Dial gauge: 100400 WARNING The allocation of the connecting rod drum and flanged bearing cover must be maintained. If the connecting rod drum and the flanged bearing cover are switched when assembled, the connecting rod drum will not be usable! Do not damage the breaking surfaces of the connecting rod drum and flanged bearing cover!

Check the connecting rod small end bush 1.

m

Prepare the internal bore meter: n Fit the probes for the corresponding measurement interval in an internal bore meter. n

Fit the dial gauge with a preload of approx. 1 mm in the internal bore meter.

n

Set the bracket measurement screw to 39 mm.

n

Apply the internal bore meter between the test surfaces of the palmer and in the return point of the pointer, bring the dial gauge to “0”.

Fig. 944

30-140

Method of intervention 2.

Note

m

Measurement diagram of the connecting rod small end bush in points “a” and “b” in surfaces “1” and “2”.

Fig. 945

3.

m m

Insert the internal bore meter. Apply the internal bore meter to the measurement points required occasionally and read the value measured in the return point of the pointer. n Nominal value: 40 (+ 0.045, + 0.035) mm Note Pressed connecting rod small end bush. Measurement points, see diagram.

m

Make a note of the measured value, dimension A. Note Dimension A is used to determine the piston pin clearance.

Fig. 946

Calculate the piston pin clearance 1.

Note The clearance of the piston pin results from the difference between the inner diameter of the connecting rod small end bush (dimension A) and the diameter of the piston pin (dimension B). Construction unit 07

m

n

Nominal value: 0.035 - 0.051 mm

Table 317 Calculation example:

Target: Data: Measured value: Calculation: Dimension (a) - dimension (b) The results of all this are:

Piston pin clearance (A) = 40.045 mm (B) = 40.006 mm = 0.039 mm

30-141

Method of intervention Check the connecting rod bearing hole 1.

m

Apply the flanged bearing cover. WARNING Pay attention to coupling the flanged bearing cover. The numeric marks (1) on the connecting rod drum and on the connecting rod bearing cover must be identical and positioned in front of each other during assembly.

1

Fig. 947

2.

m

Alternatively tighten the screws with the rotation angle gauge and the box spanner insert. n Stage 1: 30 Nm n

Stage 2: 60°

n

Stage 3: 60°

Fig. 948

3.

m

Prepare the internal bore meter: n Fit the probes for the corresponding measurement interval in an internal bore meter. n

Fit the dial gauge with a preload of approx. 1 mm in the internal bore meter.

n

Set the bracket measurement screw to 73 mm.

n

Apply the internal bore meter between the test surfaces of the palmer and in the return point of the pointer, bring the dial gauge to “0”.

Fig. 949

30-142

Method of intervention 4.

Note Measurement diagram of the connecting rod bearing hole in points “a” and “b” in surfaces “1” and “2”.

Fig. 950

5.

m m

Insert the internal bore meter. Apply the internal bore meter to the measurement points required occasionally and read the value measured in the return point of the pointer. n Nominal value: 73.6 (+ 0.019, + 0) mm Note If the measured values diverse minimally, take additional measurements with new bearing shells.

Fig. 951

Check the internal diameter of the connecting rod bearing shells 1.

m

Insert the connecting rod bearing shell into the connecting rod drum. DANGER Take care to couple the bearing shells. The anti-twist safety (1) must enter the groove (2). The allocation of the connecting rod drum and flanged bearing cover must be maintained. If the connecting rod drum and the flanged bearing cover are switched when assembled, the connecting rod drum will not be usable! Do not damage the breaking surfaces of the connecting rod drum and flanged bearing cover!

2

1

Fig. 952

30-143

Method of intervention 2.

m

Insert the connecting rod bearing shell into the relative flanged bearing cover.

2

DANGER Take care to couple the bearing shells. The anti-twist safety (1) must enter the groove (2).

1

Fig. 953

3.

m

Apply the flanged bearing cover. WARNING The numeric marks (1) on the connecting rod drum and on the connecting rod bearing cover must be identical and positioned in front of each other during assembly.

1

Fig. 954

4.

m

Alternatively tighten the screws with the rotation angle gauge and the box spanner insert. n Stage 1: 30 Nm n

Stage 2: 60°

n

Stage 3: 60°

Fig. 955

30-144

Method of intervention 5.

m

Prepare the internal bore meter: n Fit the probes for the corresponding measurement interval in an internal bore meter. n

Fit the dial gauge with a preload of approx. 1 mm in the internal bore meter.

n

Set the bracket measurement screw to 70 mm.

n

Apply the internal bore meter between the test surfaces of the palmer and in the return point of the pointer, bring the dial gauge to “0”.

Fig. 956

6.

Note Measurement diagram of the internal diameter of the connecting rod bearing shells in points “a” and “b” in surfaces “1” and “2”.

Fig. 957

7.

m m

Insert the internal bore meter. Apply the internal bore meter to the measurement points required occasionally and read the value measured in the return point of the pointer. n Nominal value: 70.026 - 70.065 mm Note If the values lie up to a maximum of 0.015 mm above the tolerances for the bearing, the connecting rod drum can still be used. If the limit is reached, the connecting rod drum must be replaced.

m

Insert the measured value, measure (C). Note The dimension (C) is required to define the connecting rod bearing clearance.

Fig. 958

30-145

Method of intervention Determine the clearance of the connecting rod bearing Note The clearance of the connecting rod bearing results from the difference between the inner diameter of the connecting rod bearing shell (C) and the diameter of the main journal (D). l

m

Nominal value: 0.036 - 0.095 mm

Table 318 Calculation example:

Target: Data: Measured value: Calculation: Dimension (a) - dimension (b) The results of all this are:

Clearance of the connecting rod bearing (C) = 70.030 mm D = 69.994 mm = 0.036 mm

Check the connecting rod drum 1.

m

Assemble the connecting rod drum without bearing shells on the tester.

A

DANGER It is not permitted to straighten the connecting rod drum.

m m m

B

Move the test fork towards the arrow. Check the parallelism of the connecting rod drum. Difference permitted from (A) to (B): 0.04 mm Note Distance between “C“ and “D“ = 100 mm. Fig. 959

2.

m m m

Move the test fork towards the arrow. Check the angulation of the connecting rod drum. Difference permitted from (C) to (D): 0.04 mm Note Distance between “C“ and “D“ = 100 mm.

C D

Fig. 960

Technical data Test data and settings

Table 319 ID no.

P02 41

30-146

Designation

Additional information

Value

Connecting rod, parallelism with maximum permissible deviation 0.04 mm respect to the piston pin with a distance of 100 mm, vertical

Method of intervention ID no.

Designation

P02 42

Additional information

Connecting rod, parallelism with maximum permissible deviation respect to the piston pin with a distance of 100 mm, horizontal Connecting rod small end bush, installed, not machined internal diameter Bearing play between piston pin and big end bush Hole for crankpin bush in connecting rod Connecting rod bearing shell above and below, width Connecting rod bearing shell, From assembled inner diameter Connecting rod bearing shell, one degree of undersizing inner diameter Connecting rod, bearing hole, inner diameter Theoretical clearance between the connecting rod bearing and the main journal

P02 43 P02 45 P02 49 P02 51 P02 52 P02 54 P02 55 P02 56

Value

0.04 mm 40 (+ 0.045, + 0.035) mm 0.035 - 0.051 mm 43 (+ 0.02, + 0) mm 24 (− 0, − 0.3) mm 70.026 - 70.065 mm 0.25 mm 73.6 (+ 0.019, + 0) mm 0.036 - 0.095 mm

Tightening torque

Table 320 ID no.

Designation

A02 020

Connecting rod bearing M10x1 cover in correspondence of the connecting rod drum Connecting rod bearing cover in correspondence of the connecting rod drum Connecting rod bearing cover in correspondence of the connecting rod drum

A02 020

A02 020

Screws type

Indications/observa- Value tions

Stage 1: Use new screws 30 Nm

Stage 2:

60°

Stage 3:

60°

Note When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.4.51 - Replace the crankshaft O-ring (flywheel end) (L3) Readily available commercial tools: l l

Bradawl: 8202 Assembly lever: 9017

Special tools: l

Assembly tool: 142830

l

Self-tapping screw Washer

l

30-147

Method of intervention Removal of the crankshaft oil seal 1.

m m m m m

1- Gear case 2- Hex screw 3- Hex screw 4- Shaft O-ring 234- Sealant

Fig. 961

2.

m

Remove the flywheel. Construction unit 05

m

Using a bradawl, make a hole about 3 mm in diameter in the old crankshaft oil seal. DANGER Do not damage the gearbox cover or the crankshaft.

Fig. 962

3.

m

Insert a self-tapping screw (1) with washer.

1

Fig. 963

30-148

Method of intervention 4.

m m

Extract the crankshaft O-ring using the assembly lever. Carefully examine the crankshaft O-ring sliding surfaces.

Fig. 964

Fit the crankshaft O-ring 1.

m m

Fit guide bush (1). Tighten screws (2). Note The holes in the guide bush must be aligned with the threaded holes in the crankshaft flange.

1

2

Fig. 965

2.

m m

Lightly oil the lip of the crankshaft O-ring. Carefully place the crankshaft O-ring on the sliding surface. Note The seal lip should be facing the engine crankcase.

Fig. 966

30-149

Method of intervention 3.

m

Fit spacer (1).

Note If the crankshaft flange has an entry groove, the Oring can be installed at three different depths: - First assembly = 2 washers. 1st repair - assembly level = 1 washer 2nd repair - assembly level = 0 washers

1

Fig. 967

4.

m m

Fit installation bush (1). Push the crankshaft O-ring to the support. 1

Fig. 968

5.

m m

Insert bearing (1). Screw in nut (2);

1

2

Fig. 969

30-150

Method of intervention 6.

m

Screw in the nut until it seats against installation bush (1). Note The crankshaft oil seal is now installed at the correct depth.

m m

1

Remove the installation tool. Fit the flywheel. Construction unit 05

Fig. 970

30.4.52 - Disassembly and assembly of the gear box (L3) l

DEUTZ DW 67 sealant

Disassembly of the gear case. 1.

m m m m m

1- Gear case 2- Hex screw 3- Hex screw 4- Shaft O-ring 234- Sealant

Fig. 971

30-151

Method of intervention 2.

m

Disassemble the starter. Construction unit 44

m

Disassemble the connector box. Construction unit 52

m

Remove the flywheel. Construction unit 05

m

Fig. 972

Remove the oil sump pan. Construction unit 02

m m m

3.

m

Remove screws (1). Remove screws (2). Remove the gear case cover. Remove the crankshaft O-ring (1). WARNING

1

Be careful not to damage the mating surfaces when removing the front cover.

Fig. 973

30-152

Method of intervention Assembly of the gear case 1.

m

Clean the sealing surfaces of the gear box cover and the crankcase. Note The mating surfaces must be clean, dry and free of grease or other contaminants. Sealing edge thickness, approx. 1.4 mm. Apply mastic (arrowed). WARNING Assembly must be completed within a maximum of 1 hour.

Fig. 974

2.

m

m m

Apply the gear box cover. Note After applying it, do not move the gear box cover. Note that the screws are of different lengths M8 x 35 mm (1) M8 x 45 mm (2) Tighten screws (1). Tighten screws (2).

Fig. 975

3.

m

Push up the gear box cover and align it flush with the sealing surface of the oil sump (arrows).

Fig. 976

30-153

Method of intervention 4.

m m

Tighten the screws in the sequence indicated: 30 Nm Assemble a new crankshaft O-ring (flywheel side). Construction unit 09

m

Fit the flywheel. Construction unit 05

m

Assemble the connector box. Construction unit

Fig. 977

52

m

Assemble the starter. Construction unit 44

Technical data Tightening torque

Table 321 ID no.

Designation

Screws type

A03 092

Gearbox to engine block M8x35-10.9 M8x45-10.9

Indications/observa- Value tions

Observe the indicated 30 Nm tightening sequence.

Note When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.4.53 - Disassembly and assembly of the gear box (L3) l

DEUTZ DW 67 sealant

Disassembly of the gear case. 1.

m m m m m

1- Gear case 2- Hex screw 3- Hex screw 4- Shaft O-ring 234- Sealant

Fig. 978

30-154

Method of intervention 2.

m

Disassemble the starter. Construction unit 44

m

Remove the flywheel. Construction unit 05

m

Disassemble the connector box. Construction unit 52

m

Fig. 979

Remove the oil sump pan. Construction unit 02

m m

3.

m

Remove all the screws (1). Remove the gear case cover. Remove the crankshaft O-ring (1). WARNING

1

Be careful not to damage the mating surfaces when removing the front cover.

Fig. 980

30-155

Method of intervention Assembly of the gear case 1.

m

Clean the sealing surfaces of the gear box cover and the crankcase. Note The mating surfaces must be clean, dry and free of grease or other contaminants. Sealing edge thickness, approx. 1.4 mm. Apply mastic (arrowed). WARNING Assembly must be completed within a maximum of 1 hour.

Fig. 981

2.

m

m m

Apply the gear box cover. Note After applying it, do not move the gear box cover. Note that the screws are of different lengths M8 x 35 mm (1) M8 x 45 mm (2) Tighten screws (1). Tighten screws (2).

Fig. 982

3.

m

Push up the gear box cover and align it flush with the sealing surface of the oil sump (arrows).

Fig. 983

30-156

Method of intervention 4.

m m

Tighten the screws in the sequence indicated: 30 Nm Assemble a new crankshaft O-ring (flywheel side). Construction unit 09

m

Assemble the connector box. Construction unit 52

m

Fit the flywheel. Construction unit

Fig. 984

05

m

Assemble the starter. Construction unit 44

Technical data Tightening torque

Table 322 ID no.

Designation

Screws type

A03 092

Gearbox to engine block M8x35-10.9 M8x45-10.9

Indications/observa- Value tions

Observe the indicated 30 Nm tightening sequence.

Note When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.4.54 - Disassembly and assembly of the gear box (L3) Disassembly of the gear case. 1.

m m

5- Hex screw 6 - Washer

Fig. 985

30-157

Method of intervention 2.

Note

m

See spare parts documentation.

m

Disassemble the gear case. Construction unit 09 Remove screws (1).

Fig. 986

Assembly of the gear case 1.

m

Fit washers (1). Tighten screws (2). Note See spare parts documentation. Assemble the gear case. Construction unit 09 Tighten the screws (2): 70 Nm Fig. 987

Technical data Tightening torque

Table 323 ID no.

Designation

Screws type

A03 092

Gearbox to engine block M16x60-10.9

Indications/observa- Value tions

70 Nm

Note When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30-158

Method of intervention 30.4.55 - Assembly and disassembly of the camshaft (L3) Disassembly of the camshaft 1.

m

1 - Camshaft

Fig. 988

2.

m

Disassemble the high pressure pump and the roller tappet (assembly position A). Construction unit 17

m

Disassemble the high pressure pump and the roller tappet (assembly position B). Construction unit 17

m

Disassemble the distribution valve. Construction unit

Fig. 989

11

m

Disassemble the crankshaft. Construction unit 05

m m

Rotate the camshaft. Remove the camshaft carefully (1).

30-159

Method of intervention Assembly of the camshaft 1.

m m m m

Lightly oil the camshaft bearings. Lightly oil the camshaft pins. Delicately insert the camshaft. Assemble the crankshaft. Construction unit 05

m

Assemble the distribution valve. Construction unit 11

m

Assemble the high pressure pump and the roller tappet (assembly position B). Construction unit

Fig. 990

17

m

Assemble the high pressure pump and the roller tappet (assembly position A). Construction unit 17

30.4.56 - Check the camshaft (L3) Readily available commercial tools: l l

Palmer Prisms

Check the camshaft 1.

m m

Visually check the wear of the cams and main journal. Visually check the wear of the camshaft ring gear. Note Measurement diagram of the main journals on points 1 and 2 in surfaces a and b.

Fig. 991

30-160

Method of intervention Check the diameter of the bearing pin 1.

m

Measure the main journals: 63 (-0.05, -0.07) mm Note Measurement points, see diagram. If the limit value has been reached, replace the camshaft.

Fig. 992

Technical data Test data and settings

Table 324 ID no.

P10 31

Designation

Camshaft, bearing pin, diameter

Additional information

Value

63 (− 0.05, − 0.07) mm

30.4.57 - Assembly and disassembly of the distribution valve (L3) Readily available commercial tools: l

Screwdriver insert for hexagonal pins (5 mm): 8193

Disassembly of the distribution valve 1.

Table 325 1 2 3 4 5 6 7 8 9 10 11 12

Hex valve Rocker support Spring pin Rocker Rocker Adjuster screw Hexagonal head nut Compression spring Rotating ring bearing Circlip Rocker axis Plug

Inlet Drain

Fig. 993

30-161

Method of intervention 2.

m

Remove the cylinder head cover. Construction unit 08

m

m m

Turn the crankshaft until all the cylinder 3 and 4 pushrods reach the lowest point. Disengage the check nuts (1). Turn all the adjustment screws (2) in the direction of the arrow.

Fig. 994

3.

m m m m

Remove the pushrods. Remove screws (1). Lift the entire distribution valve (2). Remove the tightening pins (3).

Fig. 995

Assembly of the distribution valve 1.

m m

m m

Insert pushrods. Turn the crankshaft until all the cylinder 3 and 4 pushrods reach the lowest point. Disengage the check nuts (1). Turn the adjustment screw (2) in the direction of the arrow to the end of stop.

Fig. 996

30-162

Method of intervention 2.

m m m

Insert the tightening bushes (1). Fit the distribution valve (2). Tighten screws (3).

Fig. 997

3.

m

Tighten the screws to torque in an even manner following the indicated tightening sequence. n Stage 1: Hand-tighten n Stage 2: 20 Nm n Stage 3: 30 Nm Check the valve clearances and adjust if necessary. Construction unit 11

Fig. 998

Technical data Tightening torque

Table 326 ID no.

Designation

A01 002

Rocker support in corre- M8x75-10.9 spondence of the cylinder head Rocker support in correspondence of the cylinder head Rocker support in correspondence of the cylinder head

A01 002 A01 002

Screws type

Indications/observa- Value tions

Stage 1: Tighten the Hand-tighten screws evenly. Stage 2

20 Nm

Stage 3

30 Nm

Note When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30-163

Method of intervention 30.4.58 - Removing and refitting the valve timing system (L3) Disassembly of the distribution valve 1.

Table 327 1 2 3 4 5 6 7 8 9 10 11 12

Hex valve Rocker support Spring pin Rocker Rocker Adjuster screw Hexagonal head nut Compression spring Rotating ring bearing Circlip Rocker axis Plug

Inlet Drain

Fig. 999

2.

m

Disassemble the distribution valve. Construction unit 11

m m m

Remove circlip (1). Remove corrugated washer (2). Remove the rocker (3).

Fig. 1000

3.

m m m m

Remove circlip (1). Remove corrugated washer (2). Remove the rocker (3). Remove the rocker mount (4).

Fig. 1001

30-164

Method of intervention 4.

m m

Detach the rocker mount and the rocker from the rocker shaft. Put the components to one side in the correct order of assembly.

Fig. 1002

Assembly of the distribution valve 1.

m m

Fit a stop pin (1) in the groove (2). Fit rocker pedestal (3). Note The oil holes (4) must face towards the cylinder head.

Fig. 1003

2.

m

Slide the components onto the rocker shaft in the correct order of assembly. Note Fit the intake rocker first (1), then the mount and finally the exhaust rocker (2). Ensure that the rocker mounts are assembled in the correct positions.

Fig. 1004

30-165

Method of intervention 3.

m m m

Insert the rocker (1). Fit the corrugated washer (2). Insert the O-ring (3) in the groove.

Fig. 1005

4.

m m m m

Insert the rocker (1). Fit the corrugated washer (2). Insert the O-ring (3) in the groove. Assemble the distribution valve. Construction unit 11

Fig. 1006

30.4.59 - Assembly and disassembly of the control elements (L3) Disassembly of the control elements 1.

m m m

1- Tappet 2- Pushrod 3 - Valve bridge

Fig. 1007

30-166

Method of intervention 2.

m

Disassemble the distribution valve. Construction unit 11

m m

Remove the valve bridges (1). Withdraw pushrods (2).

Fig. 1008

3.

m

Disassemble the camshaft. Construction unit 10

m

Remove all the tappets (1). Note Put the components to one side in the order in which they were removed. Note the cylinder order.

m

Carry out a visual inspection of the components. Fig. 1009

Assembly of the control elements 1.

m m

Lightly oil all the tappets. Insert all the tappets (1). Note Pay attention to couple the tappets.

m

Assemble the camshaft. Construction unit 10

Fig. 1010

30-167

Method of intervention 2.

m m m

Insert pushrods (1). Fit the valve bridges (2). Assemble the distribution valve. Construction unit 11

Fig. 1011

30.4.60 - Assembly and disassembly of the oil intake pipe (L3) Removal of the oil pickup pipe 1.

m m m m

1- Oil intake pipe 2- Hex screw 3- Hex screw 4- Gasket

Fig. 1012

2.

m

Remove the oil sump pan. Construction unit 02

m m m m m

Remove screws (1). Unscrew screw (2) Remove oil pickup pipe (3). Remove gasket (4). Carry out a visual inspection of the components.

Fig. 1013

30-168

Method of intervention Refitting the oil pickup pipe 1.

m m m m

Clean the mating surfaces. Fit the new gasket (1). Fit the oil intake pipe (2). Tighten the screws (3): M8 x 25 mm Note Check that the gasket assembly position is correct.

m

Tighten the screws (4): M8 x 16 mm

Fig. 1014

2.

m m m

Tighten the screws (1): 21 Nm Tighten the screw (2): 21 Nm Fit the oil sump pan. Construction unit 02

Fig. 1015

Technical data Tightening torque

Table 328 ID no.

Designation

A08 015

Oil intake pipe on the M8x25-10.9 crankcase Oil intake pipe, support M8x16-10.9 on the crankcase

A08 016

Screws type

Indications/observa- Value tions

21 Nm 21 Nm

Note When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30-169

Method of intervention 30.4.61 - Assembly and disassembly of the oil intake pipe (L3) Removal of the oil pickup pipe 1.

m m m m

1- Oil intake pipe 2- Hex screw 3- Hex screw 4- Gasket

Fig. 1016

2.

m

Remove the oil sump pan. Construction unit 02

m m m m m

Remove screws (1). Unscrew screw (2) Remove oil pickup pipe (3). Remove gasket (4). Carry out a visual inspection of the components.

Fig. 1017

Refitting the oil pickup pipe 1.

m m m m

Clean the mating surfaces. Fit the new gasket (1). Fit the oil intake pipe (2). Tighten the screws (3): M8 x 25 mm Note Check that the gasket assembly position is correct.

m

Tighten the screws (4): M8 x 16 mm

Fig. 1018

30-170

Method of intervention 2.

m m m

Tighten the screws (1): 21 Nm Tighten the screw (2): 21 Nm Fit the oil sump pan. Construction unit 02

Fig. 1019

Technical data Tightening torque

Table 329 ID no.

Designation

A08 015

Oil intake pipe on the M8x25-10.9 crankcase Oil intake pipe, support M8x16-10.9 on the crankcase

A08 016

Screws type

Indications/observa- Value tions

21 Nm 21 Nm

Note When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.4.62 - Disassembly and completion of the pilot unit (L3) Special tools: l l l

Plugs and caps: 01899144 Disassembly tool: 02992127 Assembly product: DEUTZ AP1908 DANGER Never work on the fuel system when the engine is running. The fuel system is under high pressure - risk of death. The pressure in the fuel system may still be as high as several hundred bar even after the engine has been switched off. In this case, the fuel pressure can only be reduced by opening the fuel system to allow fuel to escape. WARNING During work on the fuel system always maintain conditions of the maximum cleanliness. Thoroughly clean the area around the components to be worked on. Dry any wet areas with a compressed air jet. When handling fuel observe the safety directives and specific local regulations. All lines and unions should be closed immediately after opening using new, clean plugs or caps. Remove plugs and caps only immediately prior to assembly. Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations. After any operation, bleed the fuel distribution system - see the user manual, chapter “6 Fuel distribution system”.

30-171

Method of intervention Removal of the fuel control unit 1.

m m m m m m m m

1- Fuel control unit 2- Overflow valve 3- O-ring 4- O-ring 5- Torx screw 6- Solenoid valve 7- O-ring 8- O-ring

Fig. 1020

2.

m

Remove the fuel control unit. Construction unit 17

m m m

Remove screws (1). Disassemble the solenoid valve (2). Carry out a visual inspection of the components.

Fig. 1021

3.

m m

Remove seal (1) using the removal tool. Remove seal (2) using the removal tool.

Fig. 1022

30-172

Method of intervention 4.

m m

Unscrew the throttle (1). Carry out a visual inspection of the components.

Fig. 1023

5.

m m m m

Unscrew the overflow valve (1). Remove seal (2) Remove the O-ring (3). Carry out a visual inspection of the components.

Fig. 1024

Completion of the fuel control unit 1.

m m

Clean the components. Thoroughly wash all the holes.

Fig. 1025

30-173

Method of intervention 2.

m m m

m m

Fit a new O-ring (1). Apply a thin coating of assembly product on the new O-ring. Apply a thin coating of assembly product on the overflow valve (arrow). Fit a new O-ring (2). Tighten the overflow valve (3): 33 Nm

Fig. 1026

3.

m

Tighten the throttle (1): 12 Nm

Fig. 1027

4.

m m m

Apply a light coating of assembly product to the new O-rings. Fit new O-ring (1). Fit a new O-ring (2).

Fig. 1028

30-174

Method of intervention 5.

m m m

Fit the solenoid valve (1). Tighten the screws (2): 4.5 Nm Fit the fuel control unit. Construction unit 17

Fig. 1029

Technical data Tightening torque

Table 330 ID no.

Designation

A17 033

Solenoid valve on the fuel control unit Throttle on the fuel control unit housing Overflow valve on the fuel control unit housing

A17 034 A17 035

Screws type

Indications/observa- Value tions

4.5 Nm 12 Nm 33 Nm

Note When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.4.63 - Disassembly and completion of the pilot unit (L3) Special tools: l l l

Plugs and caps: 01899144 Disassembly tool: 02992127 Assembly product: DEUTZ AP1908 DANGER Never work on the fuel system when the engine is running. The fuel system is under high pressure - risk of death. The pressure in the fuel system may still be as high as several hundred bar even after the engine has been switched off. In this case, the fuel pressure can only be reduced by opening the fuel system to allow fuel to escape. WARNING During work on the fuel system always maintain conditions of the maximum cleanliness. Thoroughly clean the area around the components to be worked on. Dry any wet areas with a compressed air jet. When handling fuel observe the safety directives and specific local regulations. All lines and unions should be closed immediately after opening using new, clean plugs or caps. Remove plugs and caps only immediately prior to assembly. Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations. After any operation, bleed the fuel distribution system - see the user manual, chapter “6 Fuel distribution system”.

30-175

Method of intervention Removal of the fuel control unit 1.

m m m m m m m m

1- Fuel control unit 2- Overflow valve 3- O-ring 4- O-ring 5- Torx screw 6- Solenoid valve 7- O-ring 8- O-ring

Fig. 1030

2.

m

Remove the fuel control unit. Construction unit 17

m m m

Remove screws (1). Disassemble the solenoid valve (2). Carry out a visual inspection of the components.

Fig. 1031

3.

m m

Remove seal (1) using the removal tool. Remove seal (2) using the removal tool.

Fig. 1032

30-176

Method of intervention 4.

m m

Unscrew the throttle (1). Carry out a visual inspection of the components.

Fig. 1033

5.

m m m m

Unscrew the overflow valve (1). Remove seal (2) Remove the O-ring (3). Carry out a visual inspection of the components.

Fig. 1034

Completion of the fuel control unit 1.

m m

Clean the components. Thoroughly wash all the holes.

Fig. 1035

30-177

Method of intervention 2.

m m m

m m

Fit a new O-ring (1). Apply a thin coating of assembly product on the new O-ring. Apply a thin coating of assembly product on the overflow valve (arrow). Fit a new O-ring (2). Tighten the overflow valve (3): 33 Nm

Fig. 1036

3.

m

Tighten the throttle (1): 12 Nm

Fig. 1037

4.

m m m

Apply a light coating of assembly product to the new O-rings. Fit new O-ring (1). Fit a new O-ring (2).

Fig. 1038

30-178

Method of intervention 5.

m m m

Fit the solenoid valve (1). Tighten the screws (2): 4.5 Nm Fit the fuel control unit. Construction unit 17

Fig. 1039

Technical data Tightening torque

Table 331 ID no.

Designation

A17 033

Solenoid valve on the fuel control unit Throttle on the fuel control unit housing Overflow valve on the fuel control unit housing

A17 034 A17 035

Screws type

Indications/observa- Value tions

4.5 Nm 12 Nm 33 Nm

Note When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.4.64 - A/C drive belt alignment and tension adjustment Aligning crankshaft pulley - compressor pulley

Models: Agrotron M 600 - M 610 - M 620 - M 615 - M 625 - M 640 - M 650 - 6150.4 - 6160.4 - 6150 - 6160 - 6180 - 6190 - 150 165.7 - 265 - X 710 - X 720 - TTV 410 - TTV 420 - TTV 430 - TTV 610 - TTV 620 - TTV 630 - 6160 TTV - 6180 TTV - 6190 TTV - 7210 TTV - 7230 TTV - 7250 TTV 1. 2.

Loosen the compressor fastener screws, insert the shims 0.011.3980.0 and 0.011.3981.0 between the compressor and the mounting brackets, and re-tighten the screws. Misalignment “X”: max. 1.5 mm

Fig. 1040

30-179

Method of intervention 3.

Shim positions on AT 150, M600 - M610 - M620

Fig. 1041

4.

Shim positions on AT 165.7

Fig. 1042

5.

Shim positions on AT 265.

Fig. 1043

6.

Shim positions on AT X710 - X720

Fig. 1044

30-180

Method of intervention 7.

Shim positions on AT M615 - M625 - M640 - M650, TTV610 - TTV620 TTV630

Fig. 1045

8.

Shim positions on AT 6150 - 6160 - 6180 - 6190, AT TTV 6160 - 6180 6190.

Fig. 1046

9.

Shim positions on AT TTV 7210 - 7230 - 7250

Fig. 1047

30-181

Method of intervention Setting belt tension Models Agrotron 150, 165.7, 265, M600 - 610 - 620, X710 - 720 1. 2.

Turn the tension adjustment screw to obtain a belt tension of 550±50 N; run the engine for 5 minutes, allow the belt to cool, then repeat the tension adjustment. Tension adjustment screw AT 150, M600 - 610 - 620

Fig. 1048

3.

Tension adjustment screw AT 165.7

Fig. 1049

4.

Tension adjustment screw AT 265

Fig. 1050

5.

Tension adjustment screw AT X710 - 720

Fig. 1051

30-182

Method of intervention Setting belt tension Models Agrotron M 410 - 420 - 615 - 625 - 640 - 650; Agrotron 6150.4 - 6160.4; Agrotron 6150 - 6160 - 6180 - 6190; TTV 610 - 620 - 630 - 640; L710 - 720 - 730; TTV 410 - 420 - 430; TTV 6150.4 - 6160.4 TTV 6160 - 6180 - 6190; TTV 7210 - 7230 -7250 1. 2.

Turn the tension adjustment screw to obtain a belt tension of 590±50 N; run the engine for 5 minutes, allow the belt to cool, then repeat the tension adjustment. Tension adjustment screw with lock nut AT M410 - 420 AT 6150.4 - 6160.4; TTV 410 - 420 - 430; TTV 6150.4 - 6160.4

Fig. 1052

3.

Tension adjustment screw AT M615 - 625 - 640 - 650, TTV610 - 620 - 630

Fig. 1053

4.

Tension adjustment screw AT L710 - 720- 730

Fig. 1054

5.

tension adjustment AT 6150 - 6160 - 6180 - 6190 TTV6160 - TTV 6180 TTV 6190

Fig. 1055

30-183

Method of intervention 6.

Tension adjustment screw AT TTV 7210 - 7230 - 7250

Fig. 1056

30-184

Method of intervention 30.5 - C0 - Engine accessories

30.5.1 - Removal and installation of the fuel filter console Special tools:

Tool 5.9035.095.0 (Plugs and caps) DANGER Do not work on the fuel system while the engine is running. The fuel system is under high pressure. Risk of death. The fuel pressure can remain at several hundred bar even after the engine has been switched off. In these cases, the fuel pressure may fall only after the fuel distribution system has been opened to allow the fuel to be drained off to the outside of the circuit. WARNING During work on the fuel system always maintain conditions of the maximum cleanliness. Before disassembling, remove any paint residues and particles of dirt. Carefully clean the area around the components concerned, time by time. Dry any damp spots with a compressed air jet. WARNING When handling fuel observe the safety directives and specific local regulations. WARNING After opening the circuit, immediately close all the unions with new and clean plugs and caps. Remove plugs and caps only immediately prior to assembly. WARNING Collect auxiliary materials in suitable containers and dispose of them in compliance with the applicable regulations. WARNING After all work on the fuel system the circuit must be bled of air.

Removal of the fuel filter console 1.

Components: m m m m m m m m m m m m m m m

(1) Hex screw (2) Oil seal (3) Closing screw (4) Fuel filter (5) Filter cartridge (6) Oil seal (7) Return line (8) Hollow screw (9) Oil seal (10) Hollow screw (11) Annular part (13) Cover (950) Prop (951) Gasket (952) Exhaust valve

Fig. 1057

30-185

Method of intervention 2.

WARNING Make sure the parts are clean. WARNING Make sure no dirt falls into the fuel filter housing. WARNING Collect any spilled fuel and dispose of it correctly.

m m m

3.

m m m

Fig. 1058

Remove the filter cartridge. Unscrew hollow screws (1) Remove oil seals (2). Remove screws (1). Remove the console of fuel filter (2) Make a visual inspection of the components.

Fig. 1059

Installation of the fuel filter console 1.

m m

Fit the filter console (1). Tighten screws (2). n Tightening torque: 30 Nm

Fig. 1060

30-186

Method of intervention 2.

WARNING Use new oil seals.

m

Position the fuel pipe. WARNING Install the fuel pipes without tension. WARNING

Fig. 1061

Make sure the assembly position is correct.

m m

3.

m

m

m

Connect the fuel pipe. Fit hollow screws (1) with a new oil seal without tightening. Tighten hollow screws (1) n Tightening torque: 39 Nm Tighten hollow screw (2). n Tightening torque: 49 Nm Install the filter cartridge.

Fig. 1062

Technical data Tightening torque prescriptions

Table 332 Designation

Screws type

Fuel filter console connected to the oil M8x65-10.9 cooler frame Closing screw on the fuel filter housing M16x1.5 Tightening of pipe, annular piece Hollow screw M14x1.5 Tightening of pipe, annular piece Hollow screw M16x1.5

Note:

Value

-

30 Nm

Use a new seal ring

42 Nm

-

39 Nm

-

49 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30.5.2 - Removal and installation of the fuel lift pump Special tools:

Tool 5.9035.095.0 (Plugs and caps) DANGER Do not work on the fuel system while the engine is running. The fuel system is under high pressure. Risk of death. The fuel pressure can remain at several hundred bar even after the engine has been switched off. In these cases, the fuel pressure may fall only after the fuel distribution system has been opened to allow the fuel to be drained off to the outside of the circuit. 30-187

Method of intervention WARNING During work on the fuel system always maintain conditions of the maximum cleanliness. Before disassembling, remove any paint residues and particles of dirt. Carefully clean the area around the components concerned, time by time. Dry any damp spots with a compressed air jet. WARNING When handling fuel observe the safety directives and specific local regulations. WARNING After opening the circuit, immediately close all the unions with new and clean plugs and caps. Remove plugs and caps only immediately prior to assembly. WARNING Collect auxiliary materials in suitable containers and dispose of them in compliance with the applicable regulations. WARNING After all work on the fuel system the circuit must be bled of air.

Removing the fuel pump. 1.

Components: m

(1) Hex screw

Fig. 1063

2.

m m

m m m

Remove the reinforced vee belt Remove the fuel lines. n See para. 30.5.3 - Removal and refitting ... - page 30-189 n See para. 30.5.4 - Removal and refitting ... - page 30-193 n See para. 30.4.21 - Removal and refitting ... - page 30-66 n See para. 30.5.5 - Removal and refitting ... - page 30-195 n See para. 30.5.6 - Removal and refitting ... - page 30-198 Remove screws (1). Remove the fuel lift pump. Make a visual inspection of the components. Fig. 1064

30-188

Method of intervention Installing the fuel lift pump 1.

m m

m

m

Fit the fuel lift pump. Tighten (1) the screws. n Tightening torque: 30 Nm Fit the reinforced vee belt, ensuring you observe the correct direction of run. Install the fuel lines. n See para. 30.5.3 - Removal and refitting ... - page 30-189 n See para. 30.5.4 - Removal and refitting ... - page 30-193 n See para. 30.4.21 - Removal and refitting ... - page 30-66 n See para. 30.5.5 - Removal and refitting ... - page 30-195 n See para. 30.5.6 - Removal and refitting ... - page 30-198 Fig. 1064

Technical data Tightening torque prescriptions

Table 333 Designation

Screws type

Fuel lift pump in correspondence with the M8x105-10.9 support

Note:

-

Value

30 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30.5.3 - Removal and refitting of fuel lines (fuel lift pump - pilot block) Special tools:

Tool 5.9035.095.0 (Plugs and caps) DANGER Danger! Do not work on the fuel system when the engine is running. The fuel system is under high pressure. Danger of death! The pressure in the fuel system may still be as high as several hundred bar, even after the engine has been switched off. In this case, the fuel pressure can only be reduced by opening the fuel supply system to allow the fuel to flow out. WARNING Caution! Maximum cleanliness is essential when working on the fuel system. Carefully clean the area around the components to be worked on. Dry wet areas with a compressed air jet. WARNING When handling fuels, observe safety standards and all applicable local regulations. WARNING All fuel lines and fittings should be closed immediately after opening using new clean plugs and caps. Plugs or caps should only be removed immediately prior to assembly. WARNING Collect used service products in suitable containers and dispose of them in accordance with the applicable regulations. WARNING Always bleed the fuel system after every intervention.

30-189

Method of intervention Removal of fuel lines 1.

m m m m m m m m

(1) Fuel line (2) Fuel line (3) Fuel line (4) Hex head screw (5) Pipe retaining clip (6) Seal (7) Banjo bolt (8) Pressure sender

Fig. 1065

2.

m

Fuel line with connection fitting WARNING The release procedure is the same for all the fuel line connection fittings.

m

To release the connection fittings: n Squeeze the retaining springs (1) on both sides of the of the connection fitting. Fig. 1066

3.

m m m

Remove screw (1). Release and disconnect the connection fittings (2). Remove fuel line (3).

Fig. 1067

4.

m m

Release and disconnect the connection fittings (1). Remove fuel line (2).

Fig. 1068

30-190

Method of intervention 5.

m m m m m

Unlock the wiring connector. Unplug the wiring connector. Unscrew banjo bolt (1). Remove seals (2). Remove fuel line (3).

m

Fig. 1069

6.

m m m

Restrain adapter (1). Unscrew pressure sender (2). Remove the O-ring.

Fig. 1070

Refitting fuel lines. 1.

m m m m

Fit a new O-ring. Restrain adapter (1). Screw in pressure sender (2). Tighten the pressure sender. n Tightening torque: 30 Nm

Fig. 1070

30-191

Method of intervention 2.

DANGER Caution! When installing the fuel line, make sure it is not under tension. DANGER Check that the installation position is correct.

m

Position fuel line (1). DANGER

Fig. 1071

Tab (2) should rest on the pilot block.

DANGER Check that the installation position is correct.

m m m

3.

Fit new seals (3). Screw in banjo bolt (4). Tighten banjo bolt (4). n Tightening torque: 39 Nm DANGER Caution! When installing the fuel line, make sure it is not under tension. DANGER Check that the installation position is correct.

m m

Fit fuel line (1). Connect and lock the connection fittings (2). DANGER Check that the installation position is correct.

30-192

Fig. 1072

Method of intervention 4.

DANGER Caution! When installing the fuel line, make sure it is not under tension. DANGER Check that the installation position is correct.

m m

Fit fuel line (1). Connect and lock the connection fittings (2). Fig. 1073

DANGER Check that the installation position is correct.

m m

Locate the hose clip. Tighten screw (3). n Tightening torque: 30 Nm

Technical data Tightening torque:

Table 334 Designation

Screws type

Swivel nut on fuel line, hose diameter 8 mm M14x1.5

Fuel pressure sender in correspondence with the adapter Hose end fitting Banjo bolt M14x1.5 Pipe retaining clips, fixing M8x16-10.9 -

Note:

Value

With ball valve 39 Nm Use a new seal -

14 Nm 30 Nm

-

30 Nm

39 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30.5.4 - Removal and refitting of fuel lines (pilot block - high pressure pump) Special tools:

Tool 5.9035.072.0 (Special wrench) Tool 5.9035.095.0 (Plugs and caps) DANGER Danger! Do not work on the fuel system when the engine is running. The fuel system is under high pressure. Danger of death! The pressure in the fuel system may still be as high as several hundred bar, even after the engine has been switched off. In this case, the fuel pressure can only be reduced by opening the fuel supply system to allow the fuel to flow out. WARNING Caution! Maximum cleanliness is essential when working on the fuel system. Carefully clean the area around the components to be worked on. Dry wet areas with a compressed air jet. WARNING When handling fuels, observe safety standards and all applicable local regulations.

30-193

Method of intervention WARNING All fuel lines and fittings should be closed immediately after opening using new clean plugs or caps. Plugs or caps should only be removed immediately prior to assembly. WARNING Collect used service products in suitable containers and dispose of them in accordance with the applicable regulations. WARNING Always bleed the fuel system after every intervention.

Removal of the fuel line. 1.

m m m m m

(1) Fuel line (2) Seal (3) Banjo bolt (4) Seal (5) Banjo bolt

Fig. 1074

2.

WARNING Collect spilt fuel and dispose of it properly.

m

m m m m m

30-194

Remove the fuel return pipe. n See para. 30.5.3 - Removal and refitting ... - page 30-189 n See para. 30.5.5 - Removal and refitting ... - page 30-195 n See para. 30.5.6 - Removal and refitting ... - page 30-198 Unscrew banjo bolts (1). Remove the seals. Unscrew banjo bolt (2). Remove the seals. Remove the fuel pipe.

Fig. 1075

Method of intervention Refitting the fuel line. 1.

WARNING Fit new seals.

m

Position the fuel line. WARNING Caution! When installing the fuel line, make sure it is not under tension. WARNING

Fig. 1076

Check that the installation position is correct.

m m m

m

Install new seals on banjo bolts (2) and fit without tightening. Install new seals on banjo bolt (1) and fit without tightening. Tighten the banjo bolts in the specified sequence. n Banjo bolt (1), Tightening torque 39 Nm n Banjo bolts (2), Tightening torque 29 Nm Fit the fuel return pipe. n See para. 30.5.6 - Removal and refitting ... - page 30-198 n See para. 30.5.5 - Removal and refitting ... - page 30-195 n See para. 30.5.3 - Removal and refitting ... - page 30-189 WARNING Check that the fuel lines are positioned correctly.

Technical data Tightening torque:

Table 335 Designation

Hose end fitting, 8 mm diameter hose Hose end fitting, 10 mm diameter hose

Type of tractor

Banjo bolt M12x1.5 29 Nm Banjo bolt M14x1.5 39 Nm

Note:

Value

-

29 Nm

-

39 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.5.5 - Removal and refitting of fuel lines (pilot block - fuel lift pump) Special tools:

Tool 5.9035.095.0 (Plugs and caps) DANGER Danger! Do not work on the fuel system when the engine is running. The fuel system is under high pressure. Danger of death! The pressure in the fuel system may still be as high as several hundred bar, even after the engine has been switched off. In this case, the fuel pressure can only be reduced by opening the fuel supply system to allow the fuel to flow out. WARNING Caution! Maximum cleanliness is essential when working on the fuel system.

30-195

Method of intervention WARNING Before proceeding wit the operation, remove any paint residue and dirt. Carefully clean the area around the components to be worked on. Dry wet areas with a compressed air jet. WARNING When handling fuels, observe safety standards and all applicable local regulations. WARNING All fuel lines and fittings should be closed immediately after opening using new clean plugs or caps. Plugs or caps should only be removed immediately prior to assembly. DANGER Collect used service products in suitable containers and dispose of them in accordance with the applicable regulations. WARNING Always bleed the fuel system after every intervention.

Removal of the fuel line 1.

m m m m m m m m m m

(1) Fuel line (1) Fuel line (2) Seal (3) Banjo bolt sleeve (4) Seal (5) Banjo bolt (6) Pipe retaining clip (7) Hex head screw (8) Support (9) Hex head screw Fig. 1077

2.

m m m

Remove screw (1). Unscrew banjo bolt sleeve (2). Remove seals (3).

Fig. 1078

30-196

Method of intervention 3.

m m m

Restrain threaded fitting (1). Unscrew banjo bolt (2). Remove seals (3).

Fig. 1079

4.

m

Remove fuel line (1) from retaining clips (2). WARNING Note the installation position.

Fig. 1080

Refitting the fuel line 1.

WARNING Caution! When installing the fuel line, make sure it is not under tension. WARNING Check that the installation position is correct.

m m m m

2.

Position fuel line (1). Locate fuel line (2) in the retaining clips. Align the fuel line. Locate hose clip (3).

Fig. 1081

WARNING Caution! When installing the fuel line, make sure it is not under tension. WARNING Check that the installation position is correct.

m m

Fit new seals (1). Screw in banjo bolt (2). Fig. 1082

30-197

Method of intervention 3.

WARNING Caution! When installing the fuel line, make sure it is not under tension. WARNING Check that the installation position is correct.

m m m

4.

m

Fit new seals (1). Screw in banjo bolt sleeve (2). Screw in the screw (3).

Fig. 1083

Align fuel line (1). WARNING Caution! When installing the fuel line, make sure it is not under tension. WARNING Check that the installation position is correct.

m m

m

m

Restrain the threaded fitting. Tighten banjo bolt (2). n Tightening torque: 18 Nm Screw in banjo bolt sleeve (3). n Tightening torque: 49 Nm Tighten screw (4). n Tightening torque: 13 Nm

Fig. 1084

Technical data Tightening torque:

Table 336 Designation

Support on oil cooler housing Hose end fitting Hose end fitting Hose clips, fixing

Screws type

M8x16-10.9 Sleeve Banjo bolt M16x1.5 Banjo bolt M10x1 18 Nm M6x16-10.9 -

Note:

Value

-

20 Nm

-

49 Nm

-

18 Nm

-

13 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30.5.6 - Removal and refitting of fuel lines (rail, cylinder head, pilot block - fuel filter) Special tools:

Tool 5.9035.095.0 (Plugs and caps)

30-198

Method of intervention DANGER Danger! Do not work on the fuel system when the engine is running. The fuel system is under high pressure. Danger of death! The pressure in the fuel system may still be as high as several hundred bar, even after the engine has been switched off. In this case, the fuel pressure can only be reduced by opening the fuel supply system to allow the fuel to flow out. WARNING Caution! Maximum cleanliness is essential when working on the fuel system. WARNING Before proceeding wit the operation, remove any paint residue and dirt. Carefully clean the area around the components to be worked on. Dry wet areas with a compressed air jet. WARNING When handling fuels, observe safety standards and all applicable local regulations. WARNING All fuel lines and fittings should be closed immediately after opening using new clean plugs or caps. Plugs or caps should only be removed immediately prior to assembly. DANGER Collect used service products in suitable containers and dispose of them in accordance with the applicable regulations. WARNING Always bleed the fuel system after every intervention.

Removal of fuel lines 1.

m m m m m m m m m m

(1) Return line (2) Return line (3) Seal (4) Banjo bolt (5) Seal (6) Banjo bolt (7) Banjo bolt (8) Adapter (9) Seal (10) Seal Fig. 1085

30-199

Method of intervention 2.

m

Fuel line with connection fitting DANGER The release procedure is the same for all the fuel line connection fittings.

m

To release the connection fittings: n Squeeze the retaining springs (1) on both sides of the of the connection fitting. Fig. 1086

3.

m m

Release and disconnect the connection fittings (1). Remove fuel line (2).

Fig. 1087

4.

m m

Unscrew banjo bolts (1). Remove seals (2).

Fig. 1088

5.

m m m m

Restrain adapter (1). Unscrew banjo bolt (2). Remove seals (3). Remove fuel line (4).

Fig. 1089

30-200

Method of intervention Refitting fuel lines. 1.

WARNING Fit new seals.

m

Position the fuel line. WARNING Caution! When installing the fuel line, make sure it is not under tension. WARNING Check that the installation position is correct.

2.

m

Fit fuel line (1).

m

Fit new seals (2).

m

Screw in banjo bolt (3).

m

Fit new seals (1). Screw in banjo bolt (2). Fit new seals (3). Screw in banjo bolt (4).

m m m

Fig. 1090

Fig. 1091

3.

m m

m

m

Restrain adapter (1). Tighten banjo bolt (2). n Tightening torque: 29 Nm Tighten banjo bolt (3). n Tightening torque: 39 Nm Tighten banjo bolt (4). n Tightening torque: 49 Nm

Fig. 1092

30-201

Method of intervention 4.

WARNING Caution! When installing the fuel line, make sure it is not under tension. WARNING Check that the installation position is correct.

m m

Fit fuel line (1). Connect and lock the connection fittings (2). Fig. 1093

WARNING Check that the wiring connector is properly connected.

Technical data Tightening torque:

Table 337 Designation

Adapter on cylinder head

Screws type

M12x1.5 Banjo bolt (with connection fitting) on M14x1.5 adapter Swivel nut on fuel line, hose diameter 6 mm M 12x1.5 Hose end fitting Banjo bolt M14x1.5 Hose end fitting Banjo bolt M16x1.5

Note:

Value

Use a new seal

29 Nm

Fit new seals

29 Nm

With ball valve

20 Nm

-

39 Nm

-

49 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30.5.7 - Removal and refitting of the heater Special tools: -

30-202

Method of intervention Removal of the heater 1.

Components: m m m m m m m m m m m m m m m m m m m m m m

2.

m

(1) Charge air duct (2) Gasket (3) Hex head screw (4) Gasket (5) Hex head screw (6) Hex head screw (7) Gasket (8) Cover (9) Hex head screw (10) Pressure/temperature sender (11) Cover (12) Hex head screw (13) Charge air manifold (14) Flexible pipe union (15) Hex head screw (16) Heater (17) Insulation (18) Positive terminal (19) O-ring (20) Negative terminal (21) Insulation (22) Hex head screw

Fig. 1094

Disconnect the wiring connectors. DANGER Remove the screws, leaving only the positive terminal screw in place to support the heater.

m

Remove screws (1).

Fig. 1095

3.

DANGER Note the installation position.

m m m m m

Undo hose union (1). Remove seal (2). Withdraw heater (3). Remove gasket (4). Carry out a visual inspection of the component. Fig. 1096

30-203

Method of intervention Refitting the heater 1.

DANGER Note the installation position.

m m m m m m m

Clean the mating surfaces. Fit a new O-ring (1). Fit heater (2). Fit a new O-ring (3). Reconnect hose union (4). Fit screws (5). Tighten screws (5) alternately. n Tightening torque: 30 Nm

Fig. 1097

Technical data Tightening torque

Table 338 Designation

Heater on charge air manifold

Screw type

M8x100-10.9 -

Note:

-

Value

30 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.5.8 - Removal and refitting of the heater (details) Special tools: -

Removal of the heater 1.

Components: m m m m m m m m m m m m m m m m m m m m m m

30-204

(1) Charge air duct (2) Gasket (3) Hex head screw (4) Gasket (5) Hex head screw (6) Hex head screw (7) Gasket (8) Cover (9) Hex head screw (10) Pressure/temperature sender (11) Cover (12) Hex head screw (13) Charge air manifold (14) Hose union (15) Hex head screw (16) Heater (17) Insulation (18) Positive terminal (19) O-ring (20) Negative terminal (21) Insulation (22) Hex head screw

Fig. 1098

Method of intervention 2.

m m

Remove the heater. Hold the heater in a vice. WARNING Use a vice with jaws faced with soft material.

m

Insert hex wrench (1). n Short side

Fig. 1099

3.

m m

Locate hex wrench (1). Tilt hex wrench (1) between the plinth of the upper and lower heating elements.

Fig. 1100

4.

m m m m m

Locate hex wrench (1). Restrain hex wrench (1). Unscrew the positive terminal screw (2). Remove insulation (3). Carry out a visual inspection of the components.

Fig. 1101

30-205

Method of intervention Refitting the heater 1.

WARNING Before tightening the positive terminal screw, tighten screws (1), (2) and (3). WARNING Do not turn the heater elements.

m m m

2.

m

Position (1), Tightening torque: 8.5 Nm Position (2), Tightening torque: 11 Nm Position (3), Tightening torque: 8.5 Nm

Fig. 1102

Insert hex wrench (1). n Short side

Fig. 1103

3.

m m

Locate hex wrench (1). Tilt hex wrench (1) between the plinth of the upper and lower heating elements.

Fig. 1104

4.

m m m

Locate hex wrench (1). Fit insulation (2). Fit positive terminal screw (3). WARNING Do not turn the heating elements.

m m

Restrain hex wrench (1). Tighten positive terminal screw (3). n Tightening torque: 25 Nm Fig. 1105

30-206

Method of intervention Technical data Tightening torque

Table 339 Designation

Positive terminal on heating element Negative terminal on heating element Screws, heating element to heater

Screw type

-

Note:

Value

-

25 Nm

-

11 Nm

-

8.5 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.5.9 - Installing and removing the thermostat Special tools:

Tool 5.9035.344.0 (Percussion puller) Tool 5.9035.345.0 (Internal puller) Tool 5.9035.346.0 (Assembly tool) Tool 5.9035.347.0 (Disassembly tool) WARNING Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations. WARNING To empty and fill the engine, observe the relative instructions.

Removing the thermostat 1.

Components: m m m m m m m m m m m m m m m m

(1) Thermostat housing (2) Gasket (3) Hex screw (4) Thermostat (5) Relay (6) Washer (7) Fillister-head screw (8) Flexible hose connection (9) Oil seal (10) Gasket (11) Outlet port (12) Hex screw (13) Oil seal (14) Oil seal (15) Closing screw (16) Closing screw

Fig. 1106

30-207

Method of intervention 2.

m

m m m m

Empty, collect and dispose of the coolant in compliance with regulations. If available: Disconnect the flexible hose from the outlet port. Remove screws (1). Remove drain port (2). Make a visual inspection of the component.

Fig. 1107

3.

m

Remove seal (1).

Fig. 1108

4.

m

m

Insert extractor tool (1) in the thermostat, turn clockwise and engage thermostat. Remove thermostat from thermostat housing using puller tool.

Fig. 1109

5.

m m m m

Fit inside puller (1) on the percussion puller. Preset inside puller and insert it behind the oil seal. Adapt the inside puller so that it matches the oil seal. Use the inside puller and the percussion puller to remove oil seal (2) from the thermostat housing. WARNING Pay attention to the installation position of the oil seal. WARNING Make sure the thermostat housing is not damaged.

30-208

Fig. 1110

Method of intervention Installing the thermostat 1.

m m m

Clean the mating surfaces Fit a new oil seal (1) on the assembly tool (2). Insert the oil seal with the tool into the thermostat housing. WARNING Pay attention to the installation position of the oil seal.

Fig. 1111

2.

m

m

With the assembly tool press the new oil sea until locating disc (1) on the thermostat housing. Remove the assembly tool.

Fig. 1112

3.

m m

Install the thermostat. Fit gasket (1)

Fig. 1113

4.

m m

m m

Fit outlet union (1). Tighten screws (2). n Tightening torque: 30 Nm If available: slide the flexible hose over the outlet port and secure it. Fill the cooling system as described in the instructions.

Technical data Tightening torque prescriptions

Table 340 Designation

Outlet union on the thermostat housing

Screws type

M8x40-10.9 M8x55-10.9

Note:

-

Value

30 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30-209

Method of intervention 30.5.10 - Thermostat check (with thermostat disassembled) Readily available commercial tools: Thermometer DANGER Risk of injury! Hot water and hot thermostat.

Checking the thermostat 1.

m m

Measure the initial stroke, dimension (a). Make a note of the measured value, dimension (a).

Fig. 1114

2.

m m

Heat the thermostat in a water bath. Establish start of opening. WARNING To determine the exact opening start temperature, measure the temperature as close to the thermostat as possible. WARNING Do not touch the thermostat. WARNING

Fig. 1115

To obtain uniform temperature distribution in the bath the water should be kept in constant movement. The temperature rise should be no faster than 1°C/min., otherwise the opening start of the thermostat will be delayed by the same amount as the faster rate of temperature rise. 3.

m

Nominal value: 86 °C

m

Measure the water temperature. n Nominal value: 98 °C Measure the stroke end, dimension (b). Make a note of the measured value, dimension (b).

m m

Fig. 1116

30-210

Method of intervention 4.

Measure the lifting stroke. Calculation example Required: Lifting stroke Given: Measured: Stroke start, dimension (a) / Stroke end, dimension (b) Calculation: Dimension (b) - dimension (a) Result: = Lifting stroke m Compare the result with the nominal value. n Nominal value: minimum 9.5 mm. m

Technical data Test and adjustment data

Table 341 Designation

Denomination Additional information Value Thermostat, stroke Thermostat, stroke, test temperature

Additional Information:

at 98 °C -

Value

86°C

minimum 9.5 mm 98°C

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30.5.11 - Removal and installation of the thermostat housing Special tools: WARNING Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations. WARNING To empty and fill the engine, observe the relative instructions.

Removing the thermostat housing 1.

Components: m m m m m m m m m m m m m m m m

(1) Thermostat housing (2) Gasket (3) Hex screw (4) Thermostat (5) Relay (6) Washer (7) Fillister-head screw (8) Flexible hose connection (9) Oil seal (10) Gasket (11) Outlet port (12) Hex screw (13) Oil seal (14) Oil seal (15) Closing screw (16) Closing screw

Fig. 1117

30-211

Method of intervention 2.

m m m

m m m

Remove the belt tensioner (level 1). Remove the idle roller. Remove the fan drive n See para. 30.4.26 - Removing and installin... - page 30-81 n See para. 30.4.27 - Removing and installin... - page 30-82 n See para. 30.4.28 - Removing and installin... - page 30-85 Remove the cable tie. Remove screws (1). Shift relay (2) to the side.

Fig. 1118

3.

m m m m

Remove screws (1). Remove thermostat housing (2). Remove seal (3). Make a visual inspection of the component.

Fig. 1119

4.

m

Remove clutch element (1).

Fig. 1120

5.

m m

Remove circular gaskets (1) using the disassembly tool. Make a visual inspection of the component.

Fig. 1121

30-212

Method of intervention Installing the thermostat housing 1.

m m m

Clean the mating surfaces Apply a thin film of assembly product on the new circular gaskets. Fit the new circular seals (1).

Fig. 1122

2.

m m

Clean the mating surfaces Install clutch element (1).

Fig. 1123

3.

m m m m m m

Clean the mating surfaces Fit a new oil seal (1). Install thermostat housing (2). Tighten the screws alternately. Torque the screws in an alternate sequence. Tighten screw (3). n Tightening torque: 60 Nm

Fig. 1124

4.

m m

m m m m

Position relay (1). Tighten screws (2). n Tightening torque: 8.5 Nm Secure the cable tie. Install the fan drive. Fit the idle roller. Install the belt tensioner (level 1). n See para. 30.4.28 - Removing and installin... - page 30-85 n See para. 30.4.27 - Removing and installin... - page 30-82 n See para. 30.4.26 - Removing and installin... - page 30-81 Fig. 1125

30-213

Method of intervention Technical data Tightening torque prescriptions

Table 342 Designation

Thermostat housing to cylinder head

Screws type

M10x70-10.9 Closing screw on thermostat housing M14x1.5 Flexible hose connection on thermostat M14x1.5 housing Closing screw on thermostat housing M26x1,5 Relay (heater) on thermostat housing M6x16-8.8 -

Note:

Value

Use a new gasket

60 Nm

-

34 Nm

-

34 Nm

-

110 Nm

-

8.5 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30.5.12 - Removal and refitting of the fan support Special tools: -

Removal of the support 1.

COMPONENTS: m

(1) Hex head screw

Fig. 1126

2.

m

Remove the ribbed V-belt. WARNING Check the installation position of the fan support.

m m m

Remove screws (1). Remove fan support (2). Visually inspect the component.

Fig. 1127

30-214

Method of intervention Refitting the support 1.

WARNING Check the installation position of the fan support.

m m m

m

Fit fan support (1). Screw in screws (2) alternately. Tighten screws (2). n Tightening torque: 60 Nm When fitting the V-belt, check the direction of rotation. Fig. 1128

Technical data Tightening torque:

Table 343 Designation

Fan support to thermostat housing

Type of tractor

M10x45-10.9 M10x50-10.9

Note:

-

Value

60 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.5.13 - Removal and assembly of the fan support Special tools: DANGER Caution! When installing bearings, ensure the press tool bears only on the outer and inner races. No force should be applied to the balls of the bearing.

Removal of the fan support 1.

m m m m m m m m

(1) Fan bearing (2) Circlip (3) Ball bearing (4) Hollow spindle (5) Ball bearing (6) Washer (7) Hex head screw (8) V-belt pulley

Fig. 1129

30-215

Method of intervention 2.

m

Screw in the screws (arrowed). n M10x45-10.9

Fig. 1130

3.

m m

Hold the screws in a vice. Slacken off screw (1) by a few turns. WARNING Caution! This screw has a left-hand thread.

Fig. 1131

4.

m m

Hold the fan support in a vice. Using a rubber mallet, tap lightly on screw (1) to loosen the V-belt pulley.

Fig. 1132

5.

m m m

Remove screw (1). Remove washer (2). Remove V-belt pulley (3).

Fig. 1133

30-216

Method of intervention 6.

m m

Release the fan support. Drive out the spindle and the inner ball bearing.

Fig. 1134

7.

m

Drive out the outer ball bearing.

Fig. 1135

8.

m

Remove circlip (1).

Fig. 1136

9.

m

Drive out the washer from the inner ball bearing.

Fig. 1137

30-217

Method of intervention 10.

m m

Drive out the spindle from the inner ball bearing. Visually inspect the components.

Fig. 1138

Assembly of the fan support 1.

m

Press the spindle into the inner ball bearing until seated.

Fig. 1139

2.

m

Press the washer into the inner ball bearing until seated.

Fig. 1140

3.

m

Press the outer ball bearing into its housing until seated. DANGER The press tool (1) must bear on the outer race of the ball bearing (arrowed).

Fig. 1141

30-218

Method of intervention 4.

m

Fit circlip (1). DANGER Check that the circlip is correctly seated in the journal.

Fig. 1142

5.

m

Press the spindle and the inner ball bearing until seated. DANGER Support the inner race of the outer ball bearing using a suitable tool (arrowed).

Fig. 1143

6.

m m m m

Hold the fan support in the vice. Fit V-belt pulley (1). Fit washer (2). Screw in new screw (3). DANGER Caution! This screw has a left-hand thread.

Fig. 1144

7.

m

Hold the screws in a vice. DANGER Caution! This screw has a left-hand thread.

m

m

Tighten new screw (1). n Stage 1, Tightening torque: 30 Nm Tighten the screw using a torque angle gauge. n Stage 2, Tightening torque: 90° Fig. 1145

30-219

Method of intervention 8.

m

Remove screws (1).

Fig. 1146

Technical data Tightening torque:

Table 344 Designation

Fan bearing on fan support Fan bearing on fan support

Type of tractor

M12LHx85-12.9 M12LHx85-12.9 -

Note:

Stage 1: Use a new screw. Stage 2:

Value

30 Nm 90°

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.5.14 - Installing and removing the temperature transmitter (Exhaust gas) Special tools: -

Removing the temperature transmitter 1.

Components: m m

(1) Exhaust gas temperature transmitter (950) Closing screw

Fig. 1147

2.

m m m m

Remove the cable tie. Unlock and detach the connectors. Unscrew temperature sensor (1). Make a visual inspection of the component.

Fig. 1148

30-220

Method of intervention Installing the temperature transmitter 1.

m m

m m m

Screw down temperature sensor (1). Tighten temperature sensor (1). n Tightening torque: 45 Nm Fit and secure the connector. Make sure the connection has been made correctly. Secure the cable tie.

Fig. 1148

Technical data Tightening torque prescriptions

Table 345 Designation

Temperature transmitter (exhaust gas) on exhaust pipe Closing screw (temperature transmitter, exhaust gas) on exhaust pipe

Screws type

-

Note:

Value

-

45 Nm

-

32 Nm

IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30.5.15 - Removal and refitting of the starter motor Special tools: -

Removal of the starter motor 1.

Components: m

(1) Hex head screw

Fig. 1149

30-221

Method of intervention 2.

m m m

Disconnect the lead from the negative terminal of the battery. Unlock and disconnect wiring connector (1). Remove the cable tie.

Fig. 1150

3.

m m m

Remove screws (1). Remove starter motor (2) Visually inspect the component.

Fig. 1151

Refitting of the starter motor 1.

m m

Fit starter motor (1) Tighten screws (2). n Tightening torque: 60 Nm

Fig. 1152

2.

m m m

Re-connect and lock the wiring connector (1). Fasten cable tie. Connect the lead to the negative terminal of the battery.

Fig. 1153

30-222

Method of intervention Technical data Tightening torque:

Table 346 Designation

Type of tractor

Starter motor mounted on engine block/ M10x38-10.9 M10x60-10.9 gearbox

Note:

-

Value

60 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.5.16 - Removal and refitting of the alternator (ribbed V-belt, level 2) Special tools: -

Removal of the alternator 1.

Components: m m m m m m m m m m m m m

2.

m m m

(1) Support bracket (2) Idler roller (3) Belt tensioner (4) Hex head screw (5) Hex head screw (6) Hex head screw (7) Hex head screw (8) Alternator (10) Washer (11) Hex nut (12) Tapered retaining ring (13) V-belt pulley (950) Tension adjuster

Fig. 1154

Remove the V-belt. Disconnect the leads from the negative terminal of the battery. Disconnect the alternator wiring. WARNING Note the connection positions of the wiring! (1) = W terminal, (2) = terminal D+, (3) = B+ terminal

Fig. 1155

3.

m m m

Remove screws (1). Remove alternator (2). Carry out a visual inspection of the components.

Fig. 1156

30-223

Method of intervention Refitting the alternator 1.

m m

Fit alternator (1). Tighten screws (2). n Tightening torque: 60 Nm

Fig. 1157

2.

m

Reconnect the alternator wiring. WARNING Note the connection positions of the wiring! (1) = W terminal, (2) = terminal D+, (3) = B+ terminal

m m

Connect the leads to the negative terminal of the battery. Fit the ribbed V-belt, taking into account the direction of rotation.

Fig. 1158

Technical data Tightening torque

Table 347 Designation

Screw type

Alternator to support bracket (exhaust side) M10x80-10.9 -

Note:

-

Value

60 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.5.17 - Removal and refitting of the alternator (ribbed V-belt, level 1) Special tools: -

Removal of the lube oil pipe 1.

Removal of the alternator m m m m

(1) Support bracket (2) Support plate (3) Hex head screw (4) Hex head screw

Fig. 1159

30-224

Method of intervention 2.

m m m

Remove the V-belt. Disconnect the leads from the negative terminal of the battery. Disconnect the alternator wiring. WARNING Note the connection positions of the wiring! (1) = W terminal, (2) = terminal D+, (3) = B+ terminal

Fig. 1160

3.

m m m

Remove screws (1). Remove alternator (2). Carry out a visual inspection of the components.

Fig. 1161

Refitting the alternator 1.

m m

Fit alternator (1). Tighten screws (2). n Tightening torque: 60 Nm

Fig. 1162

2.

m

Reconnect the alternator wiring. WARNING Note the connection positions of the wiring! (1) = W terminal, (2) = terminal D+, (3) = B+ terminal

m m

Connect the leads to the negative terminal of the battery. Fit the ribbed V-belt, taking into account the direction of rotation.

Fig. 1163

30-225

Method of intervention Technical data Tightening torque

Table 348 Designation

Screw type

Alternator (control side) on support brack- M10x75-10.9 et/plate

Note:

-

Value

60 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.5.18 - Removal and refitting of the crankshaft speed sensor Special tools:

DEUTZ DW 72 mastic

Removal of the speed sensor 1.

Components: m m m m m m

(1) Hex head screw (2) Cable tie (3) Fillister-head screw (4) Speed sensor (5) Support (6) Cable tie

Fig. 1164

2.

m m m

Unlock and disconnect the wiring connectors. Withdraw screw (1). Remove speed sensor (2).

Fig. 1165

3.

m m m

Remove screws (1). Remove support (2). Visually inspect the components.

Fig. 1166

30-226

Method of intervention Refitting the speed sensor 1.

m m

Fit support (1). Tighten screws (2). n Tightening torque: 9 Nm

Fig. 1167

2.

m m m

m

Fit speed sensor (1). Fit screw (2) using thread locking agent. Tighten screw (2). n Tightening torque: 9 Nm Connect the wiring connector. WARNING Check that the wiring connector is properly connected.

m

Position the cables. Fig. 1168

WARNING Caution! Check that the cables are positioned correctly.

Technical data Tightening torque:

Table 349 Designation

Camshaft speed sensor in correspondence with support (timing cover) Crankshaft speed sensor in correspondence with support (timing cover)

Type of tractor

M6x16-8.8 M6x30-10.9 -

Note:

Value

Use DEUTZ DW72 9 Nm thread locking agent. 9 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.5.19 - Removal and refitting of the camshaft speed sensor Special tools:

Tool 5.9035.245.0 (Removal tool)

30-227

Method of intervention Removal of the speed sensor 1.

Components: m

(1) Fillister-head screw

Fig. 1169

2.

m m m m m

Unlock and disconnect wiring connectors (1). Unscrew screw (2). Remove speed sensor (3). Remove the O-ring using the specific removal tool. Visually inspect the component.

Fig. 1170

Refitting the speed sensor 1.

m m m

Clean the sealing surfaces. Fit new O-ring (1). Lightly lubricate the O-ring.

Fig. 1171

30-228

Method of intervention 2.

m

Push in speed sensor (1). WARNING Caution! Do not hit the speed sensor!

m

m

Tighten screw (2). n Tightening torque: 9 Nm Connect wiring connector (3). WARNING Fig. 1172

Check that the wiring connector is properly connected.

m

Position the cables. WARNING Caution! Check that the cables are positioned correctly.

Technical data Tightening torque:

Table 350 Designation

Type of tractor

Camshaft speed sensor in correspondence M6x16-8.8 with engine block

Note:

-

Value

9 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.5.20 - Installation and removal of the rotation device Special tools:

Tool 5.9035.336.0 (rotation device) WARNING Caution! Check the direction of rotation of the engine.

Installation of the rotation device 1.

m m

Remove screws (1). Remove cover (2).

Fig. 1173

30-229

Method of intervention 2.

m

Fit rotation device (1). WARNING The teeth on the wheel of the rotation device must mesh with the teeth on the camshaft wheel.

Fig. 1174

3.

m

Tighten screws (1). n M8x2x70, Tightening torque: 21 Nm

Fig. 1175

Removal of the rotation device 1.

m m

Remove screws (1). Remove rotation device (2).

Fig. 1176

2.

m m

Press plug (1) in fully. Tighten screws (2). n Tightening torque: 21 Nm

Fig. 1177

30-230

Method of intervention Technical data Tightening torque:

Table 351 Designation

Cover to gearbox

Type of tractor

M8x55-10.9 M8x60-10.9

Note:

-

Value

21 Nm

IMPORTANT When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of ± 10 % is permitted.

30.5.21 - Installation and removal of the rotation device (torsional vibration damper) Special tools:

Tool 5.9035.335.0 (rotation device) WARNING Caution! Check the direction of rotation of the engine.

Installation of the rotation device 1.

m

Fit rotation device (1).

Fig. 1178

2.

m

Position rotation device (1).

Fig. 1179

30-231

Method of intervention 3.

m

Depending on the installation requirements, use a suitable tool as an extension for rotation device (1). WARNING Caution! Check the direction of rotation of the engine.

m

Rotate the crankshaft in the normal direction of engine rotation using the rotation device. Fig. 1180

Removal of the rotation device 1.

m

Remove rotation device (1).

Fig. 1180

30.5.22 - Removal and installation of the air conditioning compressor Special tools:

Tool 5.9035.095.0 (Plugs and caps) WARNING Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations.

Removing the air conditioning compressor 1.

Components: m m

(1) Air conditioning compressor (2) Hex screw

Fig. 1181

30-232

Method of intervention 2.

m m

Remove the reinforced vee belt Unlock and detach connectors (1). WARNING Emptying and filling the air conditioning system must be performed as per the instructions and as shown in the respective documentation/indications of the manufacturer of the vehicle/air conditioner.

m m

Unscrew the refrigerant pipes. Fit the plugs. Fig. 1182

3.

m m

Remove all the screws (1). Remove air conditioning compressor (2).

Fig. 1183

Installing the air conditioning compressor 1.

m m

Fit the air conditioning compressor (1). Tighten screws (2). n Tightening torque: 30 Nm

Fig. 1184

2.

WARNING Emptying and filling the air conditioning system must be performed as per the instructions and as shown in the respective documentation/indications of the manufacturer of the vehicle/air conditioner. m m m m

Remove the plugs. Screw down the air conditioning compressor. Fit and secure connector (1). Fit the reinforced vee belt, ensuring you observe the correct direction of run.

Technical data Tightening torque prescriptions

Table 352 Designation

Air conditioning compressor to console

Screws type

M8x80-10.9 -

Note:

-

Value

30 Nm

30-233

Method of intervention IMPORTANT For the tightening procedure on the basis of the tightening torque, using a torque wrench a tolerance of the tightening torque value of ± 10% is permitted.

30-234

Method of intervention 30.6 - D0 - Transmission

30.6.1 - Separation of Rear Axle from Transmission (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Loosen all screw plugs (transmission/rear axle) and drain the oil. WARNING Waste oil to be disposed of ecologically and according to the legal provisions!

Fig. 1185

2.

Unscrew the filter housing and remove filter insert.

Fig. 1186

3.

Remove all pipes. Loosen all cable connectors to the rear axle.

Fig. 1187

4.

Put the complete unit (transmission with rear axle) on a heavy-duty pallet, supporting the rear axle at the same time. Then secure the rear axle by means of lifting device and loosen the screws. (S) Eyebolts (M12): 5.9035.377.0

Fig. 1188

30-235

Method of intervention 5.

Install two locating pins (S) and separate rear axle from the transmission. (S) Locating pins (M14): 5.9035.197.0 (S) Assembly lever: 5.9035.203.0

Fig. 1189

30.6.2 - Removal of cartridge (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Fix the transmission (without rear axle) on the assembly truck (see Figures) (S) Assembly truck: 5.9035.193.0 (S) Clamping device: 5.9035.388.0 (S) Holding fixtures: 5.9035.389.0 Legend: 1 = Assembly truck 2 = Support

1

DANGER Make sure that the transmission is sufficiently supported to avoid any accidents (see Figure)! 2.

2

Fig. 1190

Legend: 3 = Clamping device 3

3

Fig. 1191

3.

Loosen hexagon screw and remove the releasing cover.

Fig. 1192

30-236

Method of intervention 4.

Loosen the cylindrical screws and pull the releasing sensor lid out of the housing. IMPORTANT Pull the sensor lid out of the housing by using the hexagon screw of the cover (see previous Figure)! WARNING Do NOT use cables for pulling! Fig. 1193

5.

Turn output shaft until slotted pin in the sleeve becomes visible (also refer to the next Figure). Then force out slotted pin and push back the sleeve. (S) Assembly fixture: 5.9035.387.0 IMPORTANT Slotted pin remains in the output shaft!

Fig. 1194

6.

Legend: 1 = Output shaft 2 = Sleeve 3 = Slotted pin

2 1

3

Fig. 1195

7.

Secure cartridge by means of the lifting tackle and loosen the bolted connection. (S) Lifting hook: 5.9035.382.0

Fig. 1196

30-237

Method of intervention 8.

Separate the cartridge from the transmission housing. (S) Assembly lever set: 5.9035.203.0

Fig. 1197

9.

Pull the sleeve off the output shaft and remove the slotted pin (see Figure).

Fig. 1198

30.6.3 - Removal of Cartridge (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Fix the transmission, without rear axle, to the assembly truck (see 1^ and 2^ figures). (S) Assembly truck: 5.9035.193.0 (S) Clamping device: 5.9035.388.0 (S) Holding fixtures: 5.9035.389.0 WARNING

1

Make sure that the transmission is sufficiently supported to avoid any accidents (see figure shown)!

3

Fig. 1199

2.

To 1^ and 2^ figures: 2.1. Assembly truck 2.2. Clamping device 2.3. Support

2

2

Fig. 1200

30-238

Method of intervention 3.

Loosen hexagon screw and remove releasing cover. Remove cable clips (See arrows).

Fig. 1201

4.

Loosen cylindrical screws (2x) and pull releasing sensor cover out of the housing. WARNING Pull the sensor cover out of the housing by using the hexagon screw of the cover (3^ figure)! WARNING Do NOT use cables for pulling! Fig. 1202

5.

Turn pinion until slotted pin in the sleeve becomes visible (also refer to the following figure). Then force out slotted pin and push back the sleeve. (S) Assembly fixture: 5.9035.387.0 WARNING Slotted pin remains in the output shaft!

Fig. 1203

6.

Legend to figure: 6.1. Pinion 6.2. Sleeve 6.3. Slotted pin

Fig. 1204

30-239

Method of intervention 7.

Secure cartridge by means of the lifting tackle and loosen the bolted connection. (S) Hook: 5.9035.382.0

Fig. 1205

8.

Separate the cartridge from the transmission housing. (S) Assembly lever: 5.9035.203.0 WARNING Pay attention to releasing O-rings!

Fig. 1206

9.

Pull the pinion off the output shaft and remove the slotted pin (5 figure).

Fig. 1207

30-240

Method of intervention 30.6.4 - Disassembly of shifting drum (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Fix cartridge to the assembly truck. (S) Assembly truck: 5.9035.193.0 (S) Clamping device: 5.9035.391.0 Modular design: (S) Assembly truck: 5.9035.193.0 (S) Clamping device: 5.9035.388.0 (S) Clamping device: 5.9035.389.0

Fig. 1208

30.6.5 - Disassembly of Shifting Drum (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Loosen the plug connection cable/directional valve. Detach cylindrical screw (See arrow). Remove the releasing fixing plate and the directional valve.

Fig. 1209

2.

Loosen hexagon nuts and remove the valve block. WARNING Pay attention to releasing rectangular rings! Detach stud bolts.

Fig. 1210

3.

Fix cartridge to the assembly truck. (S) Assembly truck: 5.9035.193.0 (S) Clamping device: 5.9035.391.0

Fig. 1211

30-241

Method of intervention 30.6.6 - Disassembly of P1 ring gear carrier 1.

Loosen hexagon screws (4x)

Fig. 1212

2.

Loosen the tight-fit screws (2x) and the hexagon screws (2x). Remove the releasing bracket. WARNING To prevent seizing, loosen the tight-fit screws first. Do NOT use an impact wrench!

Fig. 1213

3.

Pull P1 ring gear carrier off the P1/P2 planetary carrier. WARNING Pay attention to releasing thrust washer! WARNING During this operation, do NOT pull planetary drive P1/P2 (See arrow) (Difficult subsequent disassembly)! Fig. 1214

4.

Bring snap ring into contact position within the annular groove of the spur gear. Pull off ring gear.

Fig. 1215

30-242

Method of intervention 5.

Unlock and loosen the slotted nut. (S) Slotted nut wrench: 5.9035.455.0

Fig. 1216

6.

Pull off the spur gear and remove the releasing tapered roller bearing. Now force both bearing outer rings out of the spur gear.

Fig. 1217

7.

Disengage the retaining ring. Pull the releasing bearing flange out of the spur gear.

Fig. 1218

8.

Disengage the retaining ring. Pull the releasing ball bearing off the bearing flange.

Fig. 1219

30-243

Method of intervention 9.

If required, pull needle bearing (1) and slotted pin (2) out of the bearing flange.

1

2

Fig. 1220

10.

Heat inner ring and press it off the bearing flange using the cut-off device (S). (S) Cut-off device: 5.9035.384.0 WARNING Difficult disassembly, bearing inner ring is secured with Loctite!

Fig. 1221

11.

Drive tapered roller bearing off the spur gear (equally thru the holes).

Fig. 1222

30-244

Method of intervention 30.6.7 - Disassembly of P1/P2 Planetary drive 1.

Disengage the retaining ring.

Fig. 1223

2.

Pull planetary carrier off the central shaft. WARNING Pay attention to releasing thrust washer!

Fig. 1224

3.

Loosen countersunk screws. Remove the releasing toothed washer.

Fig. 1225

4.

Loosen countersunk screws. Remove the releasing fixing plate.

Fig. 1226

30-245

Method of intervention 5.

Pull the planetary pins. Remove the releasing single parts.

Fig. 1227

6.

Pull the sun gear off the central shaft.

Fig. 1228

7.

Remove the central shaft together with hollow shaft and ring gear. Now pull needle sleeves out of hollow shaft and ring gear. WARNING Pay attention to releasing thrust washer!

Fig. 1229

30-246

Method of intervention 30.6.8 - Disassembly of P5/P6 Planetary drive 1.

Disengage the retaining ring.

Fig. 1230

2.

Unlock and loosen the slotted nut. (S) Slotted nut wrench: 5.9035.456.0

Fig. 1231

3.

Loosen the tight-fit screws. Remove the releasing bearing bracket. WARNING To prevent seizing, do NOT use an impact wrench to loosen the tight-fit screws!

Fig. 1232

4.

Pull the planetary drive off the clutch carrier.

Fig. 1233

30-247

Method of intervention 5.

Disengage the retaining ring and remove the spacer behind.

Fig. 1234

6.

Drive the sun gear out of the planetary carrier. Now pull the needle sleeve out of the sun gear.

Fig. 1235

7.

Disengage the snap ring. Remove the releasing ball bearing.

Fig. 1236

8.

Loosen the countersunk screws. Remove the releasing fixing plate.

Fig. 1237

30-248

Method of intervention 9.

Pull the planetary pins. Remove the releasing single parts.

Fig. 1238

30.6.9 - Disassembly of KV clutch 1.

Disengage the retaining ring and remove the adjusting washer behind.

Fig. 1239

2.

Pull KV clutch off the cutch carrier.

Fig. 1240

3.

Disengage the retaining ring. Pull the releasing sun gear out of the clutch carrier.

Fig. 1241

30-249

Method of intervention 4.

Disengage the snap ring. Pull the releasing hub out of the clutch carrier.

Fig. 1242

5.

Preload the cup springs with a press, and disengage the retaining ring. Now remove washer, cup springs and clutch ring out of the clutch carrier. (S) Assembly fixture: 5.9030.971.0 WARNING Piston remains in the clutch carrier; clutch carrier is supplied as a complete component with preassembled piston!

Fig. 1243

30.6.10 - Disassembly of K1 clutch 1.

Loosen the hexagon screws. Separate the cover from the bearing bracket.

Fig. 1244

2.

Force out the slotted pin.

Fig. 1245

30-250

Method of intervention 3.

Preload the cup springs with a press. Disengage the snap ring. (S) Pressure plate: 5.9035.464.0

Fig. 1246

4.

Pull the holder out of the cover. Remove the releasing single parts. WARNING Piston remains in the cover; cover is supplied as a complete component with preassembled piston!

Fig. 1247

30.6.11 - Disassembly of K3/K4 clutch and P3/P4 planetary drive 1.

Remove the O-rings (See arrows) from the annular grooves of the clutch carrier.

Fig. 1248

2.

Loosen the clutch carrier (complete with planetary drive) with a plastic hammer and pull it out of the bracket. WARNING Use a plastic hammer! WARNING Be careful when pulling out the clutch carrier to avoid damage to the contact faces of the piston rings in the bracket! Fig. 1249

30-251

Method of intervention 30.6.12 - Disassembly of K3/K4 clutch 1.

Disengage the snap ring. LoosSeparate the clutch carrier (K3/K4) from the planetary carrier (P3/P4). en the clutch carrier (complete with planetary drive) with a plastic hammer and pull it out of the bracket.

Fig. 1250

2.

Disengage the snap ring. Remove the releasing carrier from the clutch hub.

Fig. 1251

3.

Loosen the threaded pins (3x).

Fig. 1252

4.

Loosen the nut. Remove the releasing single parts. (S) Slotted nut wrench: 5.9035.457.0

Fig. 1253

30-252

Method of intervention 5.

Preload the cup springs with a press. Disengage the retaining ring. Now remove the releasing single parts out of the clutch carrier. (S) Press bushing: 5.9035.458.0 WARNING For disassembling the clutch ring (K3), the teeth of the clutch carrier must be leveled in those areas in which the spline was roughened by the three threaded pins! WARNING Pistons remain in the clutch carrier; clutch carrier is supplied as a complete component with preassembled pistons!

6.

If required, pull needle bearing (1) and slotted pin (2) out of the clutch carrier.

Fig. 1254

1

2

Fig. 1255

30.6.13 - Disassembly of P3/P4 planetary drive 1.

Loosen the countersunk screws and remove the releasing fixing plate.

Fig. 1256

2.

Pull the planetary pins and remove the releasing single parts.

Fig. 1257

30-253

Method of intervention 30.6.14 - Disassembly of KR clutch 1.

Loosen the hexagon screws and remove the releasing cover. Note Pay attention to the releasing clutch hub!

Fig. 1258

2.

Loosen the 3 hexagon screws (spring-preloaded) equally and remove the releasing single parts from the bracket.

Fig. 1259

3.

Loosen the tight-fit screws (2x) and the hexagon screws (2x), and remove the releasing bracket. Note Piston remains in the bracket. The bracket is supplied as a complete component with preassembled piston! WARNING To prevent seizing, loosen the tight-fit screws first. Do NOT use an impact wrench! Fig. 1260

30.6.15 - Disassembly of K2 clutch (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen the hexagon screws and separate the cover from the bearing bracket.

Fig. 1261

30-254

Method of intervention 2.

Force out the slotted pin.

Fig. 1262

3.

Preload the cup springs with a press and disengage the snap ring. (S) Pressure plate: 5.9035.464.0

Fig. 1263

4.

Pull the holder out of the cover and remove the releasing single parts. Note Piston remains in the cover; cover is supplied as a complete component with preassembled piston!

Fig. 1264

5.

Remove both ring gears from the bearing bracket.

Fig. 1265

30-255

Method of intervention 6.

Loosen the cylindrical screws and remove the releasing bearing bracket.

Fig. 1266

30.6.16 - Disassembly of K2 Clutch (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Loosen the hexagon screws. Separate the cover from the bearing bracket.

Fig. 1267

2.

Force out slotted pin.

Fig. 1268

3.

Use a press to preload the cup springs. Disengage the snap ring. (S) Pressure plate: 5.9035.464.0

Fig. 1269

30-256

Method of intervention 4.

Pull the holder out of the cover. Remove the releasing single parts. WARNING The piston remains in the cover. The cover is supplied as component with preassembled piston!

Fig. 1270

5.

Remove both ring gears from the bearing bracket.

Fig. 1271

6.

Loosen the cylindrical screws. Remove the releasing bearing bracket.

Fig. 1272

30-257

Method of intervention 30.6.17 - Disassembly of hydrostatic unit (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen the hexagon screws and remove the cover.

Fig. 1273

2.

Pull off the temperature sensor plug and loosen the screw plug (cpl. with temperature sensor).

Fig. 1274

3.

Pull the line out of the hydrostatic unit/plate.

Fig. 1275

4.

Pull the bushing out of the plate.

Fig. 1276

30-258

Method of intervention 5.

Loosen the plug with bayonet locking from the hydrostatic unit.

Fig. 1277

6.

Support the spur gear (see arrow) and loosen the hexagon screw. IMPORTANT This operation is to be done on both spur gears!

Fig. 1278

7.

Secure the hydrostatic unit with the lifting tackle (S). Now loosen the tight-fit screws and hexagon screws and lift the hydrostatic unit out of the housing lid. (S) Load carrying fixture: 5.9035.467.0 WARNING To prevent seizing, loosen the tight-fit screws first. Do NOT use an impact wrench!

Fig. 1279

8.

Pull off both spur gears and bearing brackets.

Fig. 1280

30-259

Method of intervention 30.6.18 - Disassembly of Hydrostatic Unit (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Loosen the hexagon screws. Remove the cover.

Fig. 1281

2.

Pull off the temperature sensor plug. Loosen the screw plug (cpl. with temperature sensor).

Fig. 1282

3.

Pull the line (hydrostatic unit) out of the housing lid.

Fig. 1283

4.

Pull the bushing out of the housing lid.

Fig. 1284

30-260

Method of intervention 5.

Loosen the plug with bayonet locking from the hydrostatic unit.

Fig. 1285

6.

Support the spur gear. Loosen the hexagon screw. WARNING This operation is to be done on both spur gears!

Fig. 1286

7.

Secure the hydrostatic unit with the lifting tackle (S). Loosen the tight-fit screws and hexagon screws. Lift the hydrostatic unit out of the housing lid. (S) Load-carrying fixture: 5.XXXX.XXX.X WARNING To prevent seizing, loosen the tight-fit screws first. Do NOT use an impact wrench!

Fig. 1287

8.

Pull off both spur gears and bearing brackets.

Fig. 1288

30-261

Method of intervention 9.

Detach the pressure sensors (see arrows). (S) Socket insert: 5.XXXX.XXX.X

Fig. 1289

30.6.19 - Disassembly of control (TCU) (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen the hexagon screws and nuts.

Fig. 1290

2.

Separate the control (TCU) from the housing lid and loosen all plug connections. WARNING Do NOT bend the control unit (you may use a knife to loosen the sealing compound)! NEVER dismantle the upper aluminum plate separately!

Fig. 1291

30.6.20 - Disassembly of Control (TCU) (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Loosen the hexagon screws and nuts.

Fig. 1292

30-262

Method of intervention 2.

Separate the control (TCU) from the housing lid and loosen all plug connections.. WARNING No further disassembly is permitted! WARNING Control is supplied as a component. Fig. 1293

30.6.21 - Disassembly of pump (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen the screw plug.

Fig. 1294

2.

Disengage the retaining ring (which secures the spur gear).

Fig. 1295

3.

Loosen screw plugs (2x, see arrows).

Fig. 1296

30-263

Method of intervention 4.

Pull the spacer ring and the lines (see arrows) out of the holes by means of a spring hook (S). (S) Spring hook: 5.9035.381.0 WARNING When dismantling the upper line (check valve) take care not to damage the spring!

Fig. 1297

5.

Loosen the hexagon screws and remove the lid.

Fig. 1298

6.

Remove the sleeve.

Fig. 1299

7.

Pull the pump out of the housing lid and remove the releasing spur gear.

Fig. 1300

30-264

Method of intervention 30.6.22 - Disassembly of Pump (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Loosen the screw plug.

Fig. 1301

2.

Disengage the retaining ring (which secures the spur gear).

Fig. 1302

3.

Loosen screw plugs (2x, see arrows).

Fig. 1303

4.

Remove the spacer ring and the line. WARNING When dismantling the line (check valve) take care not to damage the spring! WARNING No further disassembly of the line is permitted! WARNING The line is supplied as a component.

Fig. 1304

30-265

Method of intervention 5.

Remove the line.

Fig. 1305

6.

Loosen the hexagon screws. Remove the releasing lid.

Fig. 1306

7.

Remove the sleeve. If required, detach the inner retaining ring (sleeve).

Fig. 1307

8.

Pull the pump out of the housing lid. Remove the releasing spur gear. WARNING Pay attention to releasing O-ring!

Fig. 1308

30-266

Method of intervention 30.6.23 - Disassembly of Suction filter (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Loosen the hexagon screws. Remove the releasing lid. WARNING Pay attention to releasing O-ring!

Fig. 1309

2.

Pull the suction filter out of the housing lid hole.

Fig. 1310

30.6.24 - Disassembly of suction filter (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen the hexagon screws and remove the releasing cover.

Fig. 1311

2.

Pull the suction filter out of the housing lid hole.

Fig. 1312

30-267

Method of intervention 30.6.25 - Disassembly of filter head (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen the cable clip and separate the plug connection (service switch).

Fig. 1313

2.

Loosen the service switch and remove the releasing compression spring and valve out of the hole.

Fig. 1314

3.

Loosen the cylindrical screws and remove the releasing filter head.

Fig. 1315

30.6.26 - Disassembly of pressure relief valves (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen the screw plug.

Fig. 1316

30-268

Method of intervention 2.

Pull the pressure relief valves out of the hole. The adjacent Figure shows the installation position of the pressure relief valves. 1 = Screw plug 2 = Pressure relief valve (brake cooling oil) 3 = Spacer part 4 = Pressure relief valve (lubrication) 5 = Pressure relief valve (cooler)

4

5

3 1

2

Fig. 1317

30.6.27 - Disassembly of control unit (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Separate the plug connection.

Fig. 1318

2.

Loosen the cylindrical screws and remove the control unit.

Fig. 1319

30.6.28 - Disassembly of valves, pressure sensor, inductive sensors (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Separate all plug connections on the directional valves. IMPORTANT Mark plug connections (reassembly aid / to ensure correct functioning)!

Fig. 1320

30-269

Method of intervention Disassembly of 4/3-directional valve 1.

Loosen the hexagon nut and pull releasing coils off the valve.

Fig. 1321

2.

Remove valve.

Fig. 1322

Disassembly of 3/2-directional valves 1.

Loosen the cylindrical screw, remove claw and pull the releasing directional valve out of the hole.

Fig. 1323

Disassembly of pressure sensors 1.

Loosen plug with bayonet locking on the pressure sensor.

Fig. 1324

30-270

Method of intervention 2.

Loosen pressure sensor.

Fig. 1325

Disassembly of pressure reducing valve 1.

Loosen the pressure reducing valve.

Fig. 1326

Disassembly of inductive sensors 1.

Take cable out of cable clip and loosen the inductive sensors by means of plug insert (S). (S) Plug insert: 5.9035.404.0

Fig. 1327

30.6.29 - Disassembly of wiring harness, valve block and plate (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen the accumulator.

Fig. 1328

30-271

Method of intervention 2.

Remove all cable clips.

Fig. 1329

3.

Disengage the retaining ring.

Fig. 1330

4.

Remove the cable clip and separate the plug connection.

Fig. 1331

5.

Loosen the cylindrical screw and remove the releasing wiring harness.

Fig. 1332

30-272

Method of intervention 6.

Loosen the hexagon screws and pull the releasing wiring harness out of the housing lid.

Fig. 1333

7.

Loosen the threaded joint and remove the rele sing valve block. IMPORTANT Pay attention to the releasing seal rings!

Fig. 1334

8.

Secure plate with the lifting tackle and loosen the threaded joint. Now separate the plate from the housing lid. (S) Eyebolts (M12): 5.9035.377.0

Fig. 1335

30-273

Method of intervention 30.6.30 - Disassembly of valve block (filter head, pressure relief valves, thermocouple) (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Separate the plug connection (service switch).

Fig. 1336

2.

Loosen the service switch and remove the rele sing compression spring and valve out of the hole.

Fig. 1337

3.

Loosen the cylindrical screws and remove the releasing filter head.

Fig. 1338

4.

Loosen the screw plug.

Fig. 1339

30-274

Method of intervention 5.

Pull the pressure relief valves out of the hole. The adjacent Figure shows the installation position of the pressure relief valves. 1 = Screw plug 2 = Pressure relief valve (brake cooling oil) 3 = Spacer part 4 = Pressure relief valve (lubrication) 5 = Pressure relief valve (cooler)

4 1

2

5

3

Fig. 1340

6.

Loosen the screw plug.

Fig. 1341

7.

Remove the complete thermocouple with co pression spring from the hole.

Fig. 1342

8.

Loosen the cylindrical screws and remove the releasing valve block. IMPORTANT Pay attention to releasing O-rings and rectangular rings!

Fig. 1343

30-275

Method of intervention 30.6.31 - Disassembly of Valve Block (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Filter head, Pressure relief valves, Thermocouple 1.

Loosen the cable clip. Separate the plug connection (Service switch).

Fig. 1344

2.

Loosen the service switch. Remove the releasing compression spring and valve out of the hole.

Fig. 1345

3.

Loosen the cylindrical screws. Remove the filter head.

Fig. 1346

4.

Loosen the screw plug.

Fig. 1347

30-276

Method of intervention 5.

Pull the pressure relief valves out of the hole. The adjacent Figure shows the installation position of the pressure relief valves. 5.1. 5.2. 5.3. 5.4. 5.5.

Screw plug Pressure relief valve (Bake Cooling Oil) Spacer part Pressure relief valve (Lubrication) Pressure relief valve (Cooler)

5 4 3 1

2

Fig. 1348

6.

Loosen the screw plug.

Fig. 1349

7.

Remove the complete thermocouple with compression spring from the hole.

Fig. 1350

8.

Loosen the cylindrical screws. Remove the valve block. WARNING Pay attention to releasing O-rings and rectangular rings!

Fig. 1351

30-277

Method of intervention 9.

Loosen plug with bayonet locking. Remove wiring harness (Filter pressure).

Fig. 1352

30.6.32 - Disassembly of valve block (all-wheel-drive / park lock) (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Separate the plug connections (3x). IMPORTANT Mark the plug connections (reassembly aid / correct functioning)!

Fig. 1353

2.

Loosen the cylindrical screw, remove claw and pull the releasing directional valve out of the hole.

Fig. 1354

3.

Loosen the cylindrical screw and the hexagon nuts. Now remove the releasing valve block. IMPORTANT Pay attention to the releasing rectangular rings!

Fig. 1355

30-278

Method of intervention 4.

Loosen plug with bajonet locking and remove wiring harness (filter pressure).

Fig. 1356

30.6.33 - Disassembly of Valve Block (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Hydraulic Control 1.

Separate all plug connections on the directional valves.

Fig. 1357

2.

Loosen the cylindrical screw. Remove claw and pull the releasing directional valve out of the hole.

Fig. 1358

3.

Loosen the plug on the pressure sensor.

Fig. 1359

30-279

Method of intervention 4.

Detach the pressure sensor. Remove cable clips (See arrow).

Fig. 1360

5.

Detach the accumulator.

Fig. 1361

6.

Loosen the hexagon nuts and cylindrical screws. Now remove the releasing valve block. WARNING Pay attention to the releasing rectangular rings!

Fig. 1362

30-280

Method of intervention 30.6.34 - Disassembly of valve block (hydraulic control) (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Separate all plug connections on the directional valves.

Fig. 1363

2.

Loosen the cylindrical screw, remove claw and pull the releasing directional valve out of the hole.

Fig. 1364

3.

Loosen the plug on the pressure sensor.

Fig. 1365

4.

Loosen the pressure sensor.

Fig. 1366

30-281

Method of intervention 5.

Loosen the accumulator.

Fig. 1367

6.

Loosen the hexagon nuts and cylindrical screws. Now remove the releasing valve block. IMPORTANT Pay attention to the releasing rectangular rings!

Fig. 1368

30.6.35 - Disassembly of Valve Block (P.R.V. - Pressure Relief Valve) (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Detach the pressure relief valve.

Fig. 1369

2.

Loosen the hexagon nuts. Remove the valve block. WARNING Pay attention to releasing rectangular rings!

Fig. 1370

30-282

Method of intervention 30.6.36 - Disassembly of valve block (pressure reducing valve) (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen the pressure reducing valve.

Fig. 1371

2.

Loosen the hexagon nuts and remove the rele sing valve block. IMPORTANT Pay attention to the releasing rectangular rings!

Fig. 1372

30.6.37 - Disassembly of wiring harnesses and control unit (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen the plug at the pressure sensor.

Fig. 1373

2.

Loosen the pressure sensor.

Fig. 1374

30-283

Method of intervention 3.

Separate the cable clip and remove the releasing wiring harnesses (2x, hydraulic control and oil sensors) from the housing lid.

Fig. 1375

4.

Loosen the bayonet locking and separate the plug connection (HCU, see arrow).

Fig. 1376

5.

Loosen the hexagon screw, remove the fixing plate and remove the releasing wiring harness (TCU / HCU) from the housing lid.

Fig. 1377

6.

Loosen the cylindrical screws and remove the control unit.

Fig. 1378

30-284

Method of intervention 7.

Loosen the hexagon screw, remove the fixing plate and pull the releasing wiring harness (hydrostatic unit) out of the housing lid.

Fig. 1379

30.6.38 - Disassembly of wiring harnesses and control unit 1.

Loosen the plug at the pressure sensor.

Fig. 1379

2.

Loosen the pressure sensor.

Fig. 1379

3.

Separate the cable clip and remove the releasing wiring harnesses (2x, hydraulic control and oil sensors) from the housing lid.

Fig. 1379

30-285

Method of intervention 4.

Loosen the bayonet locking and separate the plug connection (HCU, see arrow).

Fig. 1379

5.

Loosen the hexagon screw, remove the fixing plate and remove the releasing wiring harness (TCU / HCU) from the housing lid.

Fig. 1379

6.

Loosen the cylindrical screws and remove the control unit.

Fig. 1379

7.

Loosen the hexagon screw, remove the fixing plate and pull the releasing wiring harness (hydrostatic unit) out of the housing lid.

Fig. 1379

30-286

Method of intervention 30.6.39 - Disassembly of W.H. and E.C.U. (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Loosen the plug on the pressure sensor.

Fig. 1380

2.

Detach the pressure sensor.

Fig. 1381

3.

Separate the cable clip. Remove the releasing wiring harnesses (2x, hydraulic control and oil sensors) from the housing lid.

Fig. 1382

4.

Loosen the bayonet locking and separate the plug connection (HCU, See arrow).

Fig. 1383

30-287

Method of intervention 5.

Loosen the hexagon screw. Remove the fixing plate and remove the releasing wiring harness (TCU / HCU) from the housing lid.

Fig. 1384

6.

Loosen the cylindrical screws. Remove the control unit.

Fig. 1385

7.

Loosen the hexagon screw. Remove the fixing plate and pull the releasing wiring harness (hydrostatic unit) out of the housing lid.

Fig. 1386

30-288

Method of intervention 30.6.40 - Disassembly of inductive sensors (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen the cylindrical screw and remove the releasing clip.

Fig. 1387

2.

Loosen the inductive sensors by means of plug insert (S). (S) Plug insert: 5.9035.404.0

Fig. 1388

30.6.41 - Disassembly of Inductive Sensors (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Loosen the cylindrical screw. Remove the clip.

Fig. 1389

2.

Loosen the inductive sensors by means of socket insert (S). (S) Socket insert: 5.9035.404.0 Remove the releasing wiring harness.

Fig. 1390

30-289

Method of intervention 30.6.42 - Disassembly of plug-in module (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen the hexagon screws and pull out the output shaft by approx. 10 cm.

Fig. 1391

2.

Remove pressure line.

Fig. 1392

3.

Loosen screws and lift the releasing plug-in module out of the transmission housing by using a lifting tackle (S). (S) Assembly lever set: 5.9035.203.0 (S) Load carrying fixture: AA00 633 706

Fig. 1393

4.

Fix the plug-in module to the assembly truck. (S) Assembly truck: 5.9035.193.0 (S) Clamping device: 5.9035.388.0 (S) Holding fixtures: 5.9035.389.0

Fig. 1394

30-290

Method of intervention 30.6.43 - Disassembly of Plug-In Module (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Loosen the hexagon screws. Pull out the output shaft by approx. 10 cm.

Fig. 1395

2.

Loosen hexagon screws on the cover (See arrow). Fix the load carrying fixture (S). (S) Load carrying fixture: 5.9035.460.0

Fig. 1396

3.

Loosen screws. Lift the releasing plug-in module out of the transmission housing by using a load carrying fixture (S). (S) Assembly lever: 5.9035.203.0 (S) Load carrying fixture: 5.9035.460.0

Fig. 1397

4.

Fix the plug-in module to the assembly truck. (S) Assembly truck: 5.9035.193.0 (S) Clamping device: 5.9035.388.0 (S) Holding fixtures: 5.9035.389.0

Fig. 1398

30-291

Method of intervention 5.

Loosen hexagon screws. Remove the cover plate.

Fig. 1399

6.

Remove the cover. (S) Offset screwdriver: 5.9035.260.0

Fig. 1400

7.

Unlock and loosen the slotted nut. (S) Slotted nut wrench:5.9035.427.0

Fig. 1401

8.

If required, push the clutch carrier downward by slight hits until the spur gear is in contact with the housing (See arrow). Disengage retaining ring. WARNING Protect the releasing clutch carrier from falling down!

Fig. 1402

30-292

Method of intervention 9.

Take spur gear, retaining ring and tapered roller bearing out of the housing.

Fig. 1403

10.

Remove the sealing ring (See arrow). Disengage retaining ring.

Fig. 1404

11.

Pull tapered roller bearing off the clutch carrier. (S) Grab sleeve: 5.9035.326.0 (S) Basic tool: 5.9035.320.0

Fig. 1405

12.

Use the pressure sleeve (S) to relieve retaining ring via the cup spring and disengage retaining ring. Remove the releasing washer. (S) Pressure sleeve: 5.9035.461.0

Fig. 1406

30-293

Method of intervention 13.

Remove cup springs.

Fig. 1407

14.

Disengage retaining ring and remove the releasing bell housing.

Fig. 1408

15.

Disengage retaining ring and pull off the releasing ball bearing. Now remove the retaining ring (See arrow).

Fig. 1409

16.

Use a lever to pull the pressure cylinder off the clutch carrier. Remove the releasing disk package.

Fig. 1410

30-294

Method of intervention 17.

Force piston out of the pressure cylinder.

Fig. 1411

18.

If necessary, drive both bearing outer rings out of the housing.

Fig. 1412

19.

Loosen the locknut. Remove the releasing washer.

Fig. 1413

20.

Pull the bearing bolt out of the housing. Remove the releasing spur gear out of the housing.

Fig. 1414

30-295

Method of intervention 21.

Remove tapered roller bearing. Drive both bearing outer rings out of the spur gear.

Fig. 1415

22.

Unlock and loosen the slotted nut. (S) Slotted nut wrench: 5.9035.429.0 WARNING Block pinion against rotation!

Fig. 1416

23.

Use two-armed puller to force pinion out of the housing. WARNING Protect releasing pinion from falling down! Remove the releasing tapered roller bearing.

Fig. 1417

24.

Disengage retaining ring. Remove the releasing pinion.

Fig. 1418

30-296

Method of intervention 25.

Disengage retaining ring.

Fig. 1419

26.

Pull tapered roller bearing off the pinion. (S) Grab sleeve: 5.9035.431.0 (S) Basic tool: 5.9035.293.0

Fig. 1420

27.

If necessary, drive both bearing outer rings out of the housing.

Fig. 1421

30-297

Method of intervention 30.6.44 - Disassembly of clutch (all-wheel-drive) (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen hexagon screws and remove the releasing cover late.

Fig. 1422

2.

Loosen hexagon screws and remove the releasing cover.

Fig. 1423

3.

Unlock and loosen the slotted nut. (S) Slotted nut wrench: 5.9035.427.0

Fig. 1424

4.

Use two-armed puller to force out clutch carrier until the spur gear is in contact with the housing (see arrow).

Fig. 1425

30-298

Method of intervention 5.

Disengage retaining ring. Now use the two-armed puller to push the clutch carrier out of the housing completely. WARNING Protect clutch carrier against falling down!

Fig. 1426

6.

Take spur gear, retaining ring and tapered roller bearing out of the housing.

Fig. 1427

7.

Disengage retaining ring.

Fig. 1428

8.

Pull tapered roller bearing off the clutch carrier. (S) Grab sleeve: 5.9035.416.0 (S) Basic tool: 5.9035.320.0

Fig. 1429

30-299

Method of intervention 9.

Version with slotted nut: Fix locking device (S, see arrow) in the vice. Then place the clutch onto the locking device (S), unlock and loosen the slotted nut. (S) Locking device: 5.9035.481.0 (S) Slotted nut wrench: 5.9035.465.0

Fig. 1430

10.

Version with washer and retaining ring Use the pressure sleeve (S) to relieve retaining ring via the cup spring and disengage retaining ring. Remove the releasing washer. (S) Pressure sleeve: 5.9035.461.0

Fig. 1431

11.

Remove cup springs.

Fig. 1432

12.

Disengage retaining ring and remove the releasing bell housing.

Fig. 1433

30-300

Method of intervention 13.

Disengage retaining ring and pull off the releasing ball bearing. Now remove the retaining ring (see arrow).

Fig. 1434

14.

Use a lever to pull the pressure cylinder off the clutch carrier and remove the releasing disk package.

Fig. 1435

15.

Force piston out of the pressure cylinder.

Fig. 1436

16.

If necessary, drive both bearing outer rings out of the housing.

Fig. 1437

30-301

Method of intervention 30.6.45 - Disassembly of spur gear (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen the locknut and remove the washer behind.

Fig. 1438

2.

Pull the bearing bolt out of the housing and remove the releasing spur gear out of the housing.

Fig. 1439

3.

Remove tapered roller bearing and drive both bearing outer rings out of the spur gear.

Fig. 1440

30.6.46 - Disassembly of pinion (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Unlock and loosen slotted nut. (S) Slotted nut wrench: 5.9035.429.0 IMPORTANT To prevent from turning, engage park lock (see arrow)!

Fig. 1441

30-302

Method of intervention 2.

Use two-armed puller to force pinion out of the housing until the ratchet wheel gets into contact with the housing (see arrow). Then remove the two-armed puller and the releasing tapered roller bearing.

Fig. 1442

3.

Disengage retaining ring. WARNING Pay attention to the releasing pinion!

Fig. 1443

4.

Remove spur gear, disengage retaining ring and pull tapered roller bearing off the pinion. (S) Grab sleeve: 5.9035.431.0 (S) Basic tool: 5.9035.293.0

Fig. 1444

5.

Remove ratchet wheel out of the housing and force out both bearing outer rings.

Fig. 1445

30-303

Method of intervention 30.6.47 - Disassembly of park lock (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen screw plug and remove the releasing spring and ball out of the hole.

Fig. 1446

2.

Disengage both retaining rings and remove the spacers behind. Then pull out both flange bolts and remove the releasing tab.

Fig. 1447

3.

Loosen cylindrical screws and remove fork head.

Fig. 1448

4.

Loosen hexagon screw and pull bolt out of the housing by using a pulling device (S). (S) Pulling device: 5.9035.258.0 IMPORTANT Pay attention to the releasing single parts (lever and support roller)!

Fig. 1449

30-304

Method of intervention 5.

Disengage retaining ring, pull out flange bolt and remove support roller. IMPORTANT Pay attention to the releasing rollers of the support roller!

Fig. 1450

6.

Loosen hexagon screw and pull bolt out of the housing by using a pulling device (S). (S) Pulling device: 5.9035.258.0 IMPORTANT Pay attention to the releasing single parts (ratchet and spring)!

Fig. 1451

7.

Remove cylinder bush together with piston.

Fig. 1452

8.

Remove emergency release.

Fig. 1453

30-305

Method of intervention 30.6.48 - Disassembly of output shaft (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Remove output shaft together with bearing cover out of the transmission housing.

Fig. 1454

2.

Disengage retaining ring and remove the shim behind.

Fig. 1455

3.

Drive output shaft out of the bearing cover and remove the releasing single parts.

Fig. 1456

4.

Pull bearing outer ring (1) out of the bearing cover and drive out shaft seal (2).

1 2

Fig. 1457

30-306

Method of intervention 5.

Disengage retaining rings and pull both roller bearings off the output shaft.

Fig. 1458

30.6.49 - Disassembly of Output Shaft (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Remove output shaft together with bearing cover out of the transmission housing.

Fig. 1459

2.

Disengage retaining ring. Remove the shim.

Fig. 1460

3.

Drive output shaft out of the bearing cover. Remove the releasing single parts.

Fig. 1461

30-307

Method of intervention 4.

Pull bearing outer ring (Arrow 1) out of the bearing cover. Drive out shaft seal (Arrow 2).

1

2

Fig. 1462

5.

Disengage retaining rings. Pull both roller bearings off the output shaft.

Fig. 1463

30.6.50 - Disassembly of intermediate housing (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen hexagon screws and remove oil level indicator.

Fig. 1464

2.

Pull out the drive shaft.

Fig. 1465

30-308

Method of intervention 3.

Disengage retaining ring and pull the releasing intermediate tube out of the housing.

Fig. 1466

4.

Secure the intermediate housing by a lifting tackle and loosen the threaded joint. Then separate intermediate housing from the transmission housing. (S) Eyebolts: 5.9035.425.0

Fig. 1467

30.6.51 - Disassembly of Intermediate Housing (7230 TTVAgrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Loosen hexagon screws and remove oil level indicator.

Fig. 1468

2.

Pull out the drive shaft.

Fig. 1469

30-309

Method of intervention 3.

Disengage retaining ring. Pull the releasing intermediate tube out of the housing.

Fig. 1470

4.

Secure the intermediate housing by a lifting tackle and loosen the threaded joint. Then separate intermediate housing from the transmission housing. (S) Eyebolts: 5.9035.425.0

Fig. 1471

30.6.52 - Disassembly of drive shaft (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen the hexagon screws.

Fig. 1472

2.

Install two locating pins (S) and separate bearing cover from transmission housing by using the assembly lever set (S). (S) Locating pins (M10): 5.9035.253.0 (S) Assembly lever set: 5.9035.253.0 WARNING Pay attention so that the drive shaft does not drop!

Fig. 1473

30-310

Method of intervention 3.

Remove drive shaft out of the transmission housing.

Fig. 1474

4.

Pull both tapered roller bearings off the drive shaft. (S) Grab sleeve: 5.9035.417.0 (S) Grab sleeve: 5.9035.326.0 (S) Basic tool: 5.9035.320.0

Fig. 1475

5.

Pull bearing outer ring (1) out of the bearing cover by means of pulling device (S) and drive out shaft seal (2). (S) Pulling device: 5.9035.213.0

1 2

Fig. 1476

6.

Pull bearing outer ring out of the housing hole. (S) Pulling device: 5.9035.213.0

Fig. 1477

30-311

Method of intervention 30.6.53 - Disassembly of Drive Shaft (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Loosen the hexagon screws.

Fig. 1478

2.

Install two locating pins (S). Separate bearing cover from transmission housing by using the assembly lever set (S). (S) Locating pins (M10): 5.9035.253.0 (S) Assembly lever: 5.9035.203.0 WARNING Pay attention to the releasing drive shaft!

Fig. 1479

3.

Remove drive shaft out of the transmission housing.

Fig. 1480

4.

Pull both tapered roller bearings off the drive shaft. (S) Grab sleeve: 5.9035.417.0 (S) Grab sleeve: 5.9035.466.0 (S) Basic tool: 5.9035.320.0

Fig. 1481

30-312

Method of intervention 5.

Pull bearing outer ring (Arrow 1) out of the bearing cover by means of pulling device (S). Drive out shaft seal (Arrow 2).

1

2

Fig. 1482

6.

Pull bearing outer ring out of the housing hole.

Fig. 1483

30.6.54 - Reassembly of Transmission Housing (7230 TTVAgrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Install cylindrical pins (2x, See arrows 1) and stud bolts (4x, See arrows 2). Tightening torque: MA = 33 Nm

1 2

WARNING Wet threads of stud bolts with Loctite (Type # 243)!

2 1 Fig. 1484

2.

Fit screw plug with new O-ring and install it. Tightening torque: MA = 120 Nm

Fig. 1485

30-313

Method of intervention 3.

Insert plate (See arrow) into the transmission housing and fix it by hexagon screws. Tightening torque: MA = 23 Nm

Fig. 1486

30.6.55 - Reassembly of Drive Shaft (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Insert bearing outer ring (See arrow) into the housing hole until contact is obtained.

Fig. 1487

2.

Heat both tapered roller bearings and mount them to the drive shaft until contact is obtained. WARNING Adjust both bearings after cooling down! WARNING Wear safety gloves! Fig. 1488

3.

Insert shaft seal into the bearing cover until contact is obtained. (S) Driver tool: 5.9035.359.0 (S) Handle: 5.9035.222.0 WARNING Wet outer diameter of the shaft seal ring with spirit just before installation!

Fig. 1489

30-314

Method of intervention 4.

Legend to figure: 4.1. Bearing cover 4.2. Shaft Seal

Fig. 1490

5.

Grease O-ring (See arrow) and insert it into the annular groove.

Fig. 1491

6.

Insert bearing outer ring (Arrow 1) into the bearing hole until contact is obtained. Grease O-ring (Arrow 2) and insert it into the annular groove.

1

2 Fig. 1492

7.

Setting of axial play: 0.05 mm. … 0.15 mmm Install two locating pins (S) and mount shim(s) (e.g. thickness = 0.95 mm). (S) Locating pins (M10): 5.9035.253.0

Fig. 1493

30-315

Method of intervention 8.

Insert the preassembled drive shaft into the transmission housing and fix it by means of the preassembled bearing cover.

Fig. 1494

9.

Fix bearing cover by means of hexagon screws. Tightening torque (M10/8.8): MA = 46 Nm

Fig. 1495

10.

Position the dial indicator at the drive shaft and measure the existing axial play. WARNING Any deviation from the required axial play must be corrected with appropriate shims (10 ^ figure)!

Fig. 1496

30-316

Method of intervention 30.6.56 - Reassembly of Intermediate Housing (7230 TTVAgrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Install stud bolts (2x, See arrows). Tightening torque: MA = 33 Nm WARNING Wet threads of stud bolts with Loctite (Type # 243)! Then provide all screw plugs with new seal rings and install them. Tightening torque (M12x1.5): MA = 35 Nm

Fig. 1497

Tightening torque (M18x1.5): MA = 50 Nm Tightening torque (M22x1.5): MA = 60 Nm Tightening torque (M26x1.5): MA = 80 Nm Tightening torque (M33x2): 2.

MA = 120 Nm Wet mounting face (see arrow) with sealing agent with Loctite (Type # 574).

Fig. 1498

3.

Use lifting tackle to bring the intermediate housing into contact position with the transmission housing. (S) Eyebolts: 5.9035.425.0

Fig. 1499

30-317

Method of intervention 4.

Fix intermediate housing using hexagon nuts and hexagon screws. Tightening torque: MA = 185 Nm WARNING Wet threads of hexagon nuts with Loctite (Type # 243)!

Fig. 1500

5.

Grease O-ring (See arrow) and mount it to the intermediate tube.

Fig. 1501

6.

Insert intermediate tube into the intermediate housing and fix it using a retaining ring.

Fig. 1502

7.

Mount input shaft until contact to the drive shaft is obtained.

Fig. 1503

30-318

Method of intervention 8.

Mount oil level indicator. Tightening torque: MA = 6 Nm WARNING Observe the correct installation position (See indication of MAX in the oil level indicator)!

Fig. 1504

30.6.57 - Reassembly of Plug-In Module (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

If nominal dimension deviation on pinion, tapered roller bearing and housing is zero, shim thickness is 1.40 mm. The deviations indicated on housing and pinion are understood to be in 1/100 mm.

5

e.g. +5 corresponds to + 0.05 mm e.g. –5 corresponds to – 0.05 mm Read deviation from the housing. Fig. 1505

2.

Deviation e.g.: 0.05 mm Add sign “+” to the shim thickness. Deduct sign “-” from the shim thickness. Read deviation from the pinion. Deviation e.g.: 0.00 mm Add sign “-” to the shim thickness. Deduct sign “+” from the shim thickness.

0

Fig. 1506

3.

Determination of bearing width. Bearing width e.g.: 38.95 mm. In case of deviation from the nominal dimension = 39.00mm, e.g. -0.05 mm, a. ADD sign “-” to the shim thickness, b. DEDUCT sign “+” from the shim thickness.

Fig. 1507

30-319

Method of intervention 4.

5.

Deviation / example: Basic shim dimension/thickn. = 1.40 mm Housing deviation e.g. +5 Pinion deviation e.g. 0 Bearing deviation e.g. 38.95 mm ----+ 1.40 mm + 0.05 mm ± 0.00 mm + 0.05 mm Thickness of determined shim = 1.50 mm In case of results up to 0.02 mm or 0.07, respectively, round down to next shim thickness. In case of results as of 0.03 mm or 0.08, respectively, round up to the next shim thickness. Place the determined shim (e.g. thickness = 1.50 mm) into the bearing hole. Insert bearing outer ring until contact is obtained.

Fig. 1508

6.

Heat tapered roller bearing and mount it to the pinion until contact is obtained. WARNING Wear safety gloves!

Fig. 1509

7.

Install retaining ring.

Fig. 1510

30-320

Method of intervention 8.

Mount spur gear to the pinion and fix it by using retaining ring. WARNING Observe the installation position! WARNING Mount spur gear with identifying groove (See arrow) showing upwards! Fig. 1511

9.

Install preassembled pinion.

Fig. 1512

10.

Secure pinion. Rotate housing by 180°.

Fig. 1513

11.

Insert bearing outer ring into the housing hole until contact is obtained. Then heat the tapered roller bearing and mount it to the pinion until contact is obtained. WARNING Wear safety gloves!

Fig. 1514

30-321

Method of intervention 12.

Detach pinion securing.

Fig. 1515

13.

Setting of rolling torque: 3.0 … 5.0 Nm Block pinion against rotation and tighten slotted nut until the required rolling torque of 3.0 ... 5.0 Nm has been obtained. (S) Slotted nut wrench: 5.9035.429.0

Fig. 1516

14.

Relieve bearing by means of slight hits and rotate pinion in both directions several times. Then check rolling torque using the torque wrench. Setting of the bearings: WARNING New bearings – Try to achieve the upper value of the bearing rolling torque! WARNING

Fig. 1517

Used bearings – Try to achieve the lower value of the bearing rolling torque! 15.

Secure slotted nut.

Fig. 1518

30-322

Method of intervention 16.

Mount disk package. WARNING For number and arrangement of the disks see relating spare parts list!

Fig. 1519

17.

Oil O-rings (See arrows) and place them into the annular grooves of pressure cylinder and piston.

Fig. 1520

18.

Insert piston into the pressure cylinder until contact is obtained. WARNING Observe the installation position, See figure!

Fig. 1521

19.

Mount preassembled pressure cylinder onto the clutch carrier until contact is obtained.

Fig. 1522

30-323

Method of intervention 20.

Place retaining ring (See arrow) into the bell housing. Then heat ball bearing and mount it until contact is obtained. WARNING Adjust bearing after cooling down! WARNING Wear safety gloves! Fig. 1523

21.

Fix ball bearing by means of retaining ring.

Fig. 1524

22.

Insert preassembled clutch carrier into the bell housing.

Fig. 1525

23.

Engage retaining ring (also see other figure) into the annular groove of the clutch carrier.

Fig. 1526

30-324

Method of intervention 24.

Mount cup springs (2x). WARNING Observe the installation position of cup springs, mount both cup springs with the convex side (curved upward) showing upwards!

Fig. 1527

25.

Mount shim: Optional thickness = 3.8 mm (Recommended value).

Fig. 1528

26.

Preload cup springs with pressure sleeve (S). Engage retaining ring. (S) Pressure sleeve: 5.9035.461.0

Fig. 1529

27.

Heat tapered roller bearing and mount it until contact is obtained. WARNING Adjust bearing after cooling down! WARNING Wear safety gloves!

Fig. 1530

30-325

Method of intervention 28.

Mount retaining ring.

Fig. 1531

29.

Install bearing outer ring (Arrow 1) into the housing hole until contact is obtained. Insert spur gear (Arrow 2).

1

WARNING Observe the installation position! WARNING Mount spur gear with identifying groove (See arrow) showing upwards! 30.

2 Fig. 1532

Insert preassembled All-Wheel-Drive clutch into the housing, mounting the spur gear at the same time.

Fig. 1533

31.

Engage retaining ring into the annular groove of the clutch carrier.

Fig. 1534

30-326

Method of intervention 32.

Insert bearing outer ring (See arrow) into the housing hole until contact is obtained.

Fig. 1535

33.

Then heat tapered roller bearing (See arrow) and mount it to the clutch carrier until contact is obtained. WARNING Install the tapered roller bearing whilst maintaining contact to the mounted All-Wheel-Drive clutch. WARNING Wear safety gloves! Fig. 1536

34.

Setting of axial play: 0.05 … 0.10 mm Bolt on the slotted nut until the required axial play of 0.05 … 0.10 mm is obtained (Also refer to the following Figure).

Fig. 1537

35.

Position dial indicator at the clutch carrier and measure the axial play.

Fig. 1538

30-327

Method of intervention 36.

Secure slotted nut.

Fig. 1539

37.

Grease annular groove of the clutch carrier. Place seal ring (See arrow) and position it centrically.

Fig. 1540

38.

Mount bearing unit (Tapered roller bearing with spacer ring) into the spur gear. WARNING Replace bearing unit as a complete assy only (Both tapered roller bearings and spacer ring)!

Fig. 1541

39.

Install slotted pin (See arrow) into the bearing bolt. Place preassembled spur gear into the housing and fix it by means of bearing bolt. WARNING Observe the installation position! WARNING Mount spur gear with identifying groove (See arrow of previous figure) showing upwards!

30-328

Fig. 1542

Method of intervention 40.

Fix bearing bolt with disk and new locknut. Tightening torque: MA = 55 Nm

Fig. 1543

41.

Install cover plate and fix it by means of hexagon screws. Tightening torque (M6/8.8): MA = 9.5 Nm WARNING Wet threads of hexagon screws with Loctite (Type # 243)!

Fig. 1544

42.

Grease O-ring (See arrow) and insert it into the annular groove of the cover.

Fig. 1545

43.

Place cover into the housing.

Fig. 1546

30-329

Method of intervention 44.

Fix the load carrying fixture (S). (S) Load carrying fixture: 5.9035.460.0

Fig. 1547

45.

Install cylindrical pins (2x, See arrows) into the housing.

Fig. 1548

46.

Use lifting tackle (S) to place the plug-in module into the transmission housing. Fix it by means of hexagon screws. Tightening torque (M12/10.9): MA = 115 Nm (S) Load carrying fixture: 5.9035.460.0

Fig. 1549

47.

Detach load carrying fixture and cover (See arrow). WARNING Wet mounting face with Loctite (Type # 574)! Place cover into the housing and fix it by means of hexagon screws. Tightening torque (M8/8.8): MA = 23 Nm

Fig. 1550

30-330

Method of intervention 30.6.58 - Reassembly of Output Shaft (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Engage retaining ring into the annular groove of the output shaft.

Fig. 1551

2.

Heat both tapered roller bearings and mount them onto the shaft until contact with the retaining ring is obtained. WARNING Adjust bearings after cooling down! WARNING Wear safety gloves! Then fix tapered roller bearings by means of retaining ring.

3.

Fig. 1552

Mount bearing outer ring into the bearing cover until contact is obtained.

Fig. 1553

4.

Support the bearing cover (See arrow). Mount the preassembled output shaft and insert the bearing outer ring until contact is obtained.

Fig. 1554

30-331

Method of intervention 5.

Setting of axial play of tapered roller bearing: 0.0 mm. … 0.1 mm Mount shim: optional thickness, for example 0.90 mm. DANGER Select the thickness of the shim in such a way that the retaining ring (See following Figure) is without clearance!

Fig. 1555

6.

Engage the retaining ring into the annular groove until contact with the groove base is obtained. Then oil the O-ring (See arrow) and insert it into the annular groove.

Fig. 1556

7.

Fit shaft seal. (S) Driver tool: 5.9035.424.0 DANGER Just before fitting, wet the outer diameter with spirit!

DANGER Use of the specified driver tool (S) ensures the exact installation position of the shaft seal! Fig. 1557

8.

Install screen sheet. (S) Driver tool: 5.9035.423.0 DANGER Wet inner diameter with Loctite (Type # 649)!

DANGER Use of the specified driver tool (S) ensures the exact installation position of the screen sheet! Fig. 1558

30-332

Method of intervention 9.

Insert the preassembled drive shaft into the transmission housing. Fix it by means of hexagon screws. Tightening torque (M10/8.8): MA = 46 Nm

Fig. 1559

30.6.59 - Preassembly of Housing Lid (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Fit stud bolts (1). Fit breather valve (2). Tightening torque (Breather valve): MA = 30 Nm Tightening torque (Stud bolts):

2

1

MA = 6 Nm WARNING Wet threads of stud bolts and breather valve with Loctite (Type # 243)! 2.

Fig. 1560

Fit stud bolts (2x, See arrows). Tightening torque: MA = 9 Nm WARNING Wet threads of stud bolts with Loctite (Type # 243)!

Fig. 1561

3.

Fit stud bolts (2x, See arrows). Tightening torque: MA = 9 Nm WARNING Wet threads of stud bolts with Loctite (Type # 243)!

Fig. 1562

30-333

Method of intervention 30.6.60 - Reassembly of Inductive Sensors (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Mount inductive sensors (5x) into housing lid and sensor cover. Tightening torque: MA = 45 Nm (S) Socket insert: 5.9035.404.0 WARNING Connection plugs of the inductive sensors are marked in different colors. WARNING Fig. 1563

For installation position see following figure! 2.

WARNING Wet threads of inductive sensors with Loctite (Type # 243)! Legend: 2.1. 2.2. 2.3. 2.4. 2.5.

Orange Green Brown Black Grey

1 2 3

4 5

Fig. 1564

3.

Fix cables of inductive sensors with cable clip (See arrow), clamp and cylindrical screw. Tightening torque (M6/8.8): MA = 9.5 Nm

Fig. 1565

30.6.61 - Reassembly of W.H. and E.C.U. (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Insert W.H. (Hydrostatic Unit) into the housing lid. Fasten the W.H. by means of fixing plate and hexagon screw. Tightening torque (M6/8.8): MA = 9.5 Nm

Fig. 1566

30-334

Method of intervention 2.

Wet mounting surface with the proper sealing agent. Then fix control unit by means of cylindrical screws. Tightening torque (M6/8.8): MA = 9.5 Nm WARNING Wet threads of cylindrical screws with Loctite (Type # 243)!

Fig. 1567

3.

Insert W.H. (TCU / HCU) into the housing lid. Fasten the W.H. with fixing plate and hexagon screw. Tightening torque (M6/8.8): MA = 9.5 Nm

Fig. 1568

4.

Fit plug to control unit (See arrow) and mount W.H. of Hydrostatic Unit (Bayonet Locking).

Fig. 1569

5.

Insert W.H. 8(2x, Hydraulic Control and oil sensors) into the housing lid. Fix W.H. with cable clips (See arrow).

Fig. 1570

30-335

Method of intervention 6.

Provide pressure sensor with new seal ring and mount it. Tightening torque: MA = 20 Nm

Fig. 1571

7.

Fit plug to pressure sensor.

Fig. 1572

30.6.62 - Reassembly of Valve Block (P.R.V. - Pressure Relief Valve) (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Use grease to fix rectangular rings (2x, See arrows) into the countersinks of the housing lid. WARNING Use new rectangular rings!

Fig. 1573

2.

Mount valve block and fix it with hexagon nuts. Tightening torque (M8): MA = 23 Nm

Fig. 1574

30-336

Method of intervention 3.

Fit pressure relief valve. Tightening torque: MA = 30 Nm

Fig. 1575

30.6.63 - Reassembly of Valve Block (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Hydraulic Control 1.

Fit screw plugs (See arrows) Tightening torque (M10x1.0): MA = 25 Nm Tightening torque (M12x1.5): MA = 35 Nm WARNING Operation is only required when using a new valve block! Fig. 1576

2.

Use grease to fix the rectangular rings (See arrows) into the countersinks of the valve block. WARNING Use new rectangular rings!

Fig. 1577

3.

Mount valve block and fix it with hexagon nuts and cylindrical screws. Tightening torque (M8): MA = 23 Nm

Fig. 1578

30-337

Method of intervention 4.

Install directional valves into the valve block until contact position. Now fix them by means of claw and cylindrical screw. Tightening torque: MA = 9 Nm

Fig. 1579

5.

Connect plugs on the directional valves (6x).

Fig. 1580

6.

Fit cable clip (See arrow).

Fig. 1581

7.

Provide pressure sensor with new seal ring and mount it. Tightening torque: MA = 20 Nm

Fig. 1582

30-338

Method of intervention 8.

Fit plug on pressure sensor.

Fig. 1583

9.

Provide accumulator with new O-Ring and install it. Tightening torque: MA = 30 Nm

Fig. 1584

30.6.64 - Reassembly of Valve Block (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Filter head, Pressure relief valve, Thermocouple 1.

Provide fittings and screw plugs with new seal rings and mount them. Then fit the pipe union (See figure for installation position) 1.1. Pipe Union MA = 60 Nm 1.2. Fitting MA = 90 Nm 1.3. Screw plug MA = 35 Nm

1 2 2

WARNING Wet thread of fitting with Loctite (Type # 243)!

3

3 Fig. 1585

WARNING This operation is only required when using a new valve block!

30-339

Method of intervention 2.

Use grease to fix the rectangular rings and O-Rings (See arrows) into the countersinks of the valve block. WARNING Use new rectangular rings and O-Rings!

Fig. 1586

3.

Fix valve block with cylindrical screws. Tightening torque (M8/8.8): MA = 23 Nm

Fig. 1587

4.

Mount O-Rings (See arrows) onto the cooler PRV, lubrication PRV and brake cooling oil PRV (4). WARNING Installation of the O-Rings is only necessary when they are replaced! WARNING Pressure relief valves are supplied with O-Ring. Fig. 1588

5.

Insert the pressure relief valves and the spacer part (See following figure). Legend: 5.1. 5.2. 5.3. 5.4. 5.5.

Cooler PRV Lubrication PRV Spacer part Brake cooling oil PRV Screw plug

1 2 3 5

4

Fig. 1589

30-340

Method of intervention 6.

Provide screw plug (5) with new O-Ring and fit it. Tightening torque: MA = 30 Nm

Fig. 1590

7.

Place O-Rings (2x, See arrows) into the countersinks of the filter head.

Fig. 1591

8.

Fix filter head by means of cylindrical screws. Tightening torque: MA = 10 Nm

Fig. 1592

9.

Insert valve and compression spring into the hole.

Fig. 1593

30-341

Method of intervention 10.

Install service switch. Tightening torque: MA = 25 Nm

Fig. 1594

11.

Insert compression spring and thermocouple into the hole.

Fig. 1595

12.

Provide screw plug with new O-Ring and install it. Tightening torque: MA = 30 Nm

Fig. 1596

30-342

Method of intervention 30.6.65 - Reassembly of Pump (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Grease O-Rings (See arrows) and insert them into the annular grooves of the pump housing.

Fig. 1597

2.

Insert spur gear into the housing lid. Then mount pump into the housing lid until contact by taking up the spur gear with the pump shaft. WARNING Observe installation position of the spur gear; fit spur gear with the off-set front face on side of the pump!

Fig. 1598

3.

Maintain contact position of pump shaft and fix spur gearwith retaining ring.

Fig. 1599

4.

Fit screw plug. Tightening torque: MA = 30 Nm WARNING Wet thread of screw plug with Loctite (Type # 574)!

Fig. 1600

30-343

Method of intervention 5.

Engage retaining ring into the inner annular groove of the sleeve. Then mount sleeve to the pump shaft until contact is obtained.

Fig. 1601

6.

Provide lid with O-Ring. Fix lid by means of hexagon screws. Tightening torque (M14/8.8) MA = 125 Nm

Fig. 1602

7.

Grease O-Rings and insert them into the annular grooves of the straight tube. Then insert straight tube into the housing hole until contact is obtained.

Fig. 1603

8.

Grease O-Rings and insert them into the annular grooves of the straight tube. Then insert straight tube and intermediate ring into the housing holes until contact is obtained.

Fig. 1604

30-344

Method of intervention 9.

Install screw plugs (2x). Tightening torque: MA = 30 Nm

Fig. 1605

30.6.66 - Reassembly of Control (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Connect all plugs. WARNING Arrangement of plugs is marked on the control unit with the corresponding colors (Also refer to the following sketch)!

Fig. 1606

2.

Legend to figure:

Table 353 Digit / Numer

Colour

A Grey B Black C Green D Brown 1 Grey 2 Black 3 Green 4 Brown 5 Orange W.H. = Wiring Harness I.S. = Inductive Sensor

A C 1

4

B D 2

3 5

Typology

(W.H.)

(I.S.) Fig. 1607

30-345

Method of intervention 3.

Fix control unit by means of hexagon screws and hexagon nuts with washers. Tightening torque (M6):

1 9

MA = 9.5 Nm WARNING

5

4

8

13

12 14

Observe order of tightening. Start from the center to tighten the screws and nuts!

10

11 6

2

3

7 Fig. 1608

WARNING Wet mounting surface with proper sealing agent.

30.6.67 - Reassembly of Hydrostatic Unit (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Mount pressure sensors (See arrows). (S) Plug insert: 5.9035.459.0 Tightening torque: MA= 25 Nm

Fig. 1609

2.

Preassemble the hydrostatic unit as shown. 2.1. Hydrostatic Unit 2.2. Bearing Bracket 2.3. Spur Gear

1 3

2

3

2

Fig. 1610

3.

Use lifting tackle (S) to position the hydrostatic unit in the housing lid, connecting the plugs wiring harness/pressure sensors at the same time. (S) Load carrying fixture: 5.9035.467.0

Fig. 1611

30-346

Method of intervention 4.

Fix hydrostatic unit by means of tight-fit screws and hexagon screws. Tightening torque: MA= 86 Nm WARNING To prevent seizing, tighten the tight-fit screws first. Do NOT use an impact wrench!

Fig. 1612

5.

Support the spur gear and fix it by means of hexagon screw and washer. Tightening torque (M10/10.9): MA = 68 Nm WARNING This operation is to be done on both spur gears!

WARNING Wet threads of hexagon screws with Loctite (Type # 243)! 6.

Fig. 1613

Fit plug (Bayonet locking).

Fig. 1614

7.

Align hydrostatic unit centrically. Insert bushing into the housing lid until contact.

Fig. 1615

30-347

Method of intervention 8.

Oil the O-Rings (2x) and insert them into the annular grooves of the line and grease them. Now insert the line into the hydrostatic unit until contact.

Fig. 1616

9.

Fit temperature sensor into the screw plug. Tightening torque: MA = 20 Nm

Fig. 1617

10.

Oil the O-Rings (2x) and insert them into the annular grooves of the screw plug. Fit the screw plug. Tightening torque: MA = 160 Nm

Fig. 1618

11.

Connect plug (Temperature Sensor).

Fig. 1619

30-348

Method of intervention 12.

Mount cover with hexagon screws. Tightening torque: MA = 9.5 Nm WARNING Pay attention to the correct position of the seal!

Fig. 1620

30.6.68 - Reassembly of Suction filter (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Oil inner O-Ring of the suction filter. Insert the suction filter into the housing hole until contact is obtained.

Fig. 1621

2.

Provide cover with new O-Ring. Fix preassembled cover with hexagon screws. Tightening torque: MA = 23 Nm

Fig. 1622

30.6.69 - Preassembly of transmission housing (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Install cylindrical pins (2x, see 1) and stud bolts (4x, see 2). Tightening torque MA = 33 Nm 2

1

WARNING Wet threads of stud bolts with Loctite (type No.: 243)!

2

1

Fig. 1623

30-349

Method of intervention 2.

Fit screw plug with new O-ring and install it. Tightening torque MA = 120 Nm

Fig. 1624

3.

Insert plate (see arrow) into the transmission housing and fix it by hexagon screws. Tightening torque MA = 23 Nm

Fig. 1625

30.6.70 - Reassembly of drive shaft (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Insert bearing outer ring (see arrow) into the housing hole until contact is obtained.

Fig. 1626

2.

Heat both tapered roller bearings and mount them to the drive shaft until contact is obtained. IMPORTANT Adjust both bearings after cooling down!

Fig. 1627

30-350

Method of intervention 3.

Insert shaft seal (also refer to the following sketch) into the bearing cover until contact is obtained. (S) Driver tool: 5.9035.359.0 (S) Handle: 5.9035.222.0 IMPORTANT Wet outer diameter of the shaft seal ring with spirit just before installation!

Fig. 1628

4.

Legend: 1 = Bearing cover 2 = Shaft seal ring 1

2

Fig. 1629

5.

Grease O-ring (see arrow) and insert it into the annular groove.

Fig. 1630

6.

Insert bearing outer ring (1) into the bearing hole until contact is obtained. Grease O-ring (2) and insert it into the annular groove.

1

2

Fig. 1631

30-351

Method of intervention 7.

Setting of axial play 0.05 … 0.15 mm Install two locating pins (S) and mount shim(s) (e.g. thickness = 0.95 mm). (S) Locating pins (M10): 5.9035.253.0

Fig. 1632

8.

Insert the preassembled drive shaft into the transmission housing and fix it by means of the preassembled bearing cover.

Fig. 1633

9.

Fix bearing cover by means of hexagon screws. Tightening torque (M10/8.8) MA = 46 Nm

Fig. 1634

10.

Position the dial indicator at the drive shaft and measure the existing axial play. IMPORTANT Any deviation from the required axial play must be corrected with appropriate shims!

Fig. 1635

30-352

Method of intervention 30.6.71 - Reassembly of intermediate housing (7210 TTVAgrotron ->WSXW830400LD50010) 1.

Install stud bolts (2x, see arrows). Tightening torque MA = 33 Nm WARNING Wet threads of stud bolts with Loctite (type No.: 243)! Then provide all screw plugs with new seal rings and install them. Tightening torque (M12x1.5) MA = 35 Nm

Fig. 1636

Tightening torque (M18x1.5) MA = 50 Nm Tightening torque (M22x1.5) MA = 60 Nm Tightening torque (M26x1.5) MA = 80 Nm Tightening torque (M33x2) 2.

MA = 120 Nm Wet mounting face (see arrow) with sealing agent (Loctite type No.: 574).

Fig. 1637

3.

Use lifting tackle to bring the intermediate housing into contact position with the transmission housing. (S) Eyebolts: 5.9035.425.0

Fig. 1638

30-353

Method of intervention 4.

Fix intermediate housing using locknuts and hexagon screws. Tightening torque MA = 185 Nm

Fig. 1639

5.

Grease O-ring (see arrow) and mount it to the intermediate tube.

Fig. 1640

6.

Insert intermediate tube into the intermediate housing and fix it using a retaining ring.

Fig. 1641

7.

Mount input shaft until contact to the drive shaft is obtained.

Fig. 1642

30-354

Method of intervention 8.

Mount oil level indicator. Tightening torque MA = 6 Nm WARNING Observe the correct installation position (see indication of max. in the oil level indicator)!

Fig. 1643

30.6.72 - Reassembly of pinion (7210 TTV Agrotron ->WSXW830400LD50010) 1.

IMPORTANT If nominal dimension deviation on pinion, tapered roller bearing and housing is zero, shim thickness is 1.40 mm.

5

The deviations indicated on housing and pinion are understood to be in 1/100 mm. e.g. 5 corresponds to + 0.05 mm e.g. –5 corresponds to – 0.05 mm 2.

Fig. 1644

Read deviation from the housing. Deviation e.g 0.05 mm Add sign „+“ to the shim thickness. Deduct sign „-“ from the shim thickness.

0

Read deviation from the pinion. Deviation e.g 0.00 mm Add sign „-“ to the shim thickness. Deduct sign „+“ from the shim thickness. Fig. 1645

3.

Determination of bearing width. Bearing width e.g 38.95 mm IMPORTANT In case of deviation from the nominal dimension = 39.00mm, e.g. -0.05 mm, add sign „-“ to the shim thickness, deduct sign „+“ from the shim thickness.

Fig. 1646

30-355

Method of intervention 4.

5.

Deviation / example: Basic shim dimension/thickn. = 1.40 mm . . . . . 1.40 mm Housing deviation e.g. +5 . . . . . . . . . . . . . . . . + 0.05 mm Pinion deviation e.g. 0 . . . . . . . . . . . . . . . . . . . ± 0.00 mm Bearing deviation e.g. 38.95 mm . . . . . . . . . . . + 0.05 mm Thickness of determined shim = . . . . . . . . . . . . .1.50 mm In case of results up to 0.02 mm or 0.07, respectively, round down to next shim thickness. In case of results as of 0.03 mm or 0.08, respectively, round up to the next shim thickness. Place the determined shim (e.g. thickness = 1.50 mm) into the bearing hole and adjust bearing outer ring until contact is obtained.

Fig. 1647

6.

Heat tapered roller bearing and mount it to the pinion until contact is obtained.

Fig. 1648

7.

Install retaining ring.

Fig. 1649

8.

Place ratchet wheel (1) and afterwards spur gear (2) into the housing. IMPORTANT Observe correct installation position of the ratchet wheel, see Figure!

2

1

Fig. 1650

30-356

Method of intervention 9.

Install preassembled pinion.

Fig. 1651

10.

Secure pinion and rotate housing by 180°.

Fig. 1652

11.

Install retaining ring.

Fig. 1653

12.

Insert bearing outer ring into the housing hole until contact is obtained. Then heat tapered roller bearing and mount it to the pinion until contact is obtained.

Fig. 1654

30-357

Method of intervention 13.

Setting of rolling torque 3.0 … 5.0 Nm Block pinion against rotation and tighten slotted nut until the required rolling torque of 3.0 ... 5.0 Nm has been obtained. (S) Slotted nut wrench: 5.9035.429.0

Fig. 1655

14.

Relieve bearing by means of slight hits and rotate pinion in both directions several times. Then check rolling torque using the torque wrench. IMPORTANT This setting of the bearing refers to the installation of new bearings! In case of used bearings try to achieve the lower value of the specified bearing rolling torque!

Fig. 1656

15.

Secure slotted nut.

Fig. 1657

30-358

Method of intervention 30.6.73 - Reassembly of park lock (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Oil O-rings (3x, see arrows) and insert them into the annular grooves of cylinder bush and piston. Then mount piston into the cylinder bush until contact is obtained.

Fig. 1658

2.

Mount cylinder bush with piston into the housing. Tightening torque MA = 60 Nm

Fig. 1659

3.

Insert ratchet with leg spring (see arrow) into the housing and fix it with bolt.

Fig. 1660

4.

Insert tab into the fork head and fix it by using flange bolt, spacer and retaining ring.

Fig. 1661

30-359

Method of intervention 5.

Mount preassembled joint plate to the piston.

Fig. 1662

6.

Insert support roller into the lever and fix it by means of flange bolt, spacer and retaining ring. IMPORTANT Observe installation direction, see Figure!

WARNING Secure the rollers of the support roller! Fig. 1663

7.

Insert support roller into the lever (see arrow). Then mount lever into the housing and fix it by means of a bolt.

Fig. 1664

8.

Secure both bolts by means of hexagon screws (see arrows). WARNING Wet threads of hexagon screws with Loctite (type No.: 243)!

Fig. 1665

30-360

Method of intervention 9.

Install tab in the lever by means of bolt, spacer and retaining ring.

Fig. 1666

10.

Petting of park lock: Push rocker arm completely downwards, with the ratchet being engaged in the ratchet wheel. Insert the adjusting device (S) into the housing until contact is obtained. (S) Setting device: 5.9035.430.0 IMPORTANT The setting device (S) is used to preset the rocker arm!

Fig. 1667

11.

In case of a correct setting (also refer to the following Figure) the support roller of the ratchet must be in contact position with the setting device (S). IMPORTANT Despite the contact position to the support roller, it must be easy to pull out the setting device (S)! Check by positioning the ratchet on a tooth of the ratchet wheel (tooth on tooth position). There must be little play (0.1 mm). Fig. 1668

12.

Carry out the setting by rotating the piston.

Fig. 1669

30-361

Method of intervention 13.

Fix fork head (after completed park lock setting) by means of cylindrical screws. Tightening torque MA = 23 Nm WARNING Wet threads of cylindrical screws with Loctite (type No.: 243)! Fig. 1670

14.

Insert ball and spring into the housing hole.

Fig. 1671

15.

Provide the screw plug with a new seal ring and install it. Tightening torque MA = 40 Nm

Fig. 1672

30-362

Method of intervention 30.6.74 - Reassembly of clutch (all-wheel-drIve) (7210 TTV Agrotron ->WSXW830400LD50010) Version with slotted nut 1.

Mount disk package. IMPORTANT For number and arrangement of the disks see relating spare parts list!

Fig. 1673

2.

Grease O-rings (see arrows) and place them into the annular grooves of pressure cylinder and piston.

Fig. 1674

3.

Insert piston into the pressure cylinder until contact is obtained. IMPORTANT Observe installation position, see Figure!

Fig. 1675

4.

Mount preassembled pressure cylinder onto the clutch carrier until contact is obtained.

Fig. 1676

30-363

Method of intervention 5.

Place retaining ring (see arrow) into the bell housing. Then heat ball bearing and mount it until contact is obtained. IMPORTANT Adjust bearing after cooling down!

Fig. 1677

6.

Fix ball bearing by means of retaining ring.

Fig. 1678

7.

Insert preassembled clutch carrier into the bell housing.

Fig. 1679

8.

Engage retaining ring (also see Figure 55) into the annular groove of the clutch carrier.

Fig. 1680

30-364

Method of intervention 9.

Mount cup springs (2x). IMPORTANT Observe installation position of cup springs, mount both cup springs with the convex side (curved upward) showing upwards!

Fig. 1681

10.

Fix locking device (S, see arrow) into the vice. Then place the clutch onto the locking device (S), bolt on and tighten slotted nut. Tightening torque MA = 115 ±10 Nm (S) Locking device: 5.9035.481.0 (S) Slotted nut wrench: 5.9035.465.0

Fig. 1682

11.

Mark position of the slotted nut. Then loosen slotted nut by 360° ± 5° (one rotation).

Fig. 1683

12.

Secure slotted nut.

Fig. 1684

30-365

Method of intervention Version with washer and retaining ring 1.

Mount disk package. IMPORTANT For the number of disks and the disk arrangement please refer to the relating spare parts list!

Fig. 1685

2.

Grease O-rings (see arrows) and place them into the annular grooves of pressure cylinder and piston.

Fig. 1686

3.

Insert piston into the pressure cylinder until contact is obtained. IMPORTANT Observe installation position, see Figure!

Fig. 1687

4.

Mount preassembled pressure cylinder onto the clutch carrier until contact is obtained.

Fig. 1688

30-366

Method of intervention 5.

Place retaining ring (see arrow) into the bell housing. Then heat ball bearing and mount it until contact is obtained. IMPORTANT Adjust bearing after cooling down!

Fig. 1689

6.

Fix ball bearing by means of retaining ring.

Fig. 1690

7.

Insert preassembled clutch carrier into the bell housing.

Fig. 1691

8.

Engage retaining ring into the annular groove of the clutch carrier.

Fig. 1692

30-367

Method of intervention 9.

Mount cup springs (2x). IMPORTANT Observe installation position of cup springs, mount both cup springs with the convex side (curved upward) showing upwards!

Fig. 1693

10.

Mount shim: optional thickness = 3.8 mm (recommended value).

Fig. 1694

11.

Preload cup springs with pressure sleeve (S) and engage retaining ring. (S) Pressure sleeve: 5.9035.461.0

Fig. 1695

30-368

Method of intervention Continues for both version 1.

Heat tapered roller bearing and mount it until contact is obtained. IMPORTANT Adjust bearing after cooling down!

Fig. 1696

2.

Mount retaining ring.

Fig. 1697

3.

Install bearing outer ring (1) into the housing hole until contact is obtained and insert spur gear (2). 1

2

Fig. 1698

4.

Mount preassembled all-wheel-drive clutch into the housing/spur gear.

Fig. 1699

30-369

Method of intervention 5.

Engage retaining ring into the annular groove of the clutch carrier.

Fig. 1700

6.

Insert bearing outer ring (see arrow) into the housing hole until contact is obtained. Then heat tapered roller bearing and mount it to the clutch carrier until contact is obtained.

Fig. 1701

7.

Setting of axial play 0.05 … 0.10 mm Bolt on the slotted nut until the required axial play of 0.05 … 0.10 mm is obtained (also refer to the following Figure)

Fig. 1702

8.

Position dial indicator at the clutch carrier and measure the axial play.

Fig. 1703

30-370

Method of intervention 9.

Secure slotted nut.

Fig. 1704

10.

Place seal ring (see arrow) into the annular groove of the clutch carrier and use grease to position it centrically.

Fig. 1705

11.

Grease O-ring (see arrow) and insert it into the annular groove of the cover.

Fig. 1706

12.

Place cover into the housing and fix it by means of hexagon screws. Tightening torque (M8/8.8) MA = 23 Nm WARNING Wet mounting face with Loctite (type No.: 574)!

Fig. 1707

30-371

Method of intervention 30.6.75 - Reassembly of spur gear (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Mount bearing unit (tapered roller bearing with spacer ring) into the spur gear. WARNING Replace bearing unit as a complete assy only (both tapered roller bearings and spacer ring)!

Fig. 1708

2.

Install slotted pin (see arrow) into the bearing bolt. Place preassembled spur gear into the housing and fix it by means of bearing bolt.

Fig. 1709

3.

Fix bearing bolt with disk and locknut. Tightening torque MA = 55 Nm

Fig. 1710

4.

Install cover plate and fix it by means of hexagon screws. Tightening torque (M6/8.8) MA = 9.5 Nm WARNING Wet threads of hexagon screws with Loctite (type No.: 243)!

Fig. 1711

30-372

Method of intervention 30.6.76 - Reinstallation of plug-in module (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Install cylindrical pins (2x, see arrows).

Fig. 1712

2.

Use lifting tackle (S) to place the plug-in module into the transmission housing and fix it by means of hexagon screws. Tightening torque (M12/10.9) MA = 115 Nm (S) Load carrying fixture: 5.9035.426.0

Fig. 1713

3.

Mount pressure line (see arrow) by means of fitting and cap screw. Tightening torque MA = 40 Nm IMPORTANT Provide fitting with a new seal ring!

Fig. 1714

4.

Preassembly of emergency release – park lock. 1 = Scraper 2 = O-ring 3 = Threaded part 4 = Seal ring 5 = Retaining ring 6 = Washer 7 = Compression spring 8 = Bolt

3 1

4

2

5

6

7

8

Fig. 1715

30-373

Method of intervention 5.

Install emergency release. Tightening torque MA = 50 Nm

Fig. 1716

30.6.77 - Reassembly of output shaft (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Engage retaining ring into the annular groove of the output shaft.

Fig. 1717

2.

Heat both tapered roller bearings and mount them onto the shaft until contact with the retaining ring is obtained. IMPORTANT Adjust bearings after cooling down!

Then fix tapered roller bearings by means of retaining ring.

Fig. 1718

3.

Mount bearing outer ring into the bearing cover until contact is obtained.

Fig. 1719

30-374

Method of intervention 4.

Support the bearing cover (see arrow), mount the preassembled output shaft and insert the bearing outer ring until contact is obtained

Fig. 1720

5.

Setting of axial play of tapered roller bearing 0.0 … 0.1 mm Mount shim: optional thickness, for example 0.90 mm. IMPORTANT Select the thickness of the shim in such a way that the retaining ring (see following Figure) is without clearance!

Fig. 1721

6.

Engage the retaining ring into the annular groove until contact with the groove base is obtained. Then grease the O-ring (see arrow) and insert it into the annular groove.

Fig. 1722

7.

Fit shaft seal ring. (S) Driver tool: 5.9035.424.0 IMPORTANT Use of the specified driver tool (S) ensures the exact installation position of the shaft seal ring! WARNING Just before fitting, wet the outer diameter with spirit! Fig. 1723

30-375

Method of intervention 8.

Install screen sheet. (S) Driver tool: 5.9035.423.0 IMPORTANT Use of the specified driver tool (S) ensures the exact installation position of the screen sheet! DANGER Wet inner diameter with Loctite (type No.: 649)! Fig. 1724

9.

Insert the preassembled drive shaft into the transmission housing and fix it by means of hexagon screws. Tightening torque (M10/8.8) MA = 46 Nm

Fig. 1725

30.6.78 - Preassembly of housing lid (7210 TTV Agrotron ->WSXW830400LD50010) 1.

IMPORTANT The following operations are only required when using a new housing lid! Fit plugs (6x, see arrows).

Fig. 1726

2.

Fit stud bolts (4x, see arrows). Tightening torque MA = 6.0 Nm Now fit breather valve (arrow). Tightening torque MA = 30 Nm WARNING Wet threads of stud bolts and breather valve with Loctite (type No.: 243)!

30-376

Fig. 1727

Method of intervention 3.

Fit stud bolts (2x, see arrows). Tightening torque MA = 9.0 Nm WARNING Wet threads of stud bolts with Loctite (type No.: 243)!

Fig. 1728

4.

Fix cable clips (2x, see arrows) with hexagon screws. Tightening torque (M6/8.8) MA = 3.0 Nm IMPORTANT Observe installation position, see adjacent Figure!

Fig. 1729

30.6.79 - Reassembly of plate (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Mount all screw plugs and stud bolts (Figure 5 and 6) into the plate.

1

Legend: 1 = Screw plug (M14x1.5) MA = 35 Nm

5

2 = Screw plug (M12x1.5)

4 3

MA = 35 Nm 3 = Screw plug (M10x1)

2

Fig. 1730

MA = 25 Nm 4 = Stud bolt (M8x60) MA = 9 Nm 5 = Stud bolt (M8x80) MA = 9 Nm IMPORTANT This operation is only required when using a new plate!

30-377

Method of intervention 2.

Legend: 1 = Screw plug (M12x1.5) MA = 35 Nm 2 = Screw plug (M12x1.5) MA = 35 Nm 3 = Screw plug (M10x1)

2

1

2

3

MA = 25 Nm Fig. 1731

WARNING Wet threads of stud bolts with Loctite (type No.: 243)!

IMPORTANT This operation is only required when using a new plate! 3.

Provide fittings with new seal rings and mount them. Then fit the pipe union (see Figure for installation position). 1 = Pipe union

2 1

2

MA = 60 Nm

3

2 = Fitting MA = 90 Nm 3 = Fitting MA = 55 Nm

4

4 = Fitting

Fig. 1732

MA = 35 Nm WARNING Wet thread of fitting (2) with Loctite (type No.: 243)!

IMPORTANT This operation is only required when using a new plate!

30-378

Method of intervention 4.

Insert one back-up ring and one O-ring each into the countersinks of the cover plate (see arrows). IMPORTANT This operation is only required when using a new plate!

Fig. 1733

5.

Fix cover plate with cylindrical screws. Tightening torque (M8/8.8) MA = 23 Nm IMPORTANT This operation is only required when using a new plate! Fig. 1734

6.

Use grease to fix O-rings and rectangular rings into the countersinks of the plate. (S) Eyebolts (M12): 5.9035.377.0 IMPORTANT Use new O-rings and rectangular rings!

Fig. 1735

7.

Use the lifting tackle to bring plate into contact position with the housing lid and fix it with cylindrical screws and hexagon nuts. Tightening torque MA = 23 Nm

Fig. 1736

30-379

Method of intervention 30.6.80 - Reassembly of valve block (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Fit screw plugs (see arrows). Tightening torque (M10x1) MA = 25 Nm Tightening torque (M12x1.5) MA = 35 Nm IMPORTANT This operation is only required when using a new valve block!

2.

Fig. 1737

Wet throttle with Loctite (type No.: 638) and mount it. IMPORTANT This operation is only required when using a new valve block!

Fig. 1738

3.

Use grease to fix the rectangular rings (see arrows) into the countersinks of the valve block. IMPORTANT Use new rectangular rings!

Fig. 1739

4.

Mount the valve block and fix it with cylindrical screws and hexagon nuts with washers. Tightening torque MA = 23 Nm

Fig. 1740

30-380

Method of intervention 30.6.81 - Reassembly of wiring harnesses (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of wiring harness (hydrostatic unit) 1.

Wet mounting surface with sealing agent (Terostat-MS 935 black DK 310, ZF order No.: 5.9035.482.0)! Then insert wiring harness into housing lid and fix it with hexagon screws. Tightening torque (M6/8.8) MA = 6.0 Nm WARNING Wet threads of Figure 16 hexagon screws with Loctite (type No.: 243)! Fig. 1741

Reassembly of wiring harness (directional valves, pressure sensors) 1.

Mount wiring harness into the housing lid and fix it with clip and cylindrical screw. Tightening torque (M6/8.8) MA = 6.0 Nm

Fig. 1742

2.

Connect plug and fix cable with cable clip (see arrow).

Fig. 1743

3.

Fix wiring harness to the plate using cable clamps (2x, see arrows).

Fig. 1744

30-381

Method of intervention 4.

Insert plug through the plate from behind and use retaining ring to fix it. IMPORTANT Ensure correct position of the O-ring!

Fig. 1745

5.

Fix holders (4x, see arrows) to the valve block using flat-head screws.

Fig. 1746

6.

Fix wiring harness to the valve block/holders using cable clamps (4x).

Fig. 1747

30-382

Method of intervention 30.6.82 - Reassembly of inductive sensors, pressure sensors, valves (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of inductive sensors 1.

Mount inductive sensors (5x) into housing lid and sensor cover. Tightening torque MA = 45 Nm (S) Plug insert: 5.9035.404.0 IMPORTANT Connection plugs of the inductive sensors are marked in different colors, for installation position see following Figure! Fig. 1748

2.

WARNING Wet threads of inductive sensors with Loctite (type No.: 243)!

1 3

1 = Orange 2 = Green 3 = Brown 4 = Black 5 = Grey

2

4

5

IMPORTANT For an improved view of the inductive sensors, the opposite Figure shows the housing lid without plate!

Fig. 1749

Reassembly of pressure reducing valve 1.

Fit pressure reducing valve. Tightening torque MA = 30 Nm

Fig. 1750

30-383

Method of intervention Reassembly of pressure sensors 1.

Fit new seal rings to both pressure sensors (see arrows) and install them. Tightening torque MA = 20 Nm

Fig. 1751

2.

Connect plugs (bayonet locking) to the pressure sensors.

Fig. 1752

Reassembly of 3/2 directional valves 1.

Mount directional valve into the valve block until contact is obtained. Then fix it by means of claw and cylindrical screw. Tightening torque MA = 9 +2 Nm

Fig. 1753

2.

The opposite sketch shows the arrangement and installation position of the directional valves.

Fig. 1754

30-384

Method of intervention Reassembly of 4/3 directional valve (PS) 1.

The opposite Figure shows the installation position of the 4/3 directional valve.

Fig. 1755

2.

Mount valve. Tightening torque MA = 30 Nm

Fig. 1756

3.

Mount coils and fix them by means of hexagon nut. Tightening torque MA = 6 Nm

Fig. 1757

4.

Connect plugs on the directional valves (8x). IMPORTANT Observe installation positions; also see disassembly instructions! When mounting a new wiring harness, plug connections are marked accordingly!

Fig. 1758

30-385

Method of intervention 5.

Fit accumulator with new O-ring and install it. Tightening torque MA = 30 Nm

Fig. 1759

30.6.83 - Reassembly of control unit (hydrostatic unit) (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Wet mounting surface with sealing agent (Terostat-MS 935 black DK 310, ZF order No.: 5.9035.482.0)! Then fix control unit by means of cylindrical screws. Tightening torque (M6/8.8) MA = 9.5 Nm IMPORTANT Wet threads of cylindrical screws with Loctite (type No.: 243)! Fig. 1760

2.

Install plug to the control unit.

Fig. 1761

30.6.84 - Reassembly of pressure relief valves (PRV) (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Insert cooler PRV (1), lubrication PRV (2), spacer part (3) and brake cooling oil PRV (4) into the hole (see following figure).

2

5

4

1

3

Fig. 1762

30-386

Method of intervention 2.

Provide screw plug (5) with new O-ring and fit it. Tightening torque MA = 30 Nm

Fig. 1763

30.6.85 - Reassembly of filter head (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Place O-rings (2x, see arrows) into the countersinks of the filter head.

Fig. 1764

2.

Fix filter head by means of cylindrical screws. Tightening torque MA = 10 Nm

Fig. 1765

3.

Insert valve and compression spring into the hole.

Fig. 1766

30-387

Method of intervention 4.

Install service switch. Tightening torque MA = 25+5 Nm

Fig. 1767

5.

Install plugs (2x, see arrows) and fix them by means of cable clip (see arrow).

Fig. 1768

30.6.86 - Reassembly of wiring harnesses and control unit (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Insert wiring harness (hydrostatic unit) into the housing lid and fasten it by means of fixing plate and hexagon screw. Tightening torque (M6/8.8) MA = 9.5 Nm

Fig. 1769

2.

Wet mounting surface with sealing agent (Terostat-MS 935 black DK 310, ZF order No.: 5.9035.482.0)! Then fix control unit by means of cylindrical screws. Tightening torque (M6/8.8) MA = 9.5 Nm WARNING Wet threads of cylindrical screws with Loctite (type No.: 243)! Fig. 1770

30-388

Method of intervention 3.

Insert wiring harness (TCU / HCU) into the housing lid and fasten it with fixing plate and hexagon screw. Tightening torque (M6/8.8) MA = 9.5 Nm

Fig. 1771

4.

Fit plug to control unit (see arrow) and mount wiring harness of hydrostatic unit (bayonet locking).

Fig. 1772

5.

Insert wiring harnesses (2x, hydraulic control and oil sensors) into the housing lid and fix them with cable clips (see arrow).

Fig. 1773

6.

Provide pressure sensor with new seal ring and mount it. Tightening torque MA = 20 Nm

Fig. 1774

30-389

Method of intervention 7.

Fit plug to pressure sensor.

Fig. 1775

30.6.87 - Reassembly of valve block (pressure reducing valve) (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Use grease to fix rectangular rings (2x, see arrows) into the countersinks of the housing lid. IMPORTANT Use new rectangular rings!

Fig. 1776

2.

Mount valve block and fix it with hexagon nuts. Tightening torque (M8) MA = 23 Nm

Fig. 1777

3.

Fit pressure reducing valve. Tightening torque MA = 30 Nm

Fig. 1778

30-390

Method of intervention 30.6.88 - Reassembly of valve block (hydraulic control) (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Fit screw plugs (see arrows). Tightening torque (M10x1) MA = 25 Nm Tightening torque (M12x1.5) MA = 35 Nm IMPORTANT Operation is only required when using a new valve block! Fig. 1779

2.

Use grease to fix the rectangular rings (see arrows) into the countersinks of the valve block. IMPORTANT Use new rectangular rings!

Fig. 1780

3.

Mount valve block and fix it with hexagon nuts and cylindrical screws. Tightening torque (M8) MA = 23 Nm

Fig. 1781

4.

Install directional valves into the valve block until contact position. Now fix them by means of claw and cylindrical screw. Tightening torque MA = 9 +2 Nm

Fig. 1782

30-391

Method of intervention 5.

Connect plugs on the directional valves (6x).

Fig. 1783

6.

Provide pressure sensor with new seal ring and mount it. Tightening torque MA = 20 Nm

Fig. 1784

7.

Fit plug on pressure sensor.

Fig. 1785

8.

Provide accumulator with new O-ring and install it. Tightening torque MA = 30 Nm

Fig. 1786

30-392

Method of intervention 30.6.89 - Reassembly of valve block (all wheel-drive / park lock) (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Mount screw plugs (see arrows). Tightening torque (M10x1) MA = 25 Nm IMPORTANT This operation is only required when using a new valve block!

Fig. 1787

2.

Use grease to fix the rectangular rings (see arrows) into the countersinks of the valve block IMPORTANT Use new rectangular rings!

Fig. 1788

3.

Mount valve block and fix it with hexagon nuts and cylindrical screw. Tightening torque (M8) MA = 23 Nm

Fig. 1789

4.

Mount directional valve into the valve block until contact is obtained. Then fix it by means of claw and cylindrical screw. Tightening torque MA = 9 +2 Nm

Fig. 1790

30-393

Method of intervention 30.6.90 - Reassembly of valve block (filter head, pressure relief valves, thermocouple) (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Provide fittings and screw plugs with new seal rings and mount them. Then fit the pipe union (see Figure for installation position). 1 = Pipe union

1 2

MA = 60 Nm 2 = Fitting MA = 90 Nm 3 = Screw plug 2

MA = 35 Nm WARNING

3 3

Fig. 1791

Wet thread of fitting with Loctite (type No.: 243)!

IMPORTANT This operation is only required when using a new valve block! 2.

Use grease to fix the rectangular rings and O-rings (see arrows) into the countersinks of the valve block. IMPORTANT Use new rectangular rings and O-rings!

Fig. 1792

3.

Fix valve block with cylindrical screws. Tightening torque (M8/8.8) MA = 23 Nm

Fig. 1793

30-394

Method of intervention 4.

Insert cooler PRV (1), lubrication PRV (2), spacer part (3) and brake cooling oil PRV (4) into the hole (see following Figure).

2 5

4

1

3

Fig. 1794

5.

Provide screw plug (5) with new O-ring and fit it. Tightening torque MA = 30 Nm

Fig. 1795

6.

Place O-rings (2x, see arrows) into the countersinks of the filter head.

Fig. 1796

7.

Fix filter head by means of cylindrical screws. Tightening torque MA = 10 Nm

Fig. 1797

30-395

Method of intervention 8.

Insert valve and compression spring into the hole.

Fig. 1798

9.

Install service switch. Tightening torque MA = 25+5 Nm

Fig. 1799

10.

Insert compression spring and thermocouple into the hole.

Fig. 1800

11.

Provide screw plug with new O-ring and install it. Tightening torque MA = 30 Nm

Fig. 1801

30-396

Method of intervention 12.

Mount wiring harness (filter pressure, see arrows).

Fig. 1802

30.6.91 - Reassembly of pump (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Grease O-rings (see arrows) and insert them into the annular grooves of the pump housing.

Fig. 1803

2.

Insert spur gear into the housing lid. Then mount pump into the housing lid until contact by taking up the spur gear with the pump shaft. WARNING Observe installation position of the spur gear; fit spur gear with the off-set front face on side of the pump!

Fig. 1804

3.

Maintain contact position of pump shaft and fix spur gear with retaining ring.

Fig. 1805

30-397

Method of intervention 4.

Fit screw plug. Tightening torque MA = 160 Nm WARNING Wet thread of screw plug with Loctite (type No.: 574)!

Fig. 1806

5.

Engage retaining ring into the inner annular groove of the sleeve. Then mount sleeve to the pump shaft until contact is obtained.

Fig. 1807

6.

Equip lid with O-ring and fix it by means of hexagon screws. Tightening torque (M14/8.8) MA = 125 Nm

Fig. 1808

7.

Grease O-rings and insert them into the annular grooves of the straight tube. Then insert straight tube into the housing hole until contact is obtained.

Fig. 1809

30-398

Method of intervention 8.

Grease O-rings and insert them into the annular grooves of the straight tube. Then insert straight tube and intermediate ring into the housing holes until contact is obtained.

Fig. 1810

9.

Install screw plugs (2x). Tightening torque MA = 30 Nm

Fig. 1811

30.6.92 - Reassembly of control (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Connect all plugs. IMPORTANT Arrangement of plugs is marked on the control unit with the corresponding colors (also refer to the following sketch)!

Fig. 1812

2.

Legend: A = Grey (wiring harness) B = Black (wiring harness) C = Green (wiring harness) D = Brown (wiring harness) 1 = Grey (inductive sensor) 2 = Black (inductive sensor) 3 = Green (inductive sensor) 4 = Brown (inductive sensor) 5 = Orange (inductive sensor)

A

C

B

D

4

1

2

3

5

Fig. 1813

30-399

Method of intervention 3.

Fix control unit by means of hexagon screws and hexagon nuts with washers. Tightening torque (M6)

9

5

8

4

1

13

MA = 9.5 Nm

12

IMPORTANT Observe order of tightening. Start from the center to tighten the screws and nuts!

11

14 2

6

10

3

7

Fig. 1814

WARNING Wet mounting surface with sealing agent (Terostat-MS 935 black DK 310, ZF order No.: 5.9035.482.0)!

30.6.93 - Reassembly of hydrostatic unit (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Preassemble hydrostatic unit as shown in the opposite Figure. 1 = Hydrostatic unit 2 = Bearing bracket 3 = Spur gear

3

2

2

3

1

Fig. 1815

2.

Use the lifting tackle (S) to lift the hydrostatic unit into the housing lid. (S) Load carrying fixture: 5.9035.467.0

Fig. 1816

3.

Fix hydrostatic unit by means of tight-fit screws and hexagon screws. Tightening torque MA = 86 Nm WARNING To prevent seizing, tighten the tight-fit screws first. Do NOT use an impact wrench!

Fig. 1817

30-400

Method of intervention 4.

Support the spur gear (see arrow) and fix it by means of hexagon screw and washer. Tightening torque (M10/10.9) MA = 68 Nm IMPORTANT This operation is to be done on both spur gears!

WARNING

Fig. 1818

Wet threads of hexagon screws with Loctite (type No.: 243)! 5.

Fit plug (bayonet locking).

Fig. 1819

6.

Align hydrostatic unit centrically and insert bushing into the housing lid until contact.

Fig. 1820

7.

Insert O-rings (2x) into the annular grooves of the line and grease them. Now insert the line into the hydrostatic unit until contact.

Fig. 1821

30-401

Method of intervention 8.

Fit temperature sensor into the screw plug. Tightening torque MA = 20 Nm

Fig. 1822

9.

Insert O-rings (2x) into the annular grooves of the screw plug and grease them. Now fit the screw plug. Tightening torque MA = 160 Nm

Fig. 1823

10.

Connect plug (temperature sensor).

11.

Mount lid with hexagon screws. Fix the cable (service switch) to the lid using a clamp (see arrow). Tightening torque MA = 9.5 Nm IMPORTANT

Fig. 1824

Pay attention to the correct position of the seal!

30-402

Method of intervention 30.6.94 - Reassembly of suction filter (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Grease O-ring and insert the suction filter into the housing hole until contact is obtained.

Fig. 1825

2.

Provide cover with new O-ring and fix it by means of hexagon screws. Tightening torque MA = 23 Nm

Fig. 1826

30.6.95 - Reassembly of K2 Clutch 1.

Insert both cylindrical pins (See arrows) into the holes until contact is obtained..

Fig. 1827

2.

Fix bearing bracket with cylindrical screws. Tightening torque (M12/8.8): MA= 80 Nm

Fig. 1828

30-403

Method of intervention 3.

Insert sleeves (2x, See arrows) into the cover until contact is obtained. WARNING Cover is supplied as a complete component with preassembled piston!

Fig. 1829

4.

Insert clutch ring into the cover.

Fig. 1830

5.

Place cup springs into the clutch ring. WARNING Observe the installation position, see following figure!

Fig. 1831

6.

Legend to figure: 6.1. Cup Springs 6.2. Clutch Ring 6.3. Cover (cpl. with piston)

1 2 3

Fig. 1832

30-404

Method of intervention 7.

Insert holder into the cover. WARNING Pay attention that both holes in holder and cover (See arrows) are overlapping!

Fig. 1833

8.

Preload cover/cup springs with a press. Engage snap ring into the annular groove of the holder. (S) Pressure plate: 5.9035.464.0

Fig. 1834

9.

Fit slotted pin (Rotation Stop) with the opening in circumferential direction. WARNING Slotted pin (See arrow) is to be flush-mounted, that means it must not protrude!

Fig. 1835

10.

Insert ring gear into the bearing bracket.

Fig. 1836

30-405

Method of intervention 11.

Fix preassembled clutch by means of hexagon screws. Tightening torque (M10/10.9): MA = 79 Nm

Fig. 1837

30.6.96 - Reassembly of KR clutch 1.

Fix bracket by means of tight-fit screws and hexagon screws. Tightening torque (tight-fit screws): MA = 86 Nm Tightening torque (M12/10.9): MA = 110 Nm Note Bracket is supplied as a complete component with preassembled piston!

Fig. 1838

CAUTION To prevent seizing, tighten the tight-fit screws first. Do NOT use an impact wrench! 2.

Insert clutch ring into the bracket.

Fig. 1839

3.

Mount cup springs to the spring holder. WARNING Ensure correct installation position, see following sketch!

Fig. 1840

30-406

Method of intervention 4.

Legend to sketch: 4.1. Spring holder 4.2. Cup springs 1 2

Fig. 1841

5.

Place preassembled spring holder into the bracket (see arrow) and fix it with hexagon screws. Tightening torque (M8/8.8): MA = 23 Nm Note Tighten spring holder equally until contact is obtained!

Fig. 1842

6.

Place clutch hub into the cover.

Fig. 1843

7.

Install cover and fix it with hexagon screws. Tightening torque (M10/8.8): MA = 46 Nm

Fig. 1844

30-407

Method of intervention 30.6.97 - Reassembly of P3/P4 planetary drive 1.

Use grease to fix the thrust washers into the planetary carrier. Note Ensure correct installation; position the rotation stop (tab) in the respective locking hole!

Fig. 1845

2.

Insert the needle cages into the planetary gears. Then insert the planetary gears into the planetary carrier/between the thrust washers. WARNING Make sure to NOT mix up the needle cages! P3 bearing (top) is nitrided (black cage)!

Fig. 1846

3.

Centrically align planetary gears and thrust washers and fix them by planetary pin.

Fig. 1847

4.

Install fixing plate and fasten it with countersunk screws. Tightening torque (M6/8.8): MA = 9.5 Nm WARNING Wet threads of countersunk screws with Loctite (type No.: 649)!

Fig. 1848

30-408

Method of intervention 30.6.98 - Reassembly of K3/K4 clutch (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Press ball bearing onto the clutch carrier until contact is obtained. IMPORTANT Clutch carrier is supplied as a complete component with preassembled piston!

Fig. 1849

2.

Insert needle bearing (1) and slotted pin (2) into the clutch carrier until contact is obtained. 1

2

Fig. 1850

3.

Fit threaded pins (2x). Tightening torque (M8/8.8) MA = 14 Nm WARNING Wet thread with Loctite (type No.: 243)!

Fig. 1851

Reassembly of K3 clutch 1.

Place clutch ring into the clutch carrier.

Fig. 1852

30-409

Method of intervention 2.

Install axial washers and cup springs. IMPORTANT Ensure correct installation position, see following sketch!

Fig. 1853

3.

Legend: 1 = Axial washer 2 = Cup springs 3 = Clutch ring 4 = Clutch carrier (cpl. with piston)

1 2 1 3 4

Fig. 1854

4.

Preload axial washer/cup springs with a press and engage retaining ring into the annular groove of the clutch carrier. (S) Press bush: 5.9035.458.0

Fig. 1855

5.

Install clutch hub.

Fig. 1856

30-410

Method of intervention Reassembly of K4 clutch 1.

Install clutch ring.

Fig. 1857

2.

Install cup springs. IMPORTANT Ensure correct installation position, see following sketch!

Fig. 1858

3.

Legend: 1 = Cup springs 2 = Clutch ring 3 = Clutch carrier

1 2 3

Fig. 1859

4.

Install clutch hub.

Fig. 1860

30-411

Method of intervention 5.

Align teeth of clutch carrier/clutch ring and bolt on the nut. Tightening torque MA = 150 Nm (S) Slotted nut wrench: 5.9035.457.0

Fig. 1861

6.

Fit threaded pins (3x). Tightening torque MA = 5 Nm IMPORTANT If the threaded pin does not fit into the tooth space, retighten the nut (do NOT loosen it)!

WARNING

Fig. 1862

Wet thread with Loctite (type No.: 243)! 7.

Insert the carrier into the clutch ring and fix it with a snap ring.

Fig. 1863

8.

Insert the preassembled clutch carrier into the P3/P4 planetary carrier and fix it with a snap ring.

Fig. 1864

30-412

Method of intervention 9.

Install piston rings (4x, see arrows).

Fig. 1865

10.

IMPORTANT Prior to reassembly, preload the piston rings in a tube with an inner diameter of 50 mm (see Figure)!

Fig. 1866

11.

Insert clutch carrier (complete with planetary drive) into the bracket until contact is obtained. WARNING Install clutch carrier with great care to avoid damage to the piston rings and contact face in the bracket!

Fig. 1867

30-413

Method of intervention 30.6.99 - Reassembly of K3/K4 Clutch (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Press ball bearing onto the clutch carrier until contact is obtained. WARNING Clutch carrier is supplied as a complete component with preassembled piston!

Fig. 1868

2.

Insert needle bearing (See arrow) into the clutch carrier until contact is obtained.

Fig. 1869

3.

Place clutch ring into the clutch carrier.

Fig. 1870

4.

Install axial washers and cup springs. WARNING Observe the installation position, see following figure!

Fig. 1871

30-414

Method of intervention 5.

Legend to figure: 5.1. 5.2. 5.3. 5.4.

Axial Washer Cup Springs Clutch Ring Clutch Carrier (cpl. with piston)

1 2 1 3 4

Fig. 1872

6.

Preload axial washer/cup springs with a press. Engage retaining ring into the annular groove of the clutch carrier. (S) Press bush: 5.9035.458.0

Fig. 1873

7.

Install clutch hub.

Fig. 1874

8.

Install clutch ring.

Fig. 1875

30-415

Method of intervention 9.

Install cup springs. WARNING Observe the installation position, see following figure!

Fig. 1876

10.

Legend to figure: 10.1. 10.2. 10.3.

Cup Springs Clutch Ring Clutch Carrier

1 2 3

Fig. 1877

11.

Install clutch hub.

Fig. 1878

12.

Align teeth of clutch carrier/clutch ring. Bolt on and fix the nut. Tightening torque: MA = 150 Nm (S) Slotted nut wrench: 5.9035.457.0

Fig. 1879

30-416

Method of intervention 13.

Fit threaded pins (3x). Tightening torque: MA = 14 Nm WARNING If the threaded pin does not fit into the tooth space, retighten the nut (DO NOT loosen it)! WARNING Wet thread with Loctite (Type # 243)!

14.

Fig. 1880

Insert the carrier into the clutch ring and fix it with a snap ring. WARNING Check correct position of teeth clutch carrier/clutch ring and align them, if required.

Fig. 1881

15.

Insert the preassembled clutch carrier into the P3/P4 planetary carrier and fix it with a snap ring.

Fig. 1882

16.

Grease the annular grooves and install piston rings (4x, See arrows).

Fig. 1883

30-417

Method of intervention 17.

Centrically align the rectangular rings with centering bush (S). (S) Centering bush: 5.9035.463.0

Fig. 1884

18.

Insert clutch carrier (Complete with planetary drive) into the bracket until contact is obtained. WARNING Install clutch carrier with great care to avoid damage to the piston rings and contact face in the bracket!

Fig. 1885

19.

Insert ring gear into the bearing bracket until contact is obtained..

Fig. 1886

30-418

Method of intervention 30.6.100 - Reassembly of K1 Clutch 1.

Preassemble K1 clutch analogously to K2 clutch. Link to part: See para. 30.6.95 - Reassembly of K2 Clutch - page 30-403

Fig. 1887

30.6.101 - Reassembly of KV Clutch 1.

Place clutch ring into the clutch carrier. WARNING Clutch carrier is supplied as a complete component with preassembled piston!

Fig. 1888

2.

Install cup springs and washer. WARNING Observe the installation position, see following figure!

Fig. 1889

3.

Legend to figure: 3.1. 3.2. 3.3. 3.4.

Washer Cup Springs Clutch Ring Clutch Carrier (cpl. with piston)

1 2 3 4

Fig. 1890

30-419

Method of intervention 4.

Preload cup springs with a press. Engage retaining ring into the annular groove of the clutch carrier. (S) Assembly fixture: 5.9030.971.0

Fig. 1891

5.

Insert adjusting washer into the clutch carrier.

Fig. 1892

6.

Place hub into the clutch carrier and fix it with a snap ring.

Fig. 1893

7.

Insert the sun gear into the clutch carrier and fix it with a retaining ring.

Fig. 1894

30-420

Method of intervention 8.

Grease O-Rings (2x, See arrows) and insert them into the annular grooves of the K3/K4 clutch carrier.

Fig. 1895

9.

Maintain contact position of P3/P4 planetary drive and mount preassembled KV clutch.

Fig. 1896

10.

Mount adjusting washer and fix clutch by means of a retaining ring.

Fig. 1897

30-421

Method of intervention 30.6.102 - Reassembly of P5/P6 planetary drive 1.

Preassemble planetary gears as shown in the opposite Figure. 1.1. 1.2. 1.3. 1.4.

Planetary Gear Needle Cage Planetary Gear (Double planetary gear) Spacer Sleeve

1 3

2 2

4

2

Fig. 1898

2.

Reassembly of single planetary gears (Next 2 figures) Use grease to fix the thrust washers into the planetary carrier. WARNING Observe the installation position! WARNING Position the rotation stop (tab) in the respective locking hole! Fig. 1899

3.

Insert the preassembled planetary gear into the planetary carrier/between the thrust washers. Then centrically align the planetary gear and thrust washers and fix them with a planetary pin. WARNING Observe installation position of planetary pins. WARNING Planetary pins for single planetary gears have only one oil hole!

4.

Fig. 1900

Reassembly of double planetary gears (Next 2 figures) Use grease to fix the thrust washers into the planetary carrier. WARNING Observe the installation position! WARNING Position the rotation stop (tab) in the respective locking hole! Fig. 1901

30-422

Method of intervention 5.

Insert the planetary gear into the planetary carrier/between the thrust washers. Then centrically align the planetary gear and thrust washers and fix them with a planetary pin. WARNING Observe installation position of planetary pins. WARNING Planetary pins for double planetary gears have two oil holes!

6.

Fig. 1902

Install fixing plate. Fasten the fixing plate with countersunk screws. Tightening torque (M6/8.8): MA = 9.5 Nm WARNING Wet threads of countersunk screws with Loctite (Type # 649)! Fig. 1903

7.

Insert ball bearing into the planetary carrier until contact is obtained and fix it with a snap ring.

Fig. 1904

8.

Press needle sleeve into the sun gear until contact is obtained.

Fig. 1905

30-423

Method of intervention 9.

Mount planetary carrier to the sun gear until contact is obtained and fit spacer.

Fig. 1906

10.

Engage retaining ring into the annular groove of the sun gear.

Fig. 1907

11.

Install preassembled planetary drive until contact is obtained.

Fig. 1908

12.

Install bracket and fix it with tight-fit screws. Tightening torque: MA = 86 Nm WARNING To prevent seizing, DO NOT use an impact wrench to tighten the tight-fit screws!

Fig. 1909

30-424

Method of intervention 13.

Insert the ball bearing into the bracket until contact is obtained and fix it with a retaining ring.

Fig. 1910

14.

Insert ball bearing into the sun gear until contact is obtained.

Fig. 1911

15.

Setting of slotted nut (Next 2 figures) Mount washer (S) until contact is obtained. (S) Washer: 5.9035.462.0 WARNING For bearing setting, install the washer (S) instead of the locking plate!

Fig. 1912

16.

Bolt on and tighten the slotted nut. Tightening torque: MA = 10 +2 Nm Then loosen the slotted nut and remove the washer (S). (S) Slotted nut wrench 5.9035.456.0

Fig. 1913

30-425

Method of intervention 17.

Install locking plate and finally fix the slotted nut. Tightening torque: MA = 1.5 +1 Nm WARNING Fit slotted nut with the chamfer facing the planetary drive!

WARNING Wet thread of slotted nut with Loctite (Type # 243)! 18.

Fig. 1914

Secure slotted nut by means of a locking plate.

Fig. 1915

30.6.103 - Reassembly of P1/P2 planetary drive 1.

Use grease to fix the thrust washer into the clutch carrier. WARNING Observe the installation position! WARNING Fit thrust washer with the chamfer (On outer diameter) facing the clutch carrier! WARNING Slotted pin in the clutch carrier must be fixed in the hole of the thrust washer (Also see following sketch)!

2.

Legend to figure: 2.1. Clutch Carrier 2.2. Slotted Pin 2.3. Thrust Washer

Fig. 1916

1 2 3

Fig. 1917

30-426

Method of intervention 3.

Oil seal rings (2x, See arrows). Fit seal rings into the annular grooves of the central shaft.

Fig. 1918

4.

Press needle sleeves into the hollow shaft from both sides until contact is obtained.

Fig. 1919

5.

Fix needle sleeve with a snap ring.

Fig. 1920

6.

Install preassembled hollow shaft on the central shaft.

Fig. 1921

30-427

Method of intervention 7.

Press needle sleeves into the ring gear from both sides until contact is obtained.

Fig. 1922

8.

Install preassembled ring gear on the central shaft.

Fig. 1923

9.

Insert preassembled central shaft into the clutch carrier until contact is obtained.

Fig. 1924

10.

Install sun gear.

Fig. 1925

30-428

Method of intervention 11.

Preassemble planetary gears as shown in the Figure. Legend to figure: 11.1. 11.2. 11.3. 11.4.

Planetary Gear Needle Cage Planetary Gear (Double planetary gear) Spacer Sleeve

2 3

1

2 2 4

Fig. 1926

12.

Reassembly of single planetary gears (Next 2 figures) Use grease to fix the thrust washers into the planetary carrier. WARNING Observe the installation position! WARNING Position the rotation stop (tab) in the respective locking hole! Fig. 1927

13.

Insert the planetary gear into the planetary carrier/between the thrust washers. Then centrically align the planetary gear and thrust washers and fix them with a planetary pin. WARNING Observe installation position of planetary pins. WARNING Planetary pins for single planetary gears have only one oil hole!

14.

Fig. 1928

Reassembly of double planetary gears (Next 2 figures) Use grease to fix the thrust washers into the planetary carrier. WARNING Observe the installation position! WARNING Position the rotation stop (tab) in the respective locking hole! Fig. 1929

30-429

Method of intervention 15.

Insert the planetary gear into the planetary carrier/between the thrust washers. Then centrically align the planetary gear and thrust washers and fix them with a planetary pin. WARNING Observe installation position of planetary pins. WARNING Planetary pins for double planetary gears have two oil holes!

16.

Fig. 1930

Install fixing plate and fasten it with countersunk screws. Tightening torque (M6/8.8): MA = 9.5 Nm WARNING Wet threads of countersunk screws with Loctite (Type # 649)!

Fig. 1931

17.

Fit toothed washer and fix it with countersunk screws. Tightening torque (M5/8.8): MA = 5,5 Nm WARNING Wet threads of countersunk screws with Loctite (Type # 649)!

Fig. 1932

18.

Use grease to fix the thrust washer into the planetary carrier. WARNING Observe the installation position! WARNING Position the rotation stop (tab) in the locking hole!

Fig. 1933

30-430

Method of intervention 19.

Install planetary drive and fix it with retaining ring.

Fig. 1934

30.6.104 - Reassembly of P1 Ring gear carrier 1.

Heat inner ring and install it on the bearing flange until contact is obtained. WARNING Wet inner diameter with Loctite (Type # 649)! WARNING Adjust inner ring after cooling-down! WARNING Wear safety gloves!

2.

Fig. 1935

Press needle bearing into the bearing flange until contact is obtained.

Fig. 1936

3.

Insert slotted pin (See arrow) into the hole until contact is obtained.

Fig. 1937

30-431

Method of intervention 4.

Put on retaining ring (See arrow) and press ball bearing to contact position.

Fig. 1938

5.

Fix the ball bearing with a retaining ring.

Fig. 1939

6.

Install needle bearing.

Fig. 1940

7.

Heat tapered roller bearing and mount it until contact with the spur gear. WARNING Adjust tapered roller bearing after cooling-down! WARNING Wear safety gloves!

Fig. 1941

30-432

Method of intervention 8.

Press both bearing outer rings into the spur gear until contact position.

Fig. 1942

9.

Place spur gear onto the tapered roller bearing.

Fig. 1943

10.

Heat tapered roller bearing and mount it until contact is obtained. CAUTION Wear safety gloves!

Fig. 1944

11.

Setting of axial play: 0.01 mm. … 0.04 mm. (Next 4 figures) WARNING Bolt on slotted nut manually to contact position – DO NOT tighten it.

Fig. 1945

30-433

Method of intervention 12.

Position dial indicator at the spur gear and measure the axial play.

Fig. 1946

13.

Set axial play: 0.01 mm. … 0.04 mm. by turning the slotted nut. (S) Slotted nut wrench: 5.9035.455.0 Then recheck the axial play.

Fig. 1947

14.

After having set the axial play, secure slotted nut by fixing it into place.

Fig. 1948

15.

Insert the preassembled bearing flange into the spur gear and fix it with a retaining ring.

Fig. 1949

30-434

Method of intervention 16.

Engage snap ring into the annular groove of the spur gear.

Fig. 1950

17.

Use the screw driver to press the snap ring into the annular groove of the spur gear and mount the ring gear. WARNING Take care that the snap ring is exactly positioned! WARNING Engagement into the annular groove of the ring gear must be audible! Fig. 1951

18.

Use grease to fix the thrust washer into the bearing flange. WARNING Observe the installation position! WARNING Fit thrust washer with the chamfer (on outer diameter) facing the bearing flange (downwards)! WARNING

Fig. 1952

Slotted pin in the bearing flange must be fixed in the hole of the thrust washer (also see following sketch)! 19.

Legend to figure: 19.1. 19.2. 19.3.

Thrust Washer Slotted Pin Bearing Flange

1 2 3

Fig. 1953

30-435

Method of intervention 20.

Mount the preassembled ring gear carrier.

Fig. 1954

21.

Mount bracket to the bearing flange until contact position is obtained. Provisionally fix the bracket by hand with hexagon screws. Then fix bracket by means of tight-fit screws and hexagon screws. Tightening torque (tight-fit screws): MA = 86 Nm Tightening torque (M10/8.8): MA = 80 Nm WARNING To prevent seizing, tighten the tight-fit screws first. DO NOT use an impact wrench!

22.

Fig. 1955

Finally tighten hexagon screws for the bearing flange. Tightening torque (M10/8.8): MA = 46 Nm WARNING Wet thread with Loctite (Type # 243)!

Fig. 1956

30-436

Method of intervention 30.6.105 - Reinstallation of cartridge (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Insert slotted pin (see arrow) approx. 5 mm into the sleeve. Then mount sleeve to the output shaft until contact is obtained. IMPORTANT Pay attention that both holes overlap!

Fig. 1957

2.

Wet mounting surface (see 1) with sealing agent (Loctite type No.: 574). Then insert cylindrical pins (see 2) into the holes until contact is obtained.

1

2

3

Fig. 1958

3.

Use grease to fix O-rings (3x, see arrows) into the countersinks of the housing lid.

Fig. 1959

4.

Mount cartridge into the transmission housing by means of lifting tackle (S) and secure it with two hexagon screws. (S) Lifting hook: 5.9035.382.0

Fig. 1960

30-437

Method of intervention 5.

Remove lifting hook and fix cartridge by means of hexagon screws. Tightening torque (M12/10.9) MA = 115 Nm

Fig. 1961

6.

Shift sleeve onto sun gear and use assembly fixture (S) to fix slotted pin (also refer to the following sketch). (S) Assembly fixture: 5.9035.387.0 IMPORTANT Use of the specified assembly fixture ensures the exact installation position of the slotted pin!

Fig. 1962

7.

Legend: 1 = Pinion 2 = Sleeve 3 = Slotted pin 4 = Sun gear

1

2

3

4

Fig. 1963

8.

Provide sensor lid with new O-ring and install it. Tightening torque (M8/8.8) MA = 23 Nm

Fig. 1964

30-438

Method of intervention 9.

Wet mounting face with sealing agent (Henkel Terostat - MS 935 black DK 310, ZF order No.: 5.9035.482.0). Then provide hexagon screw with new seal ring and install cover. Tightening torque (M6/8.8) MA = 9.5 Nm

Fig. 1965

10.

Place the O-ring (see 1) into the annular groove of the filter housing and oil it. Then insert filter into the filter housing.

1

IMPORTANT Make sure that an O-ring is installed in the filter (see 2)!

2

Fig. 1966

11.

Bolt on the filter housing with filter and tighten it. Tightening torque MA = 40 +10 Nm

Fig. 1967

12.

Install screw plug. Tightening torque MA = 120 Nm

Fig. 1968

30-439

Method of intervention 30.6.106 - Reinstallation of Cartridge (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Insert slotted pin (See arrow) approx. 5 mm into the sleeve. Then mount sleeve to the output shaft until contact is obtained. WARNING Pay attention that both holes overlap!

Fig. 1969

2.

Wet mounting surface (See arrow 1) with sealing agent (Loctite Type # 574). Then insert cylindrical pins (See arrows 2) into the holes until contact is obtained.

1 2

2

Fig. 1970

3.

Use grease to fix O-Rings (3x, See arrows) into the countersinks of the housing lid.

Fig. 1971

4.

Mount cartridge into the transmission housing by means of lifting tackle (S) and secure it with two hexagon screws. (S) Hook: 5.9035.382.0

Fig. 1972

30-440

Method of intervention 5.

Remove hook and fix cartridge by means of hexagon screws. Tightening torque (M12/10.9): MA = 115 Nm

Fig. 1973

6.

Shift sleeve onto sun gear. Use assembly fixture (S) to fix slotted pin (Also refer to the following figure). (S) Assembly fixture: 5.9035.387.0 WARNING Use of the specified assembly fixture ensures the exact installation position of the slotted pin!

Fig. 1974

7.

Legend to figure: 7.1. 7.2. 7.3. 7.4.

Pinion Sleeve Slotted Pin Sun Gear

2 3 1

4

Fig. 1975

8.

Provide sensor cover with new O-Ring and install it. Tightening torque (M8/8.8): MA = 23 Nm

Fig. 1976

30-441

Method of intervention 9.

Wet mounting face with proper sealing agent. Then provide hexagon screw with new seal ring and install cover. Tightening torque (M6/8.8): MA = 9.5 Nm

Fig. 1977

10.

Place the O-Ring (See arrow 1) into the annular groove of the filter housing and oil it. Then insert filter into the filter housing. CAUTION Make sure that an O-Ring is installed in the filter (See arrow 2)!

1 2 Fig. 1978

11.

Bolt on the filter housing with filter and tighten it. Tightening torque: MA = 40 +10 Nm

Fig. 1979

12.

Fit stud bolts (2x, See arrows) into the housing lid. Tightening torque: MA = 9 Nm WARNING Wet threads of stud bolts with Loctite (Type # 243)!

Fig. 1980

30-442

Method of intervention 13.

Use grease to fix the seal rings (See arrows) into the countersinks of the valve block.

Fig. 1981

14.

Fix preassembled valve block to the housing lid by means of hexagon nuts. Tightening torque: MA = 23 Nm

Fig. 1982

15.

Oil the O-Ring and install them into the annular grooves of the directional valve. Fasten the directional valve to the valve block by means of fixing plate and cylindrical screw. Tightening torque: MA = 23 Nm

Fig. 1983

16.

Connect plugs directional valve/wiring harness. Fasten wiring harness by means of cable clips (See arrows).

Fig. 1984

30-443

Method of intervention 30.6.107 - Fitting of rear axle to the transmission (7230 TTVAgrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Remove the transmission from the assembly truck and lay it down on a H.D. (Heavy-Duty) pallet. (S) Eyebolts (M12): 5.9035.377.0 (S) Eyebolt (M18): 5.9035.378.0

Fig. 1985

2.

Mount input shaft into the PTO clutch until contact is obtained. Install cylindrical pins (2x, See arrows).

Fig. 1986

3.

Mount two locating pins (S, See arrows). (S) Locating pin: 5.9035.197.0 WARNING Wet mounting face (See arrow) with Loctite (Type # 574)!

Fig. 1987

4.

Use a lifting tackle (S) to bring the rear axle into contact position with the transmission. Fix rear axle by means of hexagon screws. Tightening torque (M14/10.9): MA = 185 Nm (S) Eyebolts (M12): 5.9035.377.0

Fig. 1988

30-444

Method of intervention 30.6.108 - Pipes and closing components (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Pipes 1.

Install all pipes (See figure)

Fig. 1989

Closing components 1.

Tightening torques of mounted screw plugs:

Table 354 Screw

Typology

M 12 x 1.5 M 14 x 1.5 M 18 x 1.5 M 22 x 1.5 M 26 x 1.5 M 33 x 2.0 M 56 x 2.0

Tightening torques Tightening torques Tightening torques Tightening torques Tightening torques Tightening torques Tightening torques

Torque

MA = 35 Nm MA = 40 Nm MA = 50 Nm MA = 60 Nm MA = 80 Nm MA = 120 Nm MA = 160 Nm

WARNING Tightening torques are not applicable for screw plugs in the shift and control area. WARNING Please refer to the related chapters!

30-445

Method of intervention 30.7 - E0 - Rear axle

30.7.1 - Removing the axle housing (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Fasten the rear axle to the assembly trolley. (S) Assembly trolley: 5.9035.193.0 (S) Housing: 5.9035.194.0

Fig. 1990

2.

Fasten the axle housing with suitable lift equipment and loosen the union. Remove the axle housing and the ring gear. (S) Upper holes (M12): 5.9035.377.0 WARNING Support the weight of the axle housing on the opposite side.

Fig. 1991

3.

Loosen the threaded pin. Remove the planet gear carrier from the rear half axle once it is free using suitable lift equipment.

Fig. 1992

4.

Remove the circlip.

Fig. 1993

30-446

Method of intervention 5.

Remove the planet gear from the planet gear carrier using the two arm extractor tool.

Fig. 1994

6.

Remove the circlips on both sides. Remove the cylindrical roller bearing together with the shoulder rings once it is free.

Fig. 1995

7.

Loosen the ring nut. (S) Ring nut wrench: 5.9035.474.0

Fig. 1996

8.

Remove the axle housing from the rear half axle using the two arm extractor. Remove the tapered roller bearing once it is free.

Fig. 1997

30-447

Method of intervention 9.

If necessary, push the two outer bearing races out of the axle housing.

Fig. 1998

10.

Remove the tapered roller bearing from the rear half shaft. (S) Gripper tool: 5.9035.475.0

Fig. 1999

11.

Remove the seal ring from the shaft. (S) Assembly lever: 5.9035.203.0

Fig. 2000

30-448

Method of intervention 30.7.2 - Removing brakes (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Loosen the hexagonal nuts. Remove the disc.

Fig. 2001

2.

Remove the split pin (1), remove the disc and disconnect the tie-rod (2). Disconnect the tensioner spring (3) and fold the actuator mechanism upwards.

2 1 3

Fig. 2002

3.

Remove the line (bleed). Loosen the cylindrical head screws and remove the actuator mechanism

Fig. 2003

4.

Remove the centre pinion shaft. If necessary, remove the rectangular section rings and the O-ring.

Fig. 2004

30-449

Method of intervention 5.

Loosen the hexagonal head screws. Push the brake plate out of the rear axle housing using a service screw (S). (S) Service screw (M16): 5.9035.438.0 If necessary, remove the shaft seal ring.

Fig. 2005

6.

Remove the outer disc pack.

Fig. 2006

7.

Remove the brakes and the inner disc pack. WARNING When pulling the tie-rod back towards the rubber bush, take care not to damage the rubber bush with the thread of the tie-rod (cover the thread of the tie-rod with adhesive tape, or take other adequate precautions).

Fig. 2007

8.

If necessary, remove the split pin (see arrow), remove the pins and remove the tie-rod. WARNING No further disassembly of the brakes is possible. The brakes are safety components and are supplied as complete assemblies.

Fig. 2008

30-450

Method of intervention 9.

Check that the rubber bush (see arrow) is undamaged. Lift out of the hole if necessary.

Fig. 2009

30.7.3 - Removing the differential (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Remove the lubrication line (see arrow) for the ring gear.

Fig. 2010

2.

Loosen the hexagonal head screws. Remove the stop bracket once it is free. WARNING Perform the step shown in figures 2 … 3 on both sides.

Fig. 2011

3.

Loosen the adjustment screw. (S) Socket wrench: 5.9035.185.0

Fig. 2012

30-451

Method of intervention 4.

Push the differential towards the right (arrow) with an assembly lever (S). (S) Assembly lever: 5.9035.203.0 WARNING Support the differential (see figure). Then remove the right outer bearing race and lift the differential from the rear axle housing.

Fig. 2013

5.

Remove the two roller bearings. (S) Gripper tool: 5.9035.476.0 (S) Base tool: 5.9035.293.0

Fig. 2014

6.

Fasten the differential with a press. Loosen the connection.

Fig. 2015

7.

Separate the compensation chamber, complete with the piston (1) and the ring gear (2), from the differential case (3). Push the piston out of the compensation chamber with compressed air.

3 2

1

Fig. 2016

30-452

Method of intervention 8.

Remove the retainer ring, disc pack and axle pinion.

Fig. 2017

9.

Remove the spring pins (x4).

Fig. 2018

10.

Remove the compensation axles. Remove the compensation pinions together with the shoulder rings as they are free.

Fig. 2019

11.

Remove the axle pinion and the retainer ring.

Fig. 2020

30-453

Method of intervention 30.7.4 - Removing the PTO (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Loosen the pressure regulator nut. Remove the coil once it is free. WARNING Take care not to loose the O-rings when they are released!

Fig. 2021

2.

Remove the base of the pressure regulator.

Fig. 2022

3.

Remove suspension plate (x4). Remove suspension plate (x4). Remove the solenoid valves (x4).

Fig. 2023

4.

Loosen the cylindrical head screw. Remove the speed transducer.

Fig. 2024

30-454

Method of intervention 5.

Secure the cover to a lifting tool. (S) Suspension ring: 5.90XX.XXX.X Loosen the assembly fastened with screws.

Fig. 2025

6.

Separate the cover together with the PTO engagement clutch from the rear axle housing. (S) Assembly lever: 5.9035.203.0 WARNING Take care not to loose the O-rings when they are released!

Fig. 2026

7.

Fasten the cover to the assembly trolley. (S) Assembly trolley: 5.9035.193.0 (S) Angular gear: 5.9035.281.0

Fig. 2027

8.

Push the two spring pins into the piston until the control fork is free.

Fig. 2028

30-455

Method of intervention 9.

Loosen the hole blanking screw. Using magnets, remove the spacer, the spring guide and the thrust spring as they are released via the hole in the cover.

Fig. 2029

10.

Extract the piston until the O-ring (see arrow) is visible. Remove the O-ring from the ring groove. Then remove the piston completely via the hole in the cover and from the control fork.

Fig. 2030

11.

Remove the O-ring (see arrow). Push the two spring pins out of the hole in the piston.

Fig. 2031

12.

Remove the clutch housing.

Fig. 2032

30-456

Method of intervention 13.

Remove the tapered roller bearings from the clutch housing. (S) Gripper tool: 5.9035.417.0 (S) Base tool: 5.9035.215.0

Fig. 2033

14.

Remove the outer bearing race (see arrow).

Fig. 2034

15.

Lift the clutch, together with the control fork, out of the cover. Remove the control fork complete with sliders.

Fig. 2035

16.

Remove the needle roller bearing. Remove the roller bearings from the clutch shaft. (S) Gripper tool: 5.9035.283.0 (S) Base tool: 5.9035.215.0

Fig. 2036

30-457

Method of intervention 17.

Compress the thrust springs on the disc carrier with a press. Remove the circlip. (S) Thrust bush: 5.9030.971.0

Fig. 2037

18.

Remove the disc carrier from the disc pack.

Fig. 2038

19.

Remove the disc and the disc pack.

Fig. 2039

20.

Remove the thrust springs from the piston.

Fig. 2040

30-458

Method of intervention 21.

Remove the piston together with the thrust plate from the clutch shaft.

Fig. 2041

22.

Remove the circlip.

Fig. 2042

23.

Push the piston out of the thrust plate. (S) Thrust bush: 5.9030.971.0 (S) Magnet mount: 5.9035.285.0

Fig. 2043

24.

Remove the seal lip ring (see arrow).

Fig. 2044

30-459

Method of intervention 25.

Remove the two rectangular section rings and remove the seal lip ring (see arrows).

Fig. 2045

26.

Remove the tapered roller bearings from the clutch shaft. Remove the retainer ring. (S) Gripper tool: 5.9035.326.0 (S) Base tool: 5.9035.320.0

Fig. 2046

27.

Remove: the face gears, sleeve, sleeve mount and needle roller bearings.

Fig. 2047

28.

Remove the outer bearing race through the bearing hole, pulling out with the lever.

Fig. 2048

30-460

Method of intervention 29.

Remove the thrust spring. Remove the spring guide and the spacer via the hole in the cover using magnets.

Fig. 2049

30.

Remove the O-ring (see arrow). Push the two spring pins into the piston until the control fork is free.

Fig. 2050

31.

Remove the control fork complete with sliders and the sleeve.

Fig. 2051

32.

Remove the spring pin. Remove the piston.

Fig. 2052

30-461

Method of intervention 33.

Remove the thrust spring, the spring guide and the spacer via the hole in the cover using magnets.

Fig. 2053

34.

Remove the block.

Fig. 2054

35.

Remove the hole blanking screws (see arrows).

Fig. 2055

36.

Loosen the hole blanking screw. Remove the thrust spring and the pins.

Fig. 2056

30-462

Method of intervention 37.

Loosen the hexagonal head screws. (S) Assembly lever: 5.9035.203.0

Fig. 2057

38.

Fit the fastener fork (S). (S) Fastener fork: 5.9035.286.0

Fig. 2058

39.

Loosen the ring nut. (S) Ring nut wrench: 5.9035.287.0

Fig. 2059

40.

Remove the fastener fork (S), the flange and the PTO.

Fig. 2060

30-463

Method of intervention 41.

Loosen the cylindrical head screws Remove the console.

Fig. 2061

42.

Remove the roller bearings from the PTO. (S) Gripper tool: 5.90XX.XXX.X (S) Base tool: 5.9035.215.0

Fig. 2062

43.

Remove the sleeve mount, roller bearings and face gear.

Fig. 2063

44.

Remove the face gears.

Fig. 2064

30-464

Method of intervention 45.

Push the PTO out of the bearing seat. WARNING Take care not to drop the PTO when it is free.

Fig. 2065

46.

Remove the outer circlip of the bearings and the shaft seal ring (see arrows).

Fig. 2066

47.

Remove the outer bearing races (see arrows) from the rear axle housing.

Fig. 2067

30-465

Method of intervention 30.7.5 - Removing the oil feed (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Remove the lines. If necessary, remove the threaded connectors.

Fig. 2068

2.

Loosen the hexagonal head screws. Remove the valve block once it is free.

Fig. 2069

3.

Remove the line (see arrow).

Fig. 2070

4.

Loosen the nut. Remove the coil. WARNING Take care not to loose the O-rings when they are released!

Fig. 2071

30-466

Method of intervention 30.7.6 - Removing the lifter (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Remove the split pin (1), remove the disc and disconnect the pins (2). Loosen the fastener securing the brake bleed pipe to the bearing mount. WARNING Perform on both sides.

1 2

Fig. 2072

2.

Loosen the hexagonal head screws and remove the entire lifter, complete with brake shaft, using suitable lift equipment.

Fig. 2073

3.

Remove the two spring pins. Remove the ring once it is free, and the Bowden cable.

Fig. 2074

4.

Separate the bearing mount, the lifter shaft and the brake shaft. If necessary, remove the bush and the sliding bearing from the bearing mounts.

Fig. 2075

30-467

Method of intervention 5.

Loosen the hexagonal head nut and remove the tie-rods.

Fig. 2076

30.7.7 - Fitting lifter, oil feed and blanking elements (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Preassemble the rear axle housing as shown in the figure aside. 1.1. Bush 1.2. Bushes 1.3. Ventilation valve MA = hand tighten 1.4. Hole blanking screw MA= 100 Nm 1.5. Hole blanking screw MA= 120 Nm 1.6. Oil level indicator MA= 2 Nm 1.7. Stud bolt MA = 23 Nm

3 5

2

1 6 7 7 7 5

5

1

4

2

Fig. 2077

WARNING Moisten the thread of the stud bolts with Loctite 243!

30.7.8 - Fitting the lifter (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Press-fit the bush fully into the bearing mount. Fit the sliding bearing (see arrow 1) flush with the surface. Fit the grease nipple (see arrows 2 and 3) (see figure for correct installation position). WARNING

1

Grease the inner diameter of the bush after fitting!

2 3 Fig. 2078

30-468

Method of intervention 2.

Fit the bush (see arrow) into the lifter shaft. WARNING The inner diameter of the bush must be level with the milled line on the lifter shaft (also see following figure).

Fig. 2079

3.

In figure: 3.1. Lifter shaft 3.2. Milled line 3.3. Bush

3 2

1

Fig. 2080

4.

Fit the pins in the brake shaft. Fit the tie-rod through the pins, fit the pipe and tighten the hexagonal head nut. 4.1. 4.2. 4.3. 4.4. 4.5.

Brake shaft Tie-rod Pins Line Hexagonal head nut WARNING

3

5 4

5

1 4 2

3

2

In general, use only new hexagonal head nuts for assembly. Fig. 2081

5.

Fit the O-rings (x2, see arrows) on the lifter shaft. Then fit the bearing mounts and the brake shaft.

Fig. 2082

30-469

Method of intervention 6.

Fit the ring (arrow 1) and the Bowden cable (arrow 2) on the brake shaft and fasten with spring pins. 2

1

Fig. 2083

7.

Using suitable lift equipment, bring the lifter into the correct assembly position and fasten with hexagonal head screws. Torque (M20/10.9): MA= 560 Nm

Fig. 2084

8.

Fasten the tie-rod (1) onto the actuator mechanism with pins (2). Fit the disc (3) and fasten with the split pin (4).

1 2

4

3 Fig. 2085

30-470

Method of intervention 30.7.9 - Fitting the oil feed (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Fit the O-ring and the coil (see arrow).

Fig. 2086

2.

Fit the nut with an O-ring (see arrow). Torque: MA= 4 Nm

Fig. 2087

3.

Fasten the line on the valve block. Torque (threaded connectors): MA= 30 Nm Torque (sleeve nut): MA= 45 Nm

Fig. 2088

4.

Fit the valve block. Torque (M8/8.8): MA = 23 Nm WARNING Moisten the thread with Loctite 243!

WARNING Moisten the contact surfaces with Loctite 574!

Fig. 2089

30-471

Method of intervention 5.

Fit the oil lines: Pos. 1 Torque (Banjo bolt):

1 2

MA= 40 Nm Torque (sleeve nut):

6 5 3

MA= 45 Nm Pos. 2 Torque (threaded connectors): MA = 25 Nm Torque (sleeve nut): MA= 45 Nm Pos. 3 Torque (threaded connectors, valve block): MA= 50 Nm Torque (threaded connectors, rear axle housing): MA= 35 Nm Torque (sleeve nut): MA= 80 Nm Pos. 4 Torque (threaded connectors, valve block): MA= 50 Nm Torque (threaded connectors, rear axle housing): MA= 35 Nm Torque (sleeve nut): MA= 80 Nm Pos. 5 Torque (threaded connectors): MA = 25 Nm Torque (sleeve nut): MA= 45 Nm Pos. 6 Torque (threaded connectors): MA = 25 Nm Torque (sleeve nut):

30-472

4

Fig. 2090

Method of intervention 30.7.10 - Fitting blanking elements (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Torque of hole blanking screws (where not specified otherwise):

Table 355 M10×1.0 M22×1.5 M30×1.5 M33×2.0 M38×1.5

Torque Torque Torque Torque Torque

MA = 20 Nm MA= 60 Nm MA= 100 Nm MA= 120 Nm MA= 140 Nm

Fig. 2091

30.7.11 - Fitting the PTO (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Fitting the PTO transmission 1.

Fit the shaft seal ring (see arrow) fully into its seat in the hole in the cover. (S) Installation tool: 5.9035.311.0 (S) Handle: 5.9035.222.0 WARNING Moisten the outer diameter of the shaft seal ring with alcohol immediately before fitting. WARNING Fill the gap between the dust seal lip and the seal lip with grease.

2.

Fig. 2092

Fit the outer bearing race. (S) Installation tool: 5.9035.312.0 (S) Handle: 5.9035.222.0

Fig. 2093

3.

Fit the PTO in the hole from below. Install the heated roller bearing fully in its seat. WARNING Wear protective gloves!

Fig. 2094

30-473

Method of intervention 4.

Fit the face gear. WARNING Ensure that the gear is installed correctly as shown in the figure!

Fig. 2095

5.

Fit the face gear. WARNING Ensure that the gear is installed correctly as shown in the figure!

Fig. 2096

6.

Fit the face gear and the needle roller bearing. WARNING Ensure that the gear is installed correctly as shown in the figure!

Fig. 2097

7.

Fit the sleeve mount.

Fig. 2098

30-474

Method of intervention 8.

Heat the roller bearings. Install the roller bearings fully in their seats. WARNING Wear protective gloves!

Fig. 2099

9.

Fit the fastener fork (S). (S) Fastener fork: 5.9035.286.0

Fig. 2100

10.

Fit the ring nut. Torque: MA= 600 Nm (S) Ring nut wrench: 5.9035.287.0

Fig. 2101

11.

Secure the ring nut by caulking the circumference.

Fig. 2102

30-475

Method of intervention 12.

Bring the two inner bearing races into contact with the pinion using a two arm extractor tool. WARNING Pressing on the PTO bring the two inner bearing races into contact with the pinion.

Fig. 2103

13.

Adjust the bearing endfloat to a value between 0.05 and 0.10 mm: Fit the outer bearing race.

Fig. 2104

14.

Measure the distance I from the front surface of the outer bearing race to the flange mating surface of the cover. Measurement I (example) = 187.70 mm (S) Final measurements: 5.9035.316.0 (S) Measurement calliper: 5.9035.229.0 WARNING Measure at different points and calculate the average value!

Fig. 2105

15.

Measure the distance II from the flange mating surface of the rear axle housing to the contact surface of the shim. Calculation example: (Measurement II) 190.50 mm (Measurement I) 187.70 mm = -------------------------------------------------------(Difference) 2.80 mm (Bearing endfloat 0.05 ... 0.10 mm) 0.10 mm -------------------------------------------------------(Result = shim) S = 2.70 mm Fig. 2106

30-476

Method of intervention 16.

Fit the shim of the calculated thickness (e.g. 2.70 mm) in the bearing hole. Bring the outer bearing race back into contact.

Fig. 2107

17.

Fasten the PTO and the flange with hexagonal head screws. Torque (M12/12.9): MA= 135 Nm

Fig. 2108

18.

Fit the cylindrical pins (see arrow) fully into their seats in the console.

Fig. 2109

19.

Fit the console. Torque (M8/8.8): MA = 23 Nm

Fig. 2110

30-477

Method of intervention Fit the hydraulic PTO clutch 1.

Adjust the actuating travel of the disc pack to 5.75 mm. (-0.4) (figures 01 … 13): In figure: 1.1. 1.2. 1.3. 1.4. 1.5. 1.6. 1.7.

Clutch shaft Piston Circlip Thrust plate End washer Disc carrier Circlip

“X”

5

4 3

6

2

1 7

“ 5,75 - 0,40 ”

Fig. 2111

2.

Heat the thrust plate. Install the piston fully into its seat. WARNING Assemble the parts by forcibly with the thrust plate heated to a maximum temperature of 150°C, and with a maximum temperature difference of 90°C between the parts! WARNING Wear protective gloves! Fig. 2112

3.

Fasten with a circlip.

Fig. 2113

4.

Push the piston, preassembled with the thrust plate, fully into its seat on the clutch shaft. WARNING Temporarily fit all the components without seals in order to measure actuation travel.

Fig. 2114

30-478

Method of intervention 5.

Place the thrust springs (x3) at 120° from one another on the thrust plate.

Fig. 2115

6.

Fit the end washer, bringing it into contact with the disc carrier.

Fig. 2116

7.

Fit the pre-assembled disc carrier.

Fig. 2117

8.

Compress the thrust springs with a press. Install the circlip in the ring seat on the clutch shaft. (S) Thrust bush: 5.9030.971.0

Fig. 2118

30-479

Method of intervention 9.

Measure the dimension X (also see figure 01). Measurement X (example) = 44.65 mm

Fig. 2119

10.

Remove the circlip and remove all the components. (S) Thrust bush: 5.9030.971.0 WARNING Keep the thrust plate and the piston assembled (figures 02 and 03).

Fig. 2120

11.

Measure the dimension Y (thickness of entire disc pack): Check measurement A (total measurement of all inner discs). Thickness of individual inner disc (example) s = 2.80 mm Thickness of all inner discs - measurement A (example) s = 16.80 mm WARNING The inner discs are corrugated and cannot be measured in the pack. Fig. 2121

12.

Measure dimension B (total measurement of all outer discs). Thickness of individual outer disc (example) s = 2.70 mm Thickness of all outer discs - measurement B (example) s = 18.90 mm Calculation example: (Measurement A) 16.80 mm + (Measurement B) 18.90 mm = -------------------------------------------------------(within measurement Y, for example) 35.70 mm Fig. 2122

30-480

Method of intervention 13.

14.

As an alternative to measuring the individual discs, the thickness of the disc pack may be measured using a press and a load cell. Apply an axial force F of 4500 ± 4500 N to the disc pack (without spring washers) and measure the dimension II (thickness of entire disc pack). Measurement Y (example) = 35.70 mm (S) Load cell: 5.9035.236.0 Calculation example: (Measurement X) 44.70 mm. (Measurement Y) 35.70 mm = -------------------------------------------------------(Difference) 9.00 mm (Actuating travel 5.75 –0.4 mm) 5.50 mm = -------------------------------------------------------(Result = adjuster washer) s = 3.50 mm

Fig. 2123

Fit the fastener device (part 1) in the disc carrier. Fit the adjuster washer of the thickness calculated, e.g. s = 3.50 mm. (S) Fastening tool: 5.9035.237.0

Fig. 2124

15.

Fit the end washer.

Fig. 2125

16.

Fit the spring washer. WARNING See the current spare parts catalogue for the correct disc order.

Fig. 2126

30-481

Method of intervention 17.

Place the outer disc on the spring washer.

Fig. 2127

18.

Fit the inner disc (corrugated). WARNING When fitting corrugated inner discs, observe the installation instructions given in figure 19.

Fig. 2128

19.

WARNING The inner discs are corrugated and must be installed with the corrugated sides facing one another. In other terms, the inner discs must be installed in layers with the gaps between the teeth of one disc facing the gaps on the other disc. The half teeth (see arrows) must be positioned on the left and right hand sides of the gap in alternation.

Fig. 2129

20.

Oil the seal lip ring (see arrow) and fit into the ring groove on the piston. WARNING Ensure that the gear is installed correctly as shown in the following figure!

Fig. 2130

30-482

Method of intervention 21.

In figure: 21.1. 21.2. 21.3. 21.4. 21.5. 21.6. 21.7.

Seal lip ring Piston Thrust plate Disc pack End washer Disc carrier Thrust springs

2

1

3

4

5

6

7

Fig. 2131

22.

Fit the thrust springs (every 2 parts/hole) into the holes in the piston pocket using grease.

Fig. 2132

23.

Fit the piston preassembled with the thrust plate into the disc carrier.

Fig. 2133

24.

Fit part 2 of the fastening tool. Compress the disc pack (via the piston and thrust plate) with a press, then fasten by tightening the wing nuts.

Fig. 2134

30-483

Method of intervention 25.

Oil the seal lip ring (see arrow) and fit into the ring groove on the clutch shaft. WARNING Ensure that the components are assembled in the correct positions. WARNING Orient the groove on the front side upwards (facing towards the chamber). Fig. 2135

26.

Fit the preassembled clutch assembly on the clutch shaft and fasten with a circlip.

Fig. 2136

27.

Compress the clutch assembly with a press. Remove the fastening tool (S).

Fig. 2137

28.

Check that the actuating travel of the disc pack is 5.75 mm -0.4: Apply an axial force F of 4500 + 4500 N to the clutch shaft. (S) Load cell: 5.9035.236.0 WARNING If the specified actuating travel of 5.75 mm -0.4 is not reached, this means that an error was made when determining the measurement of the adjuster washer (figure 01 … 14). WARNING This error must be corrected before continuing!

30-484

Fig. 2138

Method of intervention 29.

Fit the heated roller bearing fully into its seat on the clutch shaft. WARNING Reposition the roller bearing correctly once cooled! WARNING Wear protective gloves!

Fig. 2139

30.

Fit the face gear and the needle roller bearing.

Fig. 2140

31.

Fit the sleeve mount fully into its seat. WARNING Ensure that the components are assembled in the correct positions. WARNING Fit the sleeve mount with the high collar (see arrow) facing upwards. Fig. 2141

32.

Fit the sleeve (see arrow). Fit the needle roller bearing onto the sleeve mount.

Fig. 2142

30-485

Method of intervention 33.

Fit the face gear (arrow 1) and the retainer ring (arrow 2). Fit the heated roller bearing fully into its seat.

2

WARNING Reposition the roller bearing correctly once cooled! WARNING

1

Wear protective gloves! Fig. 2143

34.

Grease the ring seats on the clutch shaft. Install the rectangular section rings (see arrow) in the ring seats on the clutch shaft, then fasten in place.

Fig. 2144

35.

Fit the roller bearings.

Fig. 2145

36.

Fit the outer bearing race (see arrow) in the clutch housing.

Fig. 2146

30-486

Method of intervention 37.

Fit the clutch housing (see arrow). Fit the heated roller bearing fully into its seat. WARNING Reposition the roller bearing correctly once cooled! WARNING Wear protective gloves! Fig. 2147

38.

Fit the outer bearing race (see arrow) fully into its seat.

Fig. 2148

Fitting the hydraulic PTO clutch 1.

Adjust the endfloat of the PTO clutch to a value between 0.05 and 0.10 mm: Fit the preassembled clutch. Fit the outer bearing race (see arrow). WARNING To ensure that the clutch is fitted in precisely the correct position, the measurements must be made without the PTO brake fitted.

Fig. 2149

2.

Measure the distance “I” from the front surface of the outer bearing race to the flat surface. Measurement I (example) = 256.65 mm (S) Final measurements: 5.9035.316.0 (S) Measurement calliper: 5.9035.229.0 Then lift the clutch off the cover again. WARNING Measure at different points and calculate the average value!

Fig. 2150

30-487

Method of intervention 3.

Measure the distance II from the flange mating surface of the rear axle housing to the contact surface of the shim. Measurement II (example) = 258.10 mm Calculation example: (Measurement II) 258.10 mm (Measurement I) 256.65 mm = -------------------------------------------------------(Difference) 1.45 mm (Endfloat 0.05 ... 0.10 mm) 0.07 mm. = -------------------------------------------------------(Result = shim) s = 1.38 mm

4.

Fig. 2151

Fit the shim of the calculated thickness (e.g. 1.38 mm) in the bearing hole. Fit the outer bearing race fully into its seat.

Fig. 2152

5.

Fit the circlip in the ring seat on the pin.

Fig. 2153

6.

Fit the preassembled pins and the thrust spring.

Fig. 2154

30-488

Method of intervention 7.

Fit the hole blanking screw with a new O-ring. Torque: MA = 60 Nm.

Fig. 2155

8.

Fit the sliders (see arrow) in the control fork using grease.

Fig. 2156

9.

Move the preassembled control fork into the correct position. WARNING Ensure that the gear is installed correctly as shown in the figure!

Fig. 2157

10.

Lift the clutch, together with the control fork, into the cover.

Fig. 2158

30-489

Method of intervention 11.

Fit the oiled O-ring (see arrow) into the ring groove on the piston.

Fig. 2159

12.

Insert the piston into the hole in the cover and into the control fork until the lower ring groove (also see following figure) can no longer be seen. WARNING Hold the control fork in the upper position (see arrow).

Fig. 2160

13.

Fit the oiled O-ring (see arrow) into the ring groove on the piston. Move the piston into the correct position. WARNING Align the holes in the control fork and in the piston.

Fig. 2161

14.

Fit the two spring pins (see arrow). WARNING The gaps in the spring pins must be aligned along the direction of the force and spaced at 180° from one another! WARNING Remove the control fork mount.

Fig. 2162

30-490

Method of intervention 15.

Adjust the selection travel of the control fork: Remove the clutch housing. Bring the clutch precisely into contact using a two arm extractor tool. WARNING This step is necessary to compensate for the pressure exerted by the PTO brake against the clutch. Adjust the control fork at a PTO rotation speed of 1000 rpm in normal mode (figure 16...21) Fig. 2163

16.

S = A – B – C + 0.2 Lift the control fork together with the sleeve, maintaining contact with the face gear. Measure the distance A from the contact surface of the hole blanking screw to the front surface of the piston. Measurement A (example) = 21.27 mm (S) Final measurements: 5.9035.316.0 (S) Measurement calliper: 5.9035.229.0

Fig. 2164

17.

Measure distance B from the front surface to the collar of the hole blanking screw. Measurement B (example) = 16.03 mm

Fig. 2165

18.

Measure dimension C, the width of the spring guide collar. Measurement B (example) = 4.94 mm Calculation example: (Measurement A) 21.27 mm (Measurement B) 16.03 mm (Measurement C) 4.94 mm = -------------------------------------------------------(Difference) 0.30 mm + (Correction value) 0.20 mm = -------------------------------------------------------(Result = adjuster washer) s = 0.50 mm

Fig. 2166

30-491

Method of intervention 19.

Fit the thrust spring and the spring guide.

Fig. 2167

20.

Fit the shim of the calculated thickness (e.g. 0.50 mm).

Fig. 2168

21.

Fit the hole blanking screw with a new O-ring. Torque: MA= 140 Nm

Fig. 2169

22.

Adjust the control fork at a PTO rotation speed of 540 rpm in ECO mode (figure 22...27) S = A – B – C + 0.2 Lift the control fork together with the sleeve, maintaining contact with the face gear. Measure the distance A from the contact surface of the hole blanking screw to the front surface of the piston. Measurement A (example) = 23.00 mm (S) Final measurements: 5.9035.316.0 (S) Measurement calliper: 5.9035.229.0

30-492

Fig. 2170

Method of intervention 23.

Measure distance B from the front surface to the collar of the hole blanking screw. Measurement B (example) = 16.03 mm

Fig. 2171

24.

Measure dimension C, the width of the spring guide collar. Measurement B (example) = 4.92 mm Calculation example: (Measurement A) 22.80 mm (Measurement B) 16.03 mm (Measurement C) 04.92 mm = -------------------------------------------------------(Difference) 2.05 mm + (Correction value) 0.20 mm = -------------------------------------------------------(Result = adjuster washer) s = 2.05 mm

25.

Fig. 2172

Fit the thrust spring and the spring guide.

Fig. 2173

26.

Fit the shim of the calculated thickness (e.g. 2.05 mm).

Fig. 2174

30-493

Method of intervention 27.

Fit the hole blanking screw with a new O-ring. Torque: MA= 140 Nm

Fig. 2175

28.

Fit the speed transducer with a new, oiled O-ring. Torque: MA = 23 Nm

Fig. 2176

29.

Fit the block (see arrow).

Fig. 2177

30.

Fit the sliders (see arrow) in the control fork using grease.

Fig. 2178

30-494

Method of intervention 31.

Fit the sleeve.

Fig. 2179

32.

Fit the piston and the control fork.

Fig. 2180

33.

Fit the spring pin.

Fig. 2181

34.

Fit the spring pins (see arrow). WARNING The gaps in the spring pins must be aligned along the direction of the force and spaced at 180° from one another!

Fig. 2182

30-495

Method of intervention 35.

Fit the oiled O-ring (see arrow) into the ring groove on the piston.

Fig. 2183

36.

Adjust the control fork at a PTO rotation speed of 1000 rpm in ECO mode (figure 36...42) S = A – B – C + 0.2 Hold the control fork in contact with the sleeve and the face gears using the piston. Measure the distance A from the contact surface of the hole blanking screw to the front surface of the piston. Measurement A (example) = 21.98 mm Fig. 2184

37.

Measure distance B from the front surface to the collar of the hole blanking screw. Measurement B (example) = 16.05 mm

Fig. 2185

38.

Measure dimension C, the width of the spring guide collar. Measurement B (example) = 4.93 mm Calculation example: (Measurement A) 21.98 mm (Measurement B) 16.05 mm (Measurement C) 04.93 mm = -------------------------------------------------------(Difference) 1.00 mm + (Correction value) 0.20 mm = -------------------------------------------------------(Result = adjuster washer) s = 1.20 mm

30-496

Fig. 2186

Method of intervention 39.

Fit the thrust spring and the spring guide.

Fig. 2187

40.

Fit the shim of the calculated thickness (e.g. 1.20 mm).

Fig. 2188

41.

Fit the hole blanking screw with a new O-ring. Torque: MA= 140 Nm

Fig. 2189

42.

Remove the two arm extractor tool. Fit the clutch housing.

Fig. 2190

30-497

Method of intervention 43.

Fit the cylindrical pins (see arrows) into the cover, protruding by approximately 5 mm.

Fig. 2191

44.

Affix the O-rings (see arrows) in the recesses on the rear axle housing with grease.

Fig. 2192

45.

Fit the two fastener pins (S). Bring the cover into contact with the rear axle housing using a lifting tool. (S) Fastener pins 5.9035.271.0 (S) Suspension ring: 5.90XX.XXX.X WARNING Moisten the contact surfaces with Loctite 574! Refit the cylindrical pins fully into their seats. Fig. 2193

46.

Fasten the cover with screws, removing the fastener pins (S). Torque (M12/8.8): MA= 79 Nm Torque (M18/8.8): MA= 280 Nm Torque (M20/10.9): MA= 620 Nm Fig. 2194

30-498

Method of intervention 47.

Fasten the solenoid valves with new oiled O-rings, using a suspension plate. Torque: MA= 9 Nm

Fig. 2195

48.

Fit the pressure regulator base with an O-ring (see arrow). Torque: MA = 25 Nm

Fig. 2196

49.

Fit the coil. Fit the nut with an O-ring (see arrow). Torque: MA= 4 Nm

Fig. 2197

30-499

Method of intervention 30.7.12 - Fitting the differential (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Fit the retainer ring and the axle pinion in the differential case. WARNING Ensure that the retainer ring is installed in the correct position! WARNING Fit the retainer ring with the bevelled inner diameter facing towards the axle pinion (upwards). Fig. 2198

2.

Fit the compensation pinion into the case with the retainer rings, and fasten with the compensation axle. WARNING Ensure that the retainer rings are aligned correctly axially! WARNING The lug (see arrow) must engage with the groove in the case. Fig. 2199

3.

Fasten the compensation axles with a spring pin. WARNING Fit the spring pin with the gap facing upwards.

Fig. 2200

4.

Fit the two fastener pins (S). Fit the ring gear. Then fit the axle pinion and the retainer ring. (S) Fastener pins: 5.9035.271.0 WARNING Ensure that the retainer ring is installed in the correct position! WARNING Fit the retainer ring with the bevelled inner diameter facing upwards, fig. 4 nd.

30-500

Fig. 2201

Method of intervention 5.

Fit the disc pack. WARNING See the current spare parts catalogue for the correct disc number and order. WARNING Ensure that the outer discs, with the lining on one side only, are fitted correctly. WARNING Fit the discs with the lining facing towards the inner disc.

6.

Fig. 2202

Oil the O-rings (see arrows) and fit in the ring seats on the piston.

Fig. 2203

7.

Press-fit the piston fully into its seat in the compensation chamber. WARNING Ensure that the gear is installed correctly as shown in the figure!

Fig. 2204

8.

Fit the compensation chamber on the differential case. Compress the differential with a press and fasten with hexagonal head screws and discs. Torque (M12/10.9): MA= 115 Nm

Fig. 2205

9.

Heat both roller bearings and install fully in their seats. WARNING Reposition the bearings once cooled!

10.

Lift the differential into the rear axle housing and support in this position (see arrow). 30-501

Method of intervention 11. 12.

13. 14.

Fit the outer bearing races through the holes in the case on both sides (bringing them into contact with the tapered roller bearings). Prefit the right hand adjuster screw (looking towards front). 12.1. Adjuster screw 12.2. Rectangular section rings 12.3. O-ring Fit the two adjustment screws. (S) Socket wrench: 5.9035.185.0 Adjust the ring gear: 1. The theoretical assembly measurement (E) is indicated on the ring gear. 2. Deviation from the theoretical value is etched on the ring gear by an electric arc etching machine. 3. The desired assembly measurement is calculated from the theoretical measurement (E) and the deviation. Set with a tolerance of ± 0.025 mm. Example: (Theoretical assembly measurement) 97.00 + (Deviation) + 0.2 = Fig. 2206 -------------------------------------------------------(Effective assembly measurement) 97.2 ± 0.025 If no deviation is indicated, observe the theoretical assembly measurement: (E) = 97.00 ± 0.025.

15.

4. The ring gear is adjusted using a measurement calliper (S) placed precisely in contact with the two cylindrical pins. When adjusting the assembly measurement, the average value of the circularity deviation of the measurement surface must be measured. The assembly measurement must be applied with reference to this average value. 5. The maximum circularity deviation permitted is 0.06 mm. 6. After adjusting the ring gear, adjust the rolling resistance torque of the differential mount to a value between 5 and 7 Nm. Adjust the assembly measurements by turning the two adjustment screws and checking the results. (S) Measurement calliper: 5.9035.229.0 (S) Gauge: 5.9035.449.0

Fig. 2207

30-502

Method of intervention 16.

Check that the bearing preload is between 5 and 7 Nm. Adjust if necessary by turning the adjuster screw. WARNING Once set, do not adjust the ring gear again!

Fig. 2208

17.

Fit the spring pin (see arrow). WARNING Perform the step shown in figures 17 … 18 on both sides.

Fig. 2209

18.

Fit the stop bracket and fasten with hexagonal head screws. Torque (M8/8.8): MA = 23 Nm WARNING Moisten the threads of the hexagonal head screws with Loctite 243!

Fig. 2210

19.

Fit the lubrication pipe (see arrow). Torque: MA= 45 Nm

Fig. 2211

30-503

Method of intervention 30.7.13 - Fitting brakes (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Fit the outer discs and lining discs in alternating order. WARNING See the current spare parts catalogue for the correct disc order.

Fig. 2212

2.

Fasten the tie-rod (1) with the pins (2) and secure with the split pin (3). 1

2

3

Fig. 2213

3.

Fit the preassembled brakes (actuator mechanism) in the housing. Then fit the remaining discs. WARNING See the current spare parts catalogue for the correct disc order.

Fig. 2214

4.

Fit the shaft seal ring fully into its seat in the brake plate. Oil the O-rings (see arrow) and fit into the ring groove. WARNING Moisten the outer diameter of the shaft seal ring with alcohol immediately before fitting. WARNING Grease the space between the seal lips. Fig. 2215

30-504

Method of intervention 5.

Fit the preassembled brake plate on the rear axle housing, bringing it against the respective contact surface. Fasten the rear axle housing with the hexagonal head screws. Torque (M12/8.8): MA= 79 Nm WARNING Fit the hexagonal head screws into the two threaded holes with the disc. Fig. 2216

6.

Fit the O-ring (see arrow 1) on the shaft of the central pinion. Fit the rectangular section rings (see arrow 2).

2 2

1

Fig. 2217

7.

Push the shaft of the central pinion completely into its seat.

Fig. 2218

8.

Fit the rubber bush on the tie-rod and into the ring groove of the tie-rod. Then fit the rubber bush completely into it seat in the rear axle housing. (S) Installation tool: 5.9035.238.0 WARNING Moisten the contact surface with Loctite 574!

Fig. 2219

30-505

Method of intervention 9.

Fit the line (see arrow) on the actuator mechanism. Torque: MA = 25 Nm

Fig. 2220

10.

Fit the actuator mechanism and fasten with cylindrical head screws. Torque (M10/10.9): MA= 68 Nm

Fig. 2221

11.

Fasten the line onto the bearing mount (see arrow) with the clamp, the hexagonal head screw and the hexagonal head nut. Torque (M5/8.8): MA= 5,5 Nm

Fig. 2222

12.

Fasten the tie-rod (1) onto the actuator mechanism with pins. Fit the disc (2) and fasten with the split pin (3). Then attach the tensioner spring (4).

2

1

3 4

Fig. 2223

30-506

Method of intervention 13.

Fit the disc with the radius facing downwards and tighten the hexagonal head nut. Torque: MA= 15 Nm Then loosen the hexagonal head nut by 2 turns.

Fig. 2224

14.

Fasten the hexagonal head nut with the check nut. Torque: MA= 80 Nm

Fig. 2225

30.7.14 - Fitting the axle housing (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) 1.

Press-fit the wheel pivots fully into their respective seats in the rear half axle. (S) Installation tool: 5.9035.304.0 (S) Insert (M22x1.5): 5.9035.305.0 WARNING The special tool (S) may only be used for replacing individual wheel pivots with the rear half axle mounted!

Fig. 2226

2.

Fit the seal ring on the shaft. (S) Thrust ring: 5.9035.480.0 WARNING Ensure that the gear is installed correctly as shown in the following figure! WARNING Use the specified presser tool (S) to install the shaft seal ring precisely in its seat. Fig. 2227

30-507

Method of intervention 3.

In figure: 1 = rear half axle 2 = shaft seal ring 3 = axle housing 4 = tapered roller bearing X = fill with grease Fill 50 – 75% of the volume with grease.

4

3 2

X

1 Fig. 2228

4.

Heat the tapered roller bearing and install fully into its respective seat in the rear half axle. WARNING Wear protective gloves! WARNING Reposition the tapered roller bearing correctly once cooled! Fig. 2229

5.

Fit the two outer bearing races against the respective contact surfaces on the axle housing.

Fig. 2230

6.

Fit the axle housing onto the rear half axle using suitable lift equipment. (S) Suspension ring: 5.9035.479.0 WARNING Moisten the surface of the shaft seal ring with alcohol immediately before fitting.

Fig. 2231

30-508

Method of intervention 7.

Heat the tapered roller bearing and install fully into its respective seat. WARNING Wear protective gloves! WARNING Reposition the tapered roller bearing correctly once cooled!

Fig. 2232

8.

Adjusting the rear half axle mount (figure 8 … 9): Fit the ring nut with the bevelled side facing towards the tapered roller bearing (downwards). Torque: MA= 250 Nm Loosen the ring nut by 90° and free the rear half axle by tapping. (S) Ring nut wrench: 5.9035.474.0

Fig. 2233

9.

Fit the mount, turning the ring nut until there is no endfloat. Maximum permissible endfloat 0 ± 0.015 mm. WARNING During adjustment, turn the axle housing several times in both directions.

Fig. 2234

10.

Fit the circlip (see arrow) into the lower ring groove on the planet gear. Fit the retainer ring. WARNING Ensure that the planet gear is installed in the right way around (part number facing upwards).

Fig. 2235

30-509

Method of intervention 11.

Fit the cylindrical roller bearing in the planet gear with the wider diameter facing downwards, pressing the cylindrical roller bearing through the bush in the housing. Fit the retainer ring and fasten the cylindrical roller bearing with a circlip.

Fig. 2236

12.

Heat the inner bearing race. Fit the planet gears in contact with the sun gear, with the broader diameter towards the planet gear carrier (downwards). WARNING Reposition the cylindrical roller bearing correctly once cooled!

Fig. 2237

13.

Fasten the planet gears with circlips.

Fig. 2238

14.

Fit the spring pin. (S) Press-fit pin: 5.9035.443.0 WARNING Using the specified installation tool will ensure that the spring pin is inserted to precisely the correct depth (see also following figure).

Fig. 2239

30-510

Method of intervention 15.

In figure: 1 = planet gear carrier 2 = spring pin X = assembly measurement 2.0 mm (+ 0.5)

1 2

Fig. 2240

16.

Fit the ball (see arrow) into the shaft, using grease. Fit a new threaded pin. WARNING Moisten the thread of the threaded pin with Loctite 243!

Fig. 2241

17.

Fit the planet gear carrier onto the rear half axle using suitable lift equipment. WARNING Ensure that the planet gear carrier is aligned correctly axially. Rotate the planet gear carrier to engage the spring pin (figure 15) correctly in one of the grooves of the ring nut.

Fig. 2242

18.

Adjust the endfloat of the planet gear carrier: 0.1 mm. … 0.4 mm: adjust the endfloat by turning the threaded pin. Refit the spring pin again (see also figure 15) after adjusting the endfloat of the sun gear. (S) Press-fit pin: 5.9035.443.0

Fig. 2243

30-511

Method of intervention 19.

Fit the cylindrical pin (see arrow).

Fig. 2244

20.

Fit the ring gear on the rear axle housing, bringing it against the respective contact surface. WARNING Moisten the flange mating surface with Loctite 574!

Fig. 2245

21.

Fit the axle housing against the respective contact surface using suitable lift equipment. (S) Upper holes (M12): 5.9035.377.0 Fasten the axle housing with hexagonal head screws and hexagonal nuts. Torque (M12/10.9): MA= 115 Nm WARNING Moisten the flange mating surface with Loctite 574! Fig. 2246

30-512

Method of intervention 30.7.15 - Separating rear axle from transmission (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen the hole blanking screws on the gearbox housing and on the rear axle housing and drain the oil.

Fig. 2247

2.

Undo the filter housing and remove the filter cartridge.

Fig. 2248

3.

Remove all the lines.

Fig. 2249

4.

Place the complete assembly (transmission and rear axle) on a pallet with a high load capacity. Then fasten the axle with lifting equipment and loosen the assembly fastened with screws. (S) Upper holes (M12): 5.9035.377.0 (S) Upper holes (M18): 5.9035.378.0

Fig. 2250

30-513

Method of intervention 5.

Fit the two fastener pins (S) and separate the rear axle from the transmission. (S) Fastener pins (M16): 5.9035.251.0 (S) Assembly lever: 5.9035.203.0

Fig. 2251

30.7.16 - Axle Stub - Disassembly (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Fasten the rear axle to the assembly trolley. m m

(S) Assembly trolley: 5.9035.193.0 (S) Support: 5.9035.194.0

Fig. 2252

2.

Secure the axle stub with lifting gear and loosen the threaded connection. Then, remove the axle stub and ring gear. m

(S) Eye bolts (M12): 5.9035.377.0

Fig. 2253

3.

Loosen the grub screw and pull the released planet carrier away from the rear axle shaft using lifting gear.

Fig. 2254

30-514

Method of intervention 4.

Pry out the retaining ring.

Fig. 2255

5.

Pull the planetary gear away from the planet carrier using a two-arm puller.

Fig. 2256

6.

Pry out the snap rings on both sides and remove the released cylindrical roller bearing along with the thrust plates.

Fig. 2257

7.

Loosen the slotted nut. m

(S) Wrench socket 5.9035.436.0

Fig. 2258

30-515

Method of intervention 8.

Pull the axle stub away from the rear axle shaft using a two-arm puller. Remove the released tapered roller bearing.

Fig. 2259

9.

If necessary, drive out the two bearing outer races from the axle stub.

Fig. 2260

10.

Pull the tapered roller bearing away from the rear axle shaft. m

(S) Gripper: 5.9035.437.0

Fig. 2261

11.

Remove the shaft seal ring. m

(S) Assembly lever: 5.9035.203.0

Fig. 2262

30-516

Method of intervention 30.7.17 - Brake Disassembly (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen the hexagon nuts and remove the washer.

Fig. 2263

2.

Pull the cotter pin (1), remove the washer and detach the pull rod (2). Then, detach the extension spring (3) and fold the actuator upward.

Fig. 2264

3.

Remove the vent line. Loosen the cap bolts and remove the actuator.

Fig. 2265

4.

Pull the pinion shaft and loosen the hexagon bolts. Pull the brake plate out of the rear axle housing using puller screws (S). m

(S) Puller screws (M16): 5.9035.438.0

Fig. 2266

30-517

Method of intervention 5.

Remove the outer disk pack.

Fig. 2267

6.

Remove the brake and inner disk pack. CAUTION When pulling the pull rod back through the rubber grommet, avoid damaging the grommet with the thread on the pull rod (apply adhesive tape, or similar, to the pull rod thread).

Fig. 2268

7.

If necessary, pull the cotter pin (see arrow), pull the bolt and remove the pull rod. DANGER No further disassembly of the brake is permitted (safety component) - the brake is supplied as a complete unit!

Fig. 2269

8.

Check the rubber grommet (see arrow) for damage - lever it out of the bore if necessary.

Fig. 2270

30-518

Method of intervention 30.7.18 - Differential - Disassembly (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Remove the lubrication lines for ring gear (1) and differential mounting (2).

Fig. 2271

2.

Loosen the hexagon bolts and remove the released locking plate.

Fig. 2272

3.

Loosen the adjusting disk. m

(S) Socket wrench: 5.9035.185.0

Fig. 2273

4.

Press the differential to the right (see arrow) using an assembly lever (S). m

(S) Assembly lever: 5.9035.203.0 CAUTION Support the differential (see illustration)!

Then, remove the right bearing outer race and lift the differential out of the rear axle housing. Fig. 2274

30-519

Method of intervention 5.

Pull off the two roller bearings.

Fig. 2275

6.

Secure the axle stub with lifting gear and loosen the threaded connection.

Fig. 2276

7.

Separate the differential housing together with piston (1) and ring gear (2) from differential casing (3). Then, push the piston out of the differential housing using compressed air.

Fig. 2277

8.

Remove the thrust plate, disk pack and axle bevel gear.

Fig. 2278

30-520

Method of intervention 9.

Drive out the roll pins (4x).

Fig. 2279

10.

Pull the differential axles and remove the released differential bevel gears and thrust plates.

Fig. 2280

11.

Take out the axle bevel gear and thrust plate.

Fig. 2281

30-521

Method of intervention 30.7.19 - PTO Transmission - Disassembly (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Remove lubrication and pressure line.

Fig. 2282

2.

Loosen the hexagon bolts and take out the two gearshift actuators.

Fig. 2283

3.

Disassemble the gearshift actuators if necessary. Drawing legend: 3.1. 3.2. 3.3. 3.4. 3.5.

Lever Roll pin Flange bearing O-ring Shift shaft

Fig. 2284

4.

Loosen the threaded connection and remove the entire PTO transmission.

Fig. 2285

30-522

Method of intervention 5.

Fasten the PTO transmission to the assembly trolley (S). m m

(S) Assembly trolley: 5.9035.193.0 (S) Angular support: 5.9035.391.0

Fig. 2286

6.

Loosen the hexagon bolts and remove the released PTO stub shaft.

Fig. 2287

7.

Loosen the cap bolt and pull out the rpm sensor from the hole.

Fig. 2288

8.

Loosen the threaded connection, take off the end cover and remove the adjusting disk located behind. Then, lever the shaft seal out of the end cover.

Fig. 2289

30-523

Method of intervention 9.

Loosen the hexagon bolts, take off the cover and remove the adjusting disk located behind.

Fig. 2290

10.

Loosen the screw plug and pull out the piston and compression spring from from the hole in the cover.

Fig. 2291

11.

Pull the bell housing away from the clutch shaft using a three-arm puller.

Fig. 2292

12.

Heat up the bell housing and pull the ball bearing out of the bore. CAUTION The ball bearing is secured with Loctite (Type No.: 649) !

Fig. 2293

30-524

Method of intervention 13.

Pry out the retaining ring. Then, remove the plate support, disk pack and pressure cylinder. CAUTION Be careful as the compression springs and balls are released!

Fig. 2294

14.

Push the piston out of the pressure cylinder using compressed air.

Fig. 2295

15.

Remove the two plain compression rings (arrow 1) and spacer ring (arrow 2).

Fig. 2296

16.

Loosen the two shift rods. CAUTION Be careful as the springs and balls are released! Remove the rear shift fork (arrow 1); the front shift fork (arrow 2) can be taken out only after the double spur gear has been removed.

Fig. 2297

30-525

Method of intervention 17.

Lift the roller bearing (see arrow) through the sensor rotor (see Drawing 19 also) and out of the bearing seat until the sensor rotor can turn freely.

Fig. 2298

18.

Turn the sensor rotor until the profiles are overlapping (flange shaft and sensor rotor). CAUTION When the two profiles are congruent with each other, the sensor rotor can be heard to click into the flange shaft.

Fig. 2299

19.

CAUTION Lift the roller bearing over the sensor rotor (see arrows)! Drawing legend: 19.1. 19.2. 19.3.

Flange shaft Roller bearing Sensor rotor

Fig. 2300

20.

Turn the housing through 180° and press out the flange shaft using a twoarm puller.

Fig. 2301

30-526

Method of intervention 21.

Loosen the hexagon nut and slotted nut (see arrow). m

(S) Wrench socket 5.9035.439.0

Fig. 2302

22.

Drive out the two bearing pins and the clutch shaft (see arrows).

Fig. 2303

23.

Remove all the individual parts (spur gears, double spur gears, sleeve carriers, shift collars) from the PTO shaft housing.

Fig. 2304

24.

Pull the roller bearing away from the double spur gear and bearing pin. m m

(S) Gripper 5.9035.440.0 (S) Basic unit: 5.9035.284.0

Fig. 2305

30-527

Method of intervention 30.7.20 - Oil Supply - Disassembly (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Remove cooling lines (3x, see arrows).

Fig. 2306

2.

Loosen the hexagon bolts and take out the released valve block.

Fig. 2307

3.

Remove pipes (2x, see arrows).

Fig. 2308

4.

Loosen the cap bolts and take out the released valve block.

Fig. 2309

30-528

Method of intervention 5.

Loosen the cap bolt and pull out the solenoid from the valve block.

Fig. 2310

6.

Remove the pressure line (arrow 1) and pressure line (arrow 2).

Fig. 2311

30.7.21 - Lifting Unit - Disassembly (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Loosen the hexagon bolts and remove the complete lifting unit and brake shaft using lifting gear.

Fig. 2312

2.

Drive out the two roll pins. Then, remove the released ring and brake lever.

Fig. 2313

30-529

Method of intervention 3.

Separate the bearing brackets, drive shaft and brake shaft from each other.

Fig. 2314

4.

Loosen the hexagon nut and remove the pull rod.

Fig. 2315

30.7.22 - Rear Axle Housing - Preassembly (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Preassemble the rear axle housing as shown in the illustration opposite. 1.1. 1.2. 1.3. 1.4. 1.5. 1.6. 1.7.

Bushing Bushings Vent valve Screw plug with seal ring MA = 35 Nm Screw plug MA = 120 Nm Oil level indicator Stud bolt MA = 23 Nm 5 DANGER Smear the thread of the stud bolts with Loctite (Type No. 243). Fig. 2316

30.7.23 - Lifting Unit - Assembly (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Press the bushing into position in the bearing bracket Insert the plain bearing (see arrow 1) till flush and mount the lubricating nipple (see arrow 2) (see Illustration 2 for installation position). CAUTION After mounting, grease twice the inside diameter of the bushing!

Fig. 2317

30-530

Method of intervention 2.

Mount the bracket with hexagon bolts. Tightening torque (M8/8.8) MA = 23 Nm

Fig. 2318

3.

Insert bushing in the drive shaft (see arrow). DANGER The flattened segment in the bushing (on the inside diameter) must be aligned with the line stamped into the drive shaft (see next drawing also).

Fig. 2319

4.

Drawing legend: 4.1. Drive shaft 4.2. Stamped line 4.3. Bushing

Fig. 2320

5.

Insert pin in brake shaft. Pass the pull rod through the pin, mount the tube and screw the hexagon nut on. Drawing legend: 5.1. 5.2. 5.3. 5.4. 5.5.

Brake shaft Pull rod Pin Tube Nut Fig. 2321

30-531

Method of intervention 6.

Fit O-rings (2x, see arrows) onto the drive shaft. Then, mount the bearing brackets and brake shaft.

Fig. 2322

7.

Mount the ring (arrow 1) and brake lever (arrow 2) on the brake shaft and fix them with roll pins.

Fig. 2323

8.

Bring the preassembled lift unit into position using lifting gear and fasten with hexagon bolts. Tightening torque (M20/10.9) MA = 560 Nm

Fig. 2324

30-532

Method of intervention 30.7.24 - Oil Supply - Assembly (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Fit the nipples with new seal rings and mount them (3x, see arrows). m

Tightening torque MA = 55 Nm

Fig. 2325

2.

Fit the nipple with a new seal ring and mount it (see arrow). m

Tightening torque MA = 55 Nm

Fig. 2326

3.

Fit the nipples (1) with new seal rings and mount them. Tightening torque MA = 90 Nm Then, mount the threaded connection (2) m

m

Tightening torque MA = 45 Nm

Fig. 2327

4.

Mount the pressure line (see arrow). m

Tightening torque MA = 45 Nm

Fig. 2328

30-533

Method of intervention 5.

Oil the O-rings (3x, see arrows) and insert in the ring grooves in the solenoid valve.

Fig. 2329

6.

Fit the nipples with new seal rings and mount them (2x, see arrows). Tightening torque (M8/8.8) MA = 35 Nm Then, fasten the solenoid valves with a claw and cap bolts. m

m

Tightening torque (M8/8.8) MA = 23 Nm

Fig. 2330

7.

Insert the O-rings (3x, see arrows) in the countersinks in the valve block.

Fig. 2331

8.

Fasten the valve block with cap bolts. m

Tightening torque (M8/8.8) MA = 23 Nm

Fig. 2332

30-534

Method of intervention 9.

Mount the pipes (2x, see arrows). m

Tightening torque MA = 35 Nm CAUTION Fit the banjo bolt with new seal rings!

Fig. 2333

10.

Fit the nipples (4x) with new seal rings and mount them. m

Tightening torque (L 10A-M) MA = 35 Nm

m

Tightening torque (L 15A-M) MA = 55 Nm

Fig. 2334

11.

Oil the O-rings (3x) and insert in the ring grooves in the solenoid valves. Then, fasten the solenoid valves with a claw and cap bolts. m

Tightening torque (M8/8.8) MA = 23 Nm

Fig. 2335

12.

Place the seal and fasten the preassembled valve block with hexagon bolts. m

Tightening torque (M8/8.8) MA = 23 Nm

Fig. 2336

30-535

Method of intervention 13.

Mount the two cooling lines (see arrows). m

Tightening torque MA = 80 Nm

Fig. 2337

14.

Remove the pressure line (1) and T-piece reducer (2). Then, mount the pipe (3) and nipple (4). Pipe (1) Tightening torque MA = 45 Nm Pipe (3) m

m

Tightening torque MA = 80 Nm

Fig. 2338

30.7.25 - Fitting the PTO transmission (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Fit the stud bolts (x4) Torque (M8/8.8): MA= 9 Nm DANGER Moisten the thread with Loctite ( 243)!.

Fig. 2339

2.

Fit the outer bearing races (x3, see arrows) in the PTO housing.

Fig. 2340

30-536

Method of intervention 3.

Preassemble the tapered roller bearings (1), tube (2), face gear (3), sleeve (4), sleeve mount (5) and face gear (6) as shown in the figure aside.

Fig. 2341

4.

Fit the preassembled components (see arrow) in the PTO housing.

Fig. 2342

5.

Heat the tapered roller bearing and install fully into its respective seat on the clutch shaft. CAUTION Reposition the bearings once cooled!

Fig. 2343

6.

Fit the clutch shaft fully in its seat using the two arm extractor tool. Fit the rectangular section rings (x3, see arrows) in the ring seats on clutch shaft and secure in the correct position with grease.

Fig. 2344

30-537

Method of intervention 7.

Fit the outer bearing race fully into its seat in the housing.

Fig. 2345

8.

Preassemble the cover as shown in the figure aside. 8.1. 8.2. 8.3. 8.4.

Cover Thrust spring Piston Hole blanking screw

Fig. 2346

9.

Adjust the bearing to a value of 0.01 mm (preload) - 0.04 mm (endfloat) Measure the distance I from the flange mating surface of the PTO housing to the front surface of the outer bearing race. Measurement I, example: 10.33 mm -

Fig. 2347

10.

Measure the distance II from the contact surface of the outer bearing race to the flange mating surface of the cover. Measurement II, example: 9.31 mm Calculation example “A”: m m m m

Measurement I, example: 10.33 mm Measurement II, example: 9.31 mm Endfloat necessary, 0.00 - 0.04 mm: 0.02 mm Difference = I - II - 0.02 = 1.00 mm = adjustment washer

Fig. 2348

30-538

Method of intervention 11.

Fit the adjustment washer (e.g. s = 1.00 mm) into the hole in the housing.

Fig. 2349

12.

Moisten the flange mating surface with Loctite ( 574) and fasten the cover with hexagonal head screws. Torque (M8/8.8): MA = 23 Nm

Fig. 2350

13.

Fit the tapered roller bearing in the outer bearing race. Fit the face gear and the bearing retainers in the PTO housing.

Fig. 2351

14.

Fit the outer bearing races and the two roller bearings into the face gear on both sides of the double face gear.

Fig. 2352

30-539

Method of intervention 15.

Fit the outer bearing race (see arrow) into the double face gear.

Fig. 2353

16.

Heat the roller bearings and install fully in their seats on the double face gear. CAUTION Reposition the bearings once cooled!

Fig. 2354

17.

Fit the control fork (see arrow). Fit the two double face gears in the PTO housing CAUTION The control fork cannot be installed after fitting the double face gears.

Fig. 2355

18.

Fit the sleeve, sleeve mount, face gear and transducer wheel.

Fig. 2356

30-540

Method of intervention 19.

Fit the flanged shaft fully in its seat using the two arm extractor tool. CAUTION Ensure that the flanged shaft and transducer wheel cover are aligned correctly.

Fig. 2357

20.

Lift the transducer wheel (see arrow) and turn by 60° (see figure).

Fig. 2358

21.

Heat the roller bearings (see arrow) and fit fully into their seats on the flanged shaft. CAUTION Reposition the bearings once cooled! DANGER The transducer wheel must be secured by contact with the roller bearing and must not be rotated again. Fig. 2359

22.

Fit the outer bearing race fully into its seat in the housing.

Fig. 2360

30-541

Method of intervention 23.

Fit the shaft seal ring (see arrow) fully into its seat in the cover. CAUTION Moisten the outer diameter of the shaft seal ring with alcohol immediately before fitting.

Fig. 2361

24.

Adjust the bearing endfloat to a value between 0.01 and 0.06 mm: Measure the distance I from the flange mating surface of the PTO housing to the front surface of the outer bearing race. Measurement I, example: 5.23 mm -

Fig. 2362

25.

Measure the distance II from the contact surface of the outer bearing race to the flange mating surface of the cover. Measurement II, example: 4.40 mm Calculation example “A”: m m m m

Measurement I, example: 5.23 mm Measurement II, example: 4.40 mm Endfloat necessary, 0.01 - 0.06 mm: 0.03 mm Difference = I - II - 0.03 = 0.80 mm = adjustment washer Fig. 2363

26.

Fit the adjustment washer (e.g. s = 0.80 mm) into the hole in the housing.

Fig. 2364

30-542

Method of intervention 27.

Moisten the flange mating surface with Loctite ( 574) and fasten the cover with hexagonal head screws and hexagonal head nuts. Torque M MA = 23 Nm

Fig. 2365

28.

Fasten the PTO output shaft with hexagonal head screws. Torque (M12/10.9): MA= 115 Nm

Fig. 2366

29.

Grease the O-ring see figure) and install in the ring seat on the bearing pins. Heat the two roller bearings and fit the bearing pins fully into their seats in the PTO housing and on the double face gear. CAUTION Ensure that the parts are aligned correctly radially. Align the groove and the hole in the housing.

Fig. 2367

30.

Grease the O-ring see figure) and install in the ring seat on the bearing pins. Heat the roller bearings and install fully in their seats on the bearing pins. CAUTION Reposition the roller bearing correctly once cooled!

Fig. 2368

30-543

Method of intervention 31.

Fit the bearing pins fully into their seats in the PTO housing and on the double face gear. CAUTION Ensure that the parts are aligned correctly radially. Align the groove and the hole in the housing.

Fig. 2369

32.

Fit the spring pins (x2, see arrows) fully into their seats on the bearing pins.

Fig. 2370

33.

Adjust the endfloat of the double face gear bearings to a value between 0.01 and 0.05 mm by turning the hexagonal head nut. Fasten with hexagonal head nuts.

Fig. 2371

34.

Adjust the endfloat of the second double face gear bearings to a value between 0.01 and 0.05 mm by turning the ring nut. (S) Ring nut wrench 5.9035.439.0 Fasten the ring nut.

Fig. 2372

30-544

Method of intervention 35.

Fit the thrust spring and the balls in the holes in the disc carrier.

Fig. 2373

36.

Fit the spring washer. CAUTION Assemble the components of the disc pack in alternating order on the disc carrier. DANGER Also see the current spare parts catalogue for the correct disc order. Fig. 2374

37.

Place the outer disc on the spring washer.

Fig. 2375

38.

Fit the inner disc.

Fig. 2376

30-545

Method of intervention 39.

Oil the O-ring (see arrow) and install in the ring seat on the piston.

Fig. 2377

40.

Install the piston fully into the pressure cylinder.

Fig. 2378

41.

Fit the preassembled pressure cylinders.

Fig. 2379

42.

Compress the entire disc pack with an installation tool (S). (S) Installation tool 5.9035.441.0

Fig. 2380

30-546

Method of intervention 43.

Fit the spacer (arrow 1). Fit the rectangular section rings (x2, see arrows 2) in the ring seats on clutch shaft and secure in the correct position with grease.

Fig. 2381

44.

Fit the preassembled clutch assembly on the clutch shaft and fasten with a circlip. Remove the installation tool (S).

Fig. 2382

45.

Press-fit the ball bearings fully into their seats in the clutch housing. DANGER Moisten the outer diameter of the ball bearings with Loctite ( 649)!

Fig. 2383

46.

Heat the ball roller bearing and install fully into its respective seat in the clutch housing.

Fig. 2384

30-547

Method of intervention 47.

Fit the thrust spring and the ball in the two control forks and fasten with a press-fit pin (S) (see figure aside). (S) Press-fit pin: 5.9035.450.0

Fig. 2385

48.

Fit the second control fork (see arrow). Fasten the control forks with the control rods. Torque MA= 60 Nm DANGER Moisten the threads of the control rods with Loctite ( 243)!

Fig. 2386

49.

Fit the speed sensor with a new O-ring. Torque (M8/8.8): MA = 23 Nm

Fig. 2387

50.

Fit the stud bolts (x2, see arrows). Torque (M8/8.8): MA= 17 Nm DANGER Moisten the threads of the stud bolts with Loctite ( 243).

Fig. 2388

30-548

Method of intervention 51.

Fit the PTO transmission in the rear axle housing and fasten with hexagonal head screws and hexagonal head nuts. Torque MA = 46 Nm CAUTION Moisten the flange mating surface with Loctite ( 574)!

Fig. 2389

52.

Preassemble the two selector actuator mechanisms. In diagram: 52.1. 52.2. 52.3. 52.4. 52.5.

Lever Spring pin Flange bearing O-Ring Control shaft

Fig. 2390

53.

Fit the two selector actuator mechanisms in the rear axle housing and fasten with hexagonal head screws. Torque (M8/8.8): MA = 23 Nm CAUTION Moisten the flange mating surface with Loctite ( 574)!

Fig. 2391

54.

Fit the lines and the delivery line (see arrows). Torque MA= 45 Nm

Fig. 2392

30-549

Method of intervention 30.7.26 - Fitting the differential (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Fit the retainer ring and the axle pinion in the differential case. CAUTION Fit the retainer ring, ensuring that it is fitted in the correct position, with the bevelled inner diameter facing towards the axle pinion (upwards).

Fig. 2393

2.

Fit the compensation pinion into the case with the retainer rings, and fasten with the compensation axle. CAUTION Ensure that the retainer rings is aligned correctly radially. The lug (see arrow) must engage with the groove in the case.

Fig. 2394

3.

Fasten the compensation axles with a spring pin. CAUTION Fit the spring pin with the gap facing upwards.

Fig. 2395

4.

Fit the two fastener pins (S) and the ring gear. Then fit the axle pinion and the retainer ring. m

(S) Fastener pins: 5.9035.271.0 CAUTION Fit the retainer ring, ensuring that it is fitted in the correct position with the bevelled inner diameter facing upwards.

Fig. 2396

30-550

Method of intervention 5.

Fit the disc pack. CAUTION See the spare parts catalogue for the correct disc number and order. DANGER Fit the discs, ensuring that the discs with the lining on one side only are fitted correctly with the lining facing towards the inner disc. Fig. 2397

6.

Oil the O-rings (see arrows) and fit in the ring seats on the piston.

Fig. 2398

7.

Press-fit the piston fully into its seat in the compensation chamber. CAUTION Ensure that the part is installed correctly as shown in the figure!

Fig. 2399

8.

Fit the compensation chamber on the differential case. Compress the differential with a press and fasten with hexagonal head screws and discs. Torque (M12/10.9): MA= 115 Nm

Fig. 2400

30-551

Method of intervention 9.

Heat both roller bearings and install fully in their seats. CAUTION Reposition the bearings once cooled!

Fig. 2401

10.

Lift the differential into the rear axle housing and support in this position (see arrow).

Fig. 2402

11.

Fit the outer bearing races through the holes in the case on both sides (bringing them into contact with the tapered roller bearings).

Fig. 2403

12.

Prefit the right hand adjuster screw (looking towards front). 12.1. 12.2. 12.3.

Adjuster screw Rectangular section rings Figure: O-ring

Fig. 2404

30-552

Method of intervention 13.

Fit the two adjustment screws. (S) Socket wrench: 5.9035.185.0

Fig. 2405

14.

Adjusting the ring gear 1. The theoretical assembly measurement (E) is indicated on the ring gear. 2. Deviation from the theoretical value is etched on the ring gear by an electric arc etching machine. 3. The desired assembly measurement is calculated from the theoretical measurement (E) and the deviation. Set with a tolerance of ± 0.025 mm.

Table 356 Example:

84,00 + Theoretical assembly measurement

15.

0,2 Deviation

=

84,2 ± 0,025 Desired assembly measurement

Fig. 2406

If no deviation is indicated, observe the theoretical assembly measurement (E) = 84.00 ± 0.025. 4. The ring gear is adjusted using a measurement calliper (S) placed precisely in contact with the two cylindrical pins. When adjusting the assembly measurement, the average value of the circularity deviation of the measurement surface must be measured. The assembly measurement must be applied with reference to this average value. 5. The maximum circularity deviation permitted is 0.06 mm. 6. After adjusting the ring gear, adjust the rolling resistance torque of the differential mount to a value between 5 and 7 Nm. Adjust the assembly measurements by turning the two adjustment screws and checking the results. (S) Measurement calliper: 5.9035.229.0

Fig. 2407

30-553

Method of intervention 16.

Check that the bearing preload is between 5 and 7 Nm. Adjust if necessary by turning the adjuster screw. DANGER Once set, do not adjust the ring gear again!

Fig. 2408

17.

Fit the spring pin (see arrow).

Fig. 2409

18.

Fit the stop bracket and fasten with hexagonal head screws. Torque (M8/8.8): MA = 23 Nm DANGER Moisten the threads of the hexagonal head screws with Loctite ( 243).

Fig. 2410

19.

Fit the lubrication pipes (x2, see arrows). Torque MA= 45 Nm

Fig. 2411

30-554

Method of intervention 30.7.27 - Brake Assembly (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Mount the external plates and coated disks alternately, starting with an external plate. CAUTION For disk coatings, also see the corresponding replacement parts list.! DANGER Note the radial installation position of the coated disks, the cooling oil bores must be mounted flush! Fig. 2412

2.

Fix the pull rod (1) with pin (2) and secure with cotter pin (3).

Fig. 2413

3.

Insert the preassembled brake (actuator) in the housing. Then, mount the other disks. CAUTION For disk coatings, also see the corresponding replacement parts list.!

Fig. 2414

4.

Insert the shaft seal in position in the brake plate. Grease the O-ring (see arrow) and insert in the ring groove. CAUTION Immediately before mounting, smear the outside diameter of the shaft seal with ethyl alcohol and grease the space between the sealing lips.

Fig. 2415

30-555

Method of intervention 5.

Mount the preassembled brake plate in position in the rear axle housing and fasten with hexagon bolts. Tightening torque (M12/8.8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . MA = 79 Nm CAUTION Fit the hexagon bolts in the two threaded holes with washers.

Fig. 2416

6.

Grease the seal ring and insert in the ring groove on the pinion (see arrow).

Fig. 2417

7.

Fit the pinion into position in the axle bevel gear.

Fig. 2418

8.

Slip the rubber grommet over the pull rod and insert it in the ring groove of the pull rod . Then, insert the rubber grommet in position in the rear axle housing. CAUTION Smear the contact surface with Loctite (Type No.574).

Fig. 2419

30-556

Method of intervention 9.

Attach the line to the actuator. m

Tightening torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . MA = 25

Fig. 2420

10.

Mount the actuator and fasten with cap bolts. m

Tightening torque (M10/10.9). . . . . . . . . . . . . . . . . . . . . . . . . . . . MA = 68 Nm

Fig. 2421

11.

Fasten the line to the bearing bracket with clamp, hexagon bolt and hexagon nut (see arrow).

Fig. 2422

12.

Attach the pull rod (1) to the pin and secure with washer (2) and cotter pin (3). Then, attach the extension spring (4).

Fig. 2423

30-557

Method of intervention 13.

Place the washer with radius facing downward and screw on the hexagon nut. Tightening torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . MA = 10 Nm Loosen the hexagon nut by 1.5 turns and secure with the jam nut (see illustration below). m

Fig. 2424

14.

Fig. 2425

30.7.28 - Axle Stub - Assembly (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Press the cylindrical roller into position in the rear axle shaft. DANGER Smear the outside diameter with Loctite (Type No. 649).

Fig. 2426

2.

Press the wheel studs into position in the rear axle shaft. m

(S) Assembly device: 5.9035.304.0

m

(S) Insert (M22x1.5): 5.9035.305.0 CAUTION Special tool (S) is used only for repairs when replacing individual wheel studs with the rear axle shaft mounted!

Fig. 2427

30-558

Method of intervention 3.

Mount the shaft seal. m

(S) Thrust ring 5.9035.442.0 CAUTION Note the installation position - see the drawing below. CAUTION You can use the specified thrust piece (S) to obtain the exact installation position of the shaft seal. Fig. 2428

4.

Drawing legend: 4.1. Rear axle shaft 4.2. Shaft seal X. Grease filling Fill 50 – 75% of the volume with grease (ZF part number: 0671 190 079). m

Fig. 2429

5.

Heat up the tapered roller bearing and mount in position on the rear axle shaft. CAUTION Re-adjust the tapered roller bearing after it has cooled.

Fig. 2430

6.

Insert the two bearing outer races in position in the axle stub.

Fig. 2431

30-559

Method of intervention 7.

Using lifting gear, slip the axle stub onto the rear axle shaft. CAUTION Smear the sealing surface of the shaft seal with ethyl alcohol immediately before mounting.

Fig. 2432

8.

Heat up the tapered roller bearing and fit into position. CAUTION Re-adjust the tapered roller bearing after it has cooled.

Fig. 2433

9.

Adjusting the rear axle shaft mounting Mount the slotted nut with the chamfer toward the tapered roller bearing (facing downward). Tightening torque MA = 250 Nm Then, loosen the slotted nut by 90° and tap the rear axle shaft till it turns freely. m

m

(S) Wrench socket 5.9035.436.0

Fig. 2434

10. 11.

Turn the slotted nut till there is no play in the mounting. DANGER Permitted axial play 0 ± 0.015 mm. While adjusting, spin the axle stub several times in both directions!

Fig. 2435

30-560

Method of intervention 12.

Fit the snap ring (see arrow) into the lower ring groove in the planetary gear and insert the thrust plate. CAUTION Check that the planetary gear is correctly positioned (parts number facing upward)!

Fig. 2436

13.

Insert the cylindrical roller bearing in the planetary gear with the large radius facing downward – to do this, push the cylindrical roller bearing through the packing sleeve. Then, insert the thrust plate and fix the cylindrical roller bearing with the snap ring.

Fig. 2437

14.

Heat up the bearing inner race and and fit the planetary gears in position with the large radius toward the planet carrier (facing downward). CAUTION Re-adjust the cylindrical roller bearing after it has cooled!

Fig. 2438

15.

Fix the planetary gears with the retaining rings.

Fig. 2439

30-561

Method of intervention 16.

Mount the roll pin m

(S) Mandrel 5.9035.443.0 CAUTION You can use the specified mounting tool to obtain the exact installation depth of the roll pin (see also next drawing)!

Fig. 2440

17.

Drawing legend 17.1. 17.2. m

Planet carrier Roll pin X. Installed dimension 2.5+0.5 mm

Fig. 2441

18.

Insert the ball with grease in the shaft (see arrow) and mount a new grub screw. DANGER Smear the thread of the grub screw with Loctite (Type No. 243).

Fig. 2442

19.

Using lifting gear, mount the planet carrier on the rear axle shaft. DANGER Note the radial installation position - turn the planet carrier so that the roll pin (illustration 15) fits into a groove in the slotted nut!

Fig. 2443

30-562

Method of intervention 20.

Set the axial play of the planet carrier 0.1 … 0.4 mm Adjust the axial play by turning the grub screw. After adjusting the play on the planet carrier, re-adjust the roll pin (see also illustration 15). m

(S) Mandrel 5.9035.443.0

Fig. 2444

21.

Mount the cylinder pin (see arrow).

Fig. 2445

22.

Fit the ring gear into position in the rear axle housing. DANGER Smear the flange-on surface with Loctite (Type No. 574).

Fig. 2446

23.

Using lifting gear, fit the preassembled axle stub into position. (S) Eye bolts (M12): 5.9035.377.0 Then, fasten the axle stub with hexagon bolts and hexagon nuts. m

m

Tightening torque (M12/10.9) MA = 115 Nm DANGER Smear the flange-on surface with Loctite (Type No.574).

Fig. 2447

30-563

Method of intervention 30.7.29 - Attaching rear axle to gearbox (7210 TTV Agrotron ->WSXW830400LD50010) 1.

Set the gearbox on a heavy-duty pallet. m m

(S) Eye bolts (M12): 5.9035.377.0 (S) Eye bolt (M18): 5.9035.378.0

Fig. 2448

2.

Mount the cylinder pins (2x, see arrows).

Fig. 2449

3.

Fit the drive shaft into position in the PTO clutch. Smear the flange-on surface (see arrow) with Loctite (Type No. 574).

Fig. 2450

4.

Using lifting gear (S), bring the rear axle into position at the gearbox and fasten with hexagon bolts. m

Tightening torque (M14/10.9) . . . . . . . . . . . . . . . . . . . .MA = 185 Nm

m

(S) Eye bolts (M12): 5.9035.377.0

Fig. 2451

30-564

Method of intervention 5.

Mount all the pipes (see illustration).

Fig. 2452

6.

DANGER Before putting the assembly into service, read the data and/or specifications and the instructions in the ZF operator’s manual, and the specifications and instructions of the vehicle manufacturer!

30.7.30 - Procedure for checking EPB travel (7210 TTV Agrotron ->WSXW830400LD50010) Purpose of the document

This procedure is applicable for machines with the following transmission: l

SMatic 180+

The purpose of this document is to illustrate the procedure for checking the travel of the EPB (Electric Parking Brake) system, P/N: 0.018.6330.4/10. The document is compatible with software versions: Transmission: l

EPB: 3.0.0.0 / 3.1.0.0 / 3.2.0.0

The document is focused on the mechanical/electronic procedures required for checking. The EPB system travel check is permitted only with the aid of: l l

the SDF Analyser diagnostic programme the A.R.T. (All Round Tester) diagnostic instrument

30-565

Method of intervention

Fig. 2453

Fig. 2454 - Connection via the A.R.T (All Round Tester)

30-566

Method of intervention

Fig. 2455 - Connection with SDF Analyzer

Operations on the brake system Work performed on the brake system includes all the workshop tasks aimed at replacing, repairing or adjusting one or more components of the service or parking brake system. The following are examples of brake system operations: l l l l l

Replacement of rear brake discs, Brake system adjustment operations, Replacement of the EPB system, Removal and refitting of the EPB system, Disconnection and reconnection of the Bowden cable from and to the brake system.

To perform the operations described above the main actions are as follows, in sequence: 1. 2. 3. 4. 5.

Removing the EPB system, Installation of the EPB system, EPB parameter setting, Adjusting the EPB system, Clearing EPB alarms and relative statistics.

Removal of the EPB system may be required in the following cases (examples given are indicative only): l l

EPB replacement due to fault, for example. Brake disc replacement.

The following section describes the operations involved in removing, refitting and adjusting the EPB system. With regard to removal, refitting and mechanically adjusting the braking system, refer to the relative standard. WARNING During maintenance [Maintenance] operations, the EPB system may be locked in a position in which it will NOT brake the vehicle. Make sure that the vehicle is in a condition of safety before performing the following operations. DANGER During maintenance [Maintenance] operations, the EPB system activates automatically. Stay out of the braking system area and do not operate in any way in order to prevent injuries to the limbs.

Replacing or disconnecting the EPB system Bowden cable When replacing or disconnecting the Bowden cable, proceed as follows:

30-567

Method of intervention Connect the ART device to the vehicle diagnostic socket and turn the ignition switch to “ON”. After a few seconds the ART® will present the screen page shown here. Select: [1] -HLHP TTV by pressing the relative button on the tester keypad.

A V A I L A B L E T E S T = = = = = = = = = = = = = = = = M E N U 1 -

H L H P

T T V

C H O I

S E

_

[

E x i

t

E ]

Fig. 2456

The following screen page will now be displayed. Press: E – Exit [Exit] on the keypad to go to the next screen page.

= = = = = D E U T Z S 1 1 T R A N S S P E E D T Y R E S U S P . A S M P T O f o R A D A R A I R C D I S T R F . L I F C A B . M [

H T C 1 - 0 M .

L T 3 4 : : : 6 : : r w : : . : . : T : R D :

H P = = V S M A 4 A F 2 - 2 0 1 4 S 2 4 0 4 0 K m 5 0 / 6 5 3 V I + Y e s N o Y e s Y e s 7 C A N o N o

E ]

E x i

= = = T I C

H D / h R 4 2

N m 3

t

Fig. 2457

Select: 2 - Calibration [Calibrations] Finally, the next page will open. l

M A I N M E N U -------------------

1 2 3 4

-

M C T A

o a e l

n l s a

i i t r

t o r s b r a t i

[

E ]

m

L i

o n s

s t

E x i

t

Fig. 2458

30-568

Method of intervention Select: B - Park Brake [Park Brake] Finally, the next page will open. l

C A L I

B R A T I

= = 1 2 3 4 5 6 7 8 9 A B CD -

= a P M f s s N s g r r r -

= = = = = = = = = = = n s m i s s i o n

[

E ]

= T P A L S S C D E A P A M

= r T S i u y A i n i a g R

O N

t p e n s i t e m t i C k o D

r i n e o n B s k C

M E N U

o n

b u t

o r

d i t i o n e r r a k e y a b i n E x i

t

Fig. 2459

Select: 2 – Maintenance [Maintenance]. Finally, the next page will open. l

P A R K

B R A K E

= = = = = = = = = = = = = = = = 1 2 3 4

-

A M C C

u a a o

t i l n

o n t i b f i

A p p l e n a n . s l g u r a

y c e o p e t i o n

= = = = = = = = = = = = = = = = [

E x i

E ]

t

Fig. 2460

Select: 3 - Default position [Default pos.] If the command is accepted the system displays the next screen page and the EPB device assumes the default position.

P A R K B R A K E M A I N T E N A N C E = S P R N = 1 2 3 4 5 6 =

= t o e u = =

= a s c m = E I D A R C =

= t i o . = E n e p e y =

= u t v = P i f p l c =

= s i e A = R t a l e l =

= : o r P = O . u y a e =

[

E ]

= = = = = A 3 n : y : P L Y = = = = = M l

t

= P 4 W

= P . A

= L 6 R

= Y 0 N 0 = = = =

p o s .

s e T e s t s = = = = = = = = = E x i

t

Fig. 2461

30-569

Method of intervention Turn the ignition switch to “Stop”.

P A R K B R A K E M A I N T E N A N C E = = = = = = = = = = = = = = = =

O p e r a t i o n e x e c u t e d

= = = = = = = = = = = = = = = = [

E ]

E x i

t

Fig. 2462

Remove the Bowden cable forked end to the transmission control lever with an appropriate clip as illustrated in the figure.

Fig. 2463

WARNING Do not remove the EPB actuator under any circumstances! Adjusting the service brakes (right wheel and left wheel) WARNING Ensure that the threaded brake adjuster screws are clean and free of rust or paint. Step 1 - Loosen check nut (1). Step 2 - Tighten the nut (2) to a torque of 30 Nm. Step 3 - Undo the nut (2) completely. Step 4 - Tighten the nut (2) to 15 Nm. Step 5 - Loosen the nut (2) by 1.75 turns. Once adjustment is complete, tighten the check nut (1) to a torque of 80 Nm.

30-570

Method of intervention

Fig. 2464

Loosen the transmission tie-rod adjustment nuts (with a suitable 19 mm wrench) to obtain a clearance of approximately 1 mm.

Fig. 2465

30-571

Method of intervention Use the appropriate feeler gauge as illustrated in the figure. During this operation pull the tie-rod in order to eliminate the mechanical system clearance.

Fig. 2466

Bedding in, adjustment and validation. After having mechanically installed the EPB system and setting the operating parameters, it must be calibrated in order to adjust the Bowden cable correctly and initialize the electronic system. The procedure is divided up into the following phases: 1. Bedding in: l

Procedure composed of 1 initialization and 9 apply and release cycles for bedding in of the Bowden cable and the brake system.

2. Fixing: l

Fastening EPB unit to bracket (not required if EPB actuator was not removed).

3. Mechanical adjustment: l

In this phase the set screws must be adjusted.

4. Validation: l

Consisting of initialization of the EPB device, whereby the system identifies the limit positions of the activation stroke:

l

Release point: System fully released. Apply point: System activated in parking brake applied mode (maximum force applied).

l

At this point the correctness of the mechanical adjustment can be checked. The individual points of the calibration procedure are described below.

Bedding in During this phase the EPB carries out 10 bedding in cycles of the entire system (engagement and release of the park brake); when these cycles have been completed the EPB goes into the Apply position. To do this, proceed as follows: Connect the ART device to the vehicle diagnostic socket and turn the ignition switch to “ON”. After a few seconds the ART® will display the screen page shown in the figure. Select in the following order: 2 - Calibration [Calibrations], B - Park Brake [Park Brake], l 2 – Maintenance [Maintenance]. The page shown in the figure will be displayed. l l

P A R K B R A K E M A I N T E N A N C E = S P R N = 1 2 3 4 5 6 =

= t o e u = =

= a s c m = E I D A R C =

= t i o . = E n e p e y =

= u t v = P i f p l c =

= s i e A = R t a l e l =

= : o r P = O . u y a e =

[

E ]

= = = = = A 3 n : y : P L Y = = = = = M l

t

= P 4 W

= P . A

= L 6 R

= Y 0 N 0 = = = =

p o s .

s e T e s t s = = = = = = = = = E x i

t

Fig. 2466

30-572

Method of intervention The following information is displayed: Status [Status]: l

indicates EPB system status. Possible values: m NOT INIT = system not initialized, m APPLY = EPB applied, m RELEASE = EPB released.

Position [Position]: Current EPB position expressed in mm. Recovery: l

any EPB alarm status. Number of applications [Num. APPLY]: l

Number of APPLY cycles performed during the procedure. In contrast, the possible commands are: EEPROM Reset [EEPROM Reset]: l

P A R K B R A K E M A I N T E N A N C E = S P R N = 1 2 3 4 5 6 =

= t o e u = =

= = a t s i c o . m = = E E I n D e A p R e C y = =

= u t v = P i f p l c =

= s i e A = R t a l e l =

= = : o n r y P P = = O M . u l y a s e = =

[

E ]

= N : : L =

= = = = = = O T I N I N W A R Y = = = = = =

t

p o s .

= T A N 0 =

e T e s t s = = = = = = = = E x i

t

Fig. 2467

Allows the system memory to be cleared. Initialize [Init.]: l

System initialization. Default position [Default pos.]: l

Brings the EPB to the correct position for adjustment of the Bowden cable. Apply [Apply]: l

Activates the EPB, braking the vehicle. Release [Release]: l

Releases the EPB, eliminating the braking force. Test cycles [Cycle tests]: l

l

Execution of the brake system bedding-in tests.

30-573

Method of intervention Select: 6 - Test cycles [Cycle tests]. If the command is accepted the initialisation procedure begins. If the initialisation procedure completes: CORRECTLY the system proceeds with the bedding-in cycle, displaying the relative screen page: “Bedding-in cycles in progress. Please wait...” indicating the number of cycles performed and the current status of the procedure. INCORRECTLY l

l

the relative following screen will be displayed: “Initialisation failed”. At this point: m Turn the ignition switch to “Stop” m Loosen the transmission tie-rod adjustment nuts (with a suitable 19 mm wrench) by 1/4 turn, as illustrated in the “Mechanical adjustment” Section. m Repeat the bedding-in procedure.

P A R K C Y C L E = S P R =

= t o e =

= a s c =

= t i o =

= u t v =

= s i e =

= : o r =

B R A K E T E S T S = = = = = = = = = n : y : = = = = = = = = =

I

n i t i a l i z a t i o n I n P r o g r e s s P l e a s e W a i t . . .

= = = = = = = = = = = = = = = = [

E x i

E ]

t

Fig. 2468

At the end of the 9 bedding-in cycles the EPB system assumes the apply position and the user is presented with the screen page shown in the figure.

P A R K B R A K E M A I N T E N A N C E = S P R N = 1 2 3 4 5 6 =

= t o e u = =

= = a t s i c o . m = = E E I n D e A p R e C y = =

= u t v = P i f p l c =

= s i e A = R t a l e l =

= = : o n r y P P = = O M . u l y a s e = =

[

E ]

= N : : L =

= = = = = = O T I N I N W A R Y = = = = = =

t

p o s .

= T A N 0 =

e T e s t s = = = = = = = = E x i

t

Fig. 2469

Now turn the ignition switch to “Stop”. (1) 2 3

1

STOP

Fig. 2470

30-574

Method of intervention Mechanical adjustment Connect the ART device to the vehicle diagnostic socket and turn the ignition switch to “ON”. After a few seconds the ART® will display the screen page shown in the figure. Select “HLHP TTV” by pressing the relative button on the tester keypad.

A V A I L A B L E T E S T = = = = = = = = = = = = = = = = M E N U 1 -

H L H P

T T V

C H O I

S E

_

[

E x i

t

E ]

Fig. 2470

Select in the following order: l

2 - Calibration [Calibrations], m B - Park Brake [Park Brake], m 2 – Maintenance [Maintenance].

The relative screen will be displayed. Then select: 3 - Default position [Default Pos.] The EPB system will go to the fully released position.

P A R K B R A K E M A I N T E N A N C E = S P R N = 1 2 3 4 5 6 =

= t o e u = =

= = a t s i c o . m = = E E I n D e A p R e C y = =

= u t v = P i f p l c =

= s i e A = R t a l e l =

= = : o n r y P P = = O M . u l y a s e = =

[

E ]

= N : : L =

= = = = = = O T I N I N W A R Y = = = = = =

t

p o s .

= T A N 0 =

e T e s t s = = = = = = = = E x i

t

Fig. 2470

Turn the ignition switch to “Stop” 2 3

1

STOP

Fig. 2470

Tighten or loosen the transmission tie-rod adjustment nuts (with a suitable 19 mm wrench) to obtain a clearance of approximately 1 mm.

Fig. 2471

30-575

Method of intervention Tighten the transmission tie-rod adjustment nuts by one more turn with a suitable 19 mm wrench.

Fig. 2472

Validation In this stage the EPB system is initialized electronically and an “Apply/Release” procedure is performed. In this manner the system is able to identify the correct operating travel, thus allowing the user to check the correct mechanical adjustment of the Bowden cable. Proceed as follows: Connect the ART device to the vehicle diagnostic socket, turn the tractor ignition switch to “ON” and select “HLHP TTV”. Then: l l l l

2 - Calibration [Calibrations], B - Park Brake [Park Brake], 2 – Maintenance [Maintenance], 2 - Initialize [Init.].

The EPB system carries out an initialisation, stopping in the Apply position. Check that on the display, in correspondence to the second line: Position: xx.xx, the value in Apply is between: 30.00 and 34.00 mm. WARNING This course refers both to a braking system with new brakes and a system in which mechanical adjustment of the brakes has been carried out. 3 possible conditions: l

l

l

a) If the value is between 30.00 and 34.00 proceed with carrying out the next operations. b) If the value is lower than 30.00, the following will appear on the display: “Initialisation failed – Switch off the system and adjust the Bowden”. Turn the tractor ignition switch to “Stop”, loosen the transmission tie-rod adjustment nuts (with a suitable 19 mm wrench) by a 1/4 turn, and restart the procedure from the beginning. c) If the value is greater than 34.00, select: [3] - Default and turn the tractor ignition switch to “Stop”. Tighten the transmission tie-rod adjustment nuts 1/4 turn (using an appropriate 19 mm wrench) and restart the procedure from the beginning.

When the procedure is complete carry out the following operations. Press the button: 5 – Release [Release] E – Exit [Exit] 4 – Apply [Apply] 3 - Default position [Default Pos.] E – Exit [Exit] Turn the tractor ignition switch to “Stop”. (1)

P A R K B R A K E M A I N T E N A N C E = S P R N = 1 2 3 4 5 6 =

= t o e u = =

= a s c m = E I D A R C =

= t i o . = E n e p e y =

= u t v = P i f p l c =

= s i e A = R t a l e l =

= : o r P = O . u y a e =

[

E ]

= = = = = A 3 n : y : P L Y = = = = = M l

t

= P 4 W

= P . A

= L 6 R

= Y 0 N 0 = = = =

p o s .

s e T e s t s = = = = = = = = = E x i

t

Fig. 2472

2 3

1

STOP

Fig. 2472

Reconnect the trailer pneumatic brake tie-rod, adjusting the length of the tie-rod so that it will fit onto the ball joints.

30-576

Method of intervention Repeat the validation procedure with the tie-rod connected.

Clearing alarms and statistics After having fitted and adjusted the EPB system, the alarms and system statistics must be deleted. Cancel alarms. To cancel EPB passive alarms, select the following, in sequence: l l l

4 - Alarm List [Alarm List] D - Delete [Delete] 6 - EPB [EPB]

M A I N M E N U -------------------

1 2 3 4

-

M C T A

o a e l

n l s a

i i t r

t o r s b r a t i

[

E ]

m

L i

o n s

s t

E x i

t

Fig. 2472

If the clearing is completed successfully the screen shown in the figure will appear.

A L A R M

L I

S T

= = = = = = = = = = = = = = = =

A l

a r

m s e r

a r

e

b e e n

a s e d .

= = = = = = = = = = = = = = = = [

E ]

E x i

t

Fig. 2473

Clear statistics To clear the system statistics saved on the Service ECU proceed as follows: Starting from the main Menu select in the following order: l l l l l

1 - Monitor [Monitor] B - Park Brake [Park Brake] 5 - Statistics [Statistics] 5 - Failure [Failure] C - Erase [Erase]

Then, starting again from the main Menu select in the following order: l l l l l

1 - Monitor [Monitor] B - Park Brake [Park Brake] 5 - Statistics [Statistics] 1 - Page 1 [Page 1] C - Erase [Erase]

30-577

Method of intervention 30.7.31 - Procedure to check EPB stroke (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Purpose of the document

The procedure described is valid for machines with the following transmission: l

SMatic 240

The purpose of this document is to illustrate the actions to take in order to check the stroke of the EPB (Electric Parking Brake) system, P/N: 0.018.6330.4/10. The document is compatible with software versions: Transmission: l

EPB: 3.0.0.0 / 3.1.0.0 / 3.2.0.0

The document is focused on the mechanical/electronic procedures required for checking. The EPB system stroke check is permitted only with the aid of: l l

the SDF Analyser diagnostic programme the A.R.T. (All Round Tester) diagnostic instrument

Fig. 2473

30-578

Method of intervention

Fig. 2473 - Connection via the A.R.T (All Round Tester)

Fig. 2473 - Connection with SDF Analyser

Operations on the brake system Work performed on the brake system includes all the workshop tasks aimed at replacing, repairing or adjusting one or more components of the service or parking brake system. The following are examples of brake system operations: l l l l l

Replacement of rear brake discs, Brake system adjustment operations, Replacement of the EPB system, Removal and refitting of the EPB system, Disconnection and reconnection of the Bowden cable from and to the brake system.

To perform the operations described above the main actions are as follows, in sequence: 1. 2. 3. 4. 5.

Removing the EPB system, Installation of the EPB system, EPB parameter setting, Adjusting the EPB system, Clearing EPB alarms and relative statistics.

Removal of the EPB system may be required in cases including but not limited to the following: l l

EPB replacement due to fault, for example. Brake disc replacement.

The following section describes the operations involved in removing, refitting and adjusting the EPB system. With regard to removal, refitting and mechanically adjusting the braking system, refer to the relative standard.

30-579

Method of intervention WARNING During “Maintenance” operations, the EPB system may be locked in a position that DOES NOT guarantee braking of the vehicle. Make sure that the vehicle is in a condition of safety before performing the following operations. DANGER During the “Maintenance” operations the EPB system carries out automatic activations. Stay out of the braking system area and do not operate in any way in order to prevent injuries to the limbs.

Replacement or disconnection of the EPB system bowden cable To replace or disconnect the Bowden cable, proceed as described below: Connect the ART device to the vehicle diagnostic socket and turn the ignition key to “ON”. After a few seconds the ART® will present the screen page shown here. Select: [1] -HLHP TTV by pressing the relative button on the tester keypad.

A V A I L A B L E T E S T = = = = = = = = = = = = = = = = M E N U 1 -

H L H P

T T V

C H O I

S E

_

[

E x i

t

E ]

Fig. 2473

The following screen page will now be displayed. Press: E - Exit [Exit] on the keypad to go to the next screen.

= = = = = D E U T Z S 1 1 T R A N S S P E E D T Y R E S U S P . A S M P T O f o R A D A R A I R C D I S T R F . L I F C A B . M [

H T C 1 - 0 M .

L T 3 4 : : : 6 : : r w : : . : . : T : R D :

H P = = V S M A 4 A F 2 - 2 0 1 4 S 2 4 0 4 0 K m 5 0 / 6 5 3 V I + Y e s N o Y e s Y e s 7 C A N o N o

E ]

E x i

= = = T I C

H D / h R 4 2

N m 3

t

Fig. 2473

30-580

Method of intervention Select: 2 - Calibrations [Calibrations] Finally, the next page will open. l

M A I N M E N U -------------------

1 2 3 4

-

M C T A

o a e l

n l s a

i i t r

t o r s b r a t i

[

E ]

m

L i

o n s

s t

E x i

t

Fig. 2473

Select: B - Park Brake [Park Brake] Finally, the next page will open. l

C A L I

B R A T I

= = 1 2 3 4 5 6 7 8 9 A B CD -

= a P M f s s N s g r r r -

= = = = = = = = = = = n s m i s s i o n

[

E ]

= T P A L S S C D E A P A M

= r T S i u y A i n i a g R

O N

t p e n s i t e m t i C k o D

r i n e o n B s k C

M E N U

o n

b u t

o r

d i t i o n e r r a k e y a b i n E x i

t

Fig. 2473

Select: 2 - Maintenance [Maintenance]. Finally, the next page will open. l

P A R K

B R A K E

= = = = = = = = = = = = = = = = 1 2 3 4

-

A M C C

u a a o

t i l n

o n t i b f i

A p p l e n a n . s l g u r a

y c e o p e t i o n

= = = = = = = = = = = = = = = = [

E ]

E x i

t

Fig. 2473

30-581

Method of intervention Select: 3 - Default position [Default pos.] If the command is accepted the system displays the next screen page and the EPB device assumes the default position.

P A R K B R A K E M A I N T E N A N C E = S P R N = 1 2 3 4 5 6 =

= t o e u = =

= a s c m = E I D A R C =

= t i o . = E n e p e y =

= u t v = P i f p l c =

= s i e A = R t a l e l =

= : o r P = O . u y a e =

[

E ]

= = = = = A 3 n : y : P L Y = = = = = M l

t

= P 4 W

= P . A

= L 6 R

= Y 0 N 0 = = = =

p o s .

s e T e s t s = = = = = = = = = E x i

t

Fig. 2473

Turn the key to “Stop”position.

P A R K B R A K E M A I N T E N A N C E = = = = = = = = = = = = = = = =

O p e r a t i o n e x e c u t e d

= = = = = = = = = = = = = = = = [

E ]

E x i

t

Fig. 2473

Remove the bowden cable forked end to the transmission control lever with an appropriate clip as illustrated in the figure.

Fig. 2473

WARNING (!) Only for Smatic 240 transmissions (!): Disconnect the trailer pneumatic brake tie-rod in order to remove any mechanical hindrance. WARNING Do not remove the EPB actuator unit under any circumstances! Adjusting the service brakes (right wheel and left wheel) WARNING Ensure that the brake threaded set screws are clean and free of rust or pain.

30-582

Method of intervention Step 1 - Loosen check nut (1). Step 2 - Tighten the nut (2) to a torque of 30 Nm. Step 3 - Fully unscrew the nut (2). Step 4 - Tighten the nut (2) to a torque of 15 Nm. Step 5 - Loosen the nut (2) by 2 turns. Once adjustment has been completed, tighten the check nut (1) to a torque of 80 Nm.

Fig. 2473

30-583

Method of intervention Loosen the transmission tie-rod adjustment nuts (with an appropriate 19 mm wrench) until obtaining clearance of about 1 mm.

Fig. 2473

Use the appropriate feeler gauge as illustrated in the figure. During this operation pull the tie-rod in order to eliminate the mechanical system clearance.

Fig. 2473

Bedding in, adjustment and validation. After having mechanically installed the EPB system and setting the operating parameters, it must be calibrated in order to adjust the Bowden cable correctly and initialize the electronic system. The procedure is divided up into the following phases: 1. Bedding in: l

Procedure composed of 1 initialization and 9 apply and release cycles for bedding in of the Bowden cable and the brake system.

2. Fixing: l

Fixing of the EPB to the bracket (not required if the EPB actuator unit was not removed).

3. Mechanical adjustment: l

In this phase the set screws must be adjusted.

4. Validation: l

Consisting of initialization of the EPB device, whereby the system identifies the limit positions of the activation stroke:

l

Release point: System fully released. Apply point: System activated in parking brake applied mode (maximum force applied).

l

At this point the correctness of the mechanical adjustment can be checked. The individual points of the calibration procedure are described below.

Bedding in During this phase the EPB carries out 10 bedding in cycles of the entire system (engagement and release of the park brake); when these cycles have been completed the EPB goes into the Apply position. To do this, proceed as follows:

30-584

Method of intervention Connect the ART device to the vehicle diagnostic socket and turn the ignition key to “ON”. After a few seconds the ART® will display the screen page shown in the figure. Select in the following order: 2 - Calibrations [Calibrations], B - Park Brake [Park Brake], l 2 - Maintenance [Maintenance]. The page shown in the figure will be displayed. l l

P A R K B R A K E M A I N T E N A N C E = S P R N = 1 2 3 4 5 6 =

= t o e u = =

= a s c m = E I D A R C =

= t i o . = E n e p e y =

= u t v = P i f p l c =

= s i e A = R t a l e l =

= : o r P = O . u y a e =

[

E ]

= = = = = A 3 n : y : P L Y = = = = = M l

t

= P 4 W

= P . A

= L 6 R

= Y 0 N 0 = = = =

p o s .

s e T e s t s = = = = = = = = = E x i

t

Fig. 2473

The following information is displayed: Status [Status]: l

indicates EPB system status. Possible values: m NOT INIT = system not initialized, m APPLY = EPB applied, m RELEASE = EPB released.

Position [Position]: Current EPB position expressed in mm. Recovery: l

any EPB alarm status. Number of APPLY cycles [Num. APPLY]: l

Number of APPLY cycles performed during the procedure. In contrast, the possible commands are: EEPROM Reset [EEPROM Reset]: l

P A R K B R A K E M A I N T E N A N C E = S P R N = 1 2 3 4 5 6 =

= t o e u = =

= = a t s i c o . m = = E E I n D e A p R e C y = =

= u t v = P i f p l c =

= s i e A = R t a l e l =

= = : o n r y P P = = O M . u l y a s e = =

[

E ]

= N : : L =

= = = = = = O T I N I N W A R Y = = = = = =

t

p o s .

= T A N 0 =

e T e s t s = = = = = = = = E x i

t

Fig. 2473

Allows the system memory to be cleared. Initialization [Init.]: l

System initialization. Default position [Default pos.]: l

Brings the EPB to the correct position for adjustment of the Bowden cable. Apply [Apply]: l

Activates the EPB, braking the vehicle. Release [Release]: l

Releases the EPB, eliminating the braking force. Cycle tests [Cycle tests]: l

l

Execution of the brake system bedding-in tests.

30-585

Method of intervention Select: 6 - Cycle tests [Cycle tests]. If the command is accepted the initialisation procedure begins. If the initialisation procedure completes: CORRECTLY the system proceeds with the bedding-in cycle, displaying the relative screen page: “Bedding-in cycles in progress. Please wait...” indicating the number of cycles performed and the current status of the procedure. INCORRECTLY l

l

the relative following screen will be displayed: “Initialisation failed”. At this point: m Turn the key to the “Stop”position. m Loosen the transmission tie-rod adjustment nuts (with an appropriate 19 mm wrench) 1/4 turn, as illustrated in the “Mechanical adjustment” Section. m Repeat the bedding-in procedure.

P A R K C Y C L E = S P R =

= t o e =

= a s c =

= t i o =

= u t v =

= s i e =

= : o r =

B R A K E T E S T S = = = = = = = = = n : y : = = = = = = = = =

I

n i t i a l i z a t i o n I n P r o g r e s s P l e a s e W a i t . . .

= = = = = = = = = = = = = = = = [

E x i

E ]

t

Fig. 2473

At the end of the 9 bedding-in cycles the EPB system assumes the apply position and the user is presented with the screen page shown in the figure.

P A R K B R A K E M A I N T E N A N C E = S P R N = 1 2 3 4 5 6 =

= t o e u = =

= = a t s i c o . m = = E E I n D e A p R e C y = =

= u t v = P i f p l c =

= s i e A = R t a l e l =

= = : o n r y P P = = O M . u l y a s e = =

[

E ]

= N : : L =

= = = = = = O T I N I N W A R Y = = = = = =

t

p o s .

= T A N 0 =

e T e s t s = = = = = = = = E x i

t

Fig. 2473

At this point the key must be turned to the “Stop” position. (1) 2 3

1

STOP

Fig. 2473

30-586

Method of intervention Mechanical adjustment Connect the ART device to the vehicle diagnostic socket and turn the ignition key to “ON”. After a few seconds the ART® will display the screen page shown in the figure. Select “HLHP TTV” by pressing the relative button on the tester keypad.

A V A I L A B L E T E S T = = = = = = = = = = = = = = = = M E N U 1 -

H L H P

T T V

C H O I

S E

_

[

E x i

t

E ]

Fig. 2473

Select in the following order: l

2 - Calibrations [Calibrations], m B - Park Brake [Park Brake], m 2 - Maintenance [Maintenance].

The relative screen will be displayed. Then select: 3 - Default position [Default Pos.] The EPB system will go to the fully released position.

P A R K B R A K E M A I N T E N A N C E = S P R N = 1 2 3 4 5 6 =

= t o e u = =

= = a t s i c o . m = = E E I n D e A p R e C y = =

= u t v = P i f p l c =

= s i e A = R t a l e l =

= = : o n r y P P = = O M . u l y a s e = =

[

E ]

= N : : L =

= = = = = = O T I N I N W A R Y = = = = = =

t

p o s .

= T A N 0 =

e T e s t s = = = = = = = = E x i

t

Fig. 2473

Turn the key to the “Stop”position 2 3

1

STOP

Fig. 2473

Tighten or loosen the transmission tie-rod adjustment nuts (with an appropriate 19 mm wrench) until obtaining clearance of about 1 mm.

Fig. 2473

30-587

Method of intervention Tighten the transmission tie-rod adjustment nuts 1 more turn (using an appropriate 19 mm wrench).

Fig. 2473

Validation In this stage the EPB system is initialized electronically and an “Apply/Release” procedure is performed. In this manner the system is able to identify the correct operating stroke, thus allowing the user to check the correct mechanical adjustment of the Bowden cable. Proceed as follows: Connect the ART device to the vehicle diagnostic socket, turn the tractor ignition key to “ON” and select “HLHP TTV”. Then: l l l l

2 - Calibrations [Calibrations], B - Park Brake [Park Brake], 2 - Maintenance [Maintenance], 2 - Initialisation [Init.].

The EPB system carries out an initialisation, stopping in the Apply position. Check that on the display, in correspondence to the second line: Position: xx.xx, the value in Apply is between: 30.00 and 34.00 mm. WARNING This course refers both to a braking system with new brakes and a system in which mechanical adjustment of the brakes has been carried out. 3 possible conditions: l

l

l

a) If the value is between 30.00 and 34.00 proceed with carrying out the next operations. b) If the value is lower than 30.00, the following will appear on the display: “Initialisation Failed – Switch off the system and adjust the bowden”. Turn the tractor ignition key to “Stop” and loosen the transmission tie-rod adjustment nuts (with an appropriate 19 mm wrench) 1/4 turn and restart the procedure from the beginning. c) If the value is greater than 34.00, select: [3] - Default and turn the tractor ignition key to “Stop”. Tighten the transmission tie-rod adjustment nuts 1/4 turn (using an appropriate 19 mm wrench) and restart the procedure from the beginning.

When the procedure is complete carry out the following operations. Press the button: 5 - Release [Release] E - Exit [Exit] 4 - Apply [Apply] 3 - Default position [Default Pos.] E - Exit [Exit] Turn the tractor ignition key to the “Stop” position. (1)

P A R K B R A K E M A I N T E N A N C E = S P R N = 1 2 3 4 5 6 =

= t o e u = =

= a s c m = E I D A R C =

= t i o . = E n e p e y =

= u t v = P i f p l c =

= s i e A = R t a l e l =

= : o r P = O . u y a e =

[

E ]

= = = = = A 3 n : y : P L Y = = = = = M l

t

= P 4 W

= P . A

= L 6 R

= Y 0 N 0 = = = =

p o s .

s e T e s t s = = = = = = = = = E x i

t

Fig. 2473

2 3

1

STOP

Fig. 2473

Reconnect the trailer pneumatic brake tie-rod, adjusting the length of the tie-rod so that it will fit onto the ball joints.

30-588

Method of intervention Repeat the validation procedure with the tie-rod connected.

Clearing alarms and statistics After having fitted and adjusted the EPB system, the alarms and system statistics must be deleted. Cancel alarms. To cancel EPB passive alarms, select the following, in sequence: l l l

4 - Alarms [Alarm List] D - Delete [Delete] 6 - EPB [EPB]

M A I N M E N U -------------------

1 2 3 4

-

M C T A

o a e l

n l s a

i i t r

t o r s b r a t i

[

E ]

m

L i

o n s

s t

E x i

t

Fig. 2473

If the clearing is completed successfully the screen shown in the figure will appear.

A L A R M

L I

S T

= = = = = = = = = = = = = = = =

A l

a r

m s e r

a r

e

b e e n

a s e d .

= = = = = = = = = = = = = = = = [

E ]

E x i

t

Fig. 2473

Clear statistics To clear the system statistics saved on the Service ECU proceed as follows: Starting from the main Menu select in the following order: l l l l l

1 - Monitor [Monitor] B - Park Brake [Park Brake] 5 - Statistics [Statistics] 5 - Failure [Failure] C - Erase [Erase]

Then, starting again from the main Menu select in the following order: l l l l l

1 - Monitor [Monitor] B - Park Brake [Park Brake] 5 - Statistics [Statistics] 1 - Page 1 [Page 1] C - Erase [Erase]

30-589

Method of intervention 30.8 - F0 - Front axle

30.8.1 - Toe-in/steering angle/assembly tests

Fig. 2474 - Toe-in/steering angle 1. 2. 3. 4. 5. 6.

Tie-rod Lock nut Ball joint rod Screw Locknut Axle beam

Toe-in check 1.

IMPORTANT: The two bars should be secured at the midpoint of their length, so that they are perfectly perpendicular to the supporting surface of the hub and parallel to the axis of the pinion; ensure the two bars are aligned. Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. Place two identical straight bars, 1 metre in length, on the outsides of the front wheels, securing them in position with two nuts on the studs on the wheel hubs.

30-590

Fig. 2475

Method of intervention 2.

NOTE: Take the shortest distance, changing the point of measurement. Using a tape measure, measure the distances in millimetres M between the two ends of the two bars.

Fig. 2476

3.

Check that the difference between the measurements at the outside edged of the wheel hubs is within the specified tolerance range. The nominal toe-in value (A) refers to the distance between the outside diameters of the wheel hub flanges, thus the distance (M) measured between the ends of the bars must be adjusted proportionally nominal. nominal = A (0, -2) => measured toe-in = M (0, -5)

Fig. 2477

4.

If the toe-in is not within the specified tolerance range, using two wrenches on tie-rods (1), screw ball joint rods (3) in or out as required, adjusting both sides equally.

Fig. 2478

5.

After adjustment, tighten lock nuts (2) of tie-rods (1) to the specified torque.

Fig. 2479

30-591

Method of intervention Steering angle adjustment 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. NOTE: The tractor is supplied with the steering angle set to 30°.

Adjust the mechanical steering stops on the pinion side to the indicated value “A”, by screwing the screws (4) in or out. Secure screws (4) in position by tightening lock nut (5) to the specified torque. Adjust the steering angle by selecting the corresponding value of “A”.

Fig. 2480

Table 357 Steering 30° angle Value of 79 mm “A”

35°

40°

45°

50°

53°

66 mm

52 mm

37 mm

23 mm

16 mm

Toe-in/steering angle/assembly tests Test Procedures Step 1 With the engine off, raise the drive wheel’s axle until the tyres are off the ground. Step 2 Engage the gear to block the pinion. Step 3 With another person on the other side of the tractor, start the assembly test by turning both wheels as far as possible in the forwards drive direction. (Both wheels should lock up after a short distance) Step 4 Witht eh pinion still locked, free the RH wheel and turn the LH wheel in the forwards drive direction. If the assembly is correct, the wheel should turn freely without forcing, while the RH wheel should turn in the opposite direction. Repeat in the opposite direction (reverse drive direction). IF EITHER OF THE WHEELS DOES NOT TURN FREELY IN BOTH DIRECTIONS, check the assembly procedure step by step. Also check that the brakes are properly adjusted.

30-592

Method of intervention 30.8.2 - Steering cylinders assembly

Fig. 2481 - Steering cylinder assembly 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.

Tie-rod Lock nut Ball joint Fixing bolt Cylinder Ball joint Lock nut Tie-rod Steering knuckle Nut Steering knuckle Nut Oil seal Oil seal Steering cylinder end cap Cylinder body Oil seal Cylinder rod Oil seal Steering cylinder head Oil seal Oil seal Bulkhead fittings Tube Fittings Tube Screws Flange Bushes

30-593

Method of intervention Disassembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. Disconnect the pipes (24) and (26) from the unions (25) on the axle beam and steering cylinder end caps.

Fig. 2482

2.

Remove the unions (25) from the steering cylinder end caps (15) and (20).

Fig. 2483

3.

If necessary, remove the bulkhead unions (23) from the axle beam assembly.

Fig. 2484

4.

NOTE: This operation will destroy the nut.

Loosen the nuts (10) and (12) securing the steering tie-rods by a few turns to take them beyond the end of the threaded pin. Tap the nut with a hammer to separate the tie-rod from the steering knuckle.

Fig. 2485

5.

Undo the screws (27) and remove the flange (28) and bushings (29) using a rubber mallet if necessary.

Fig. 2486

30-594

Method of intervention 6.

Remove steering tie-rods (1) and (8) by loosening nuts (2) and (7), and check their condition. Unscrew retaining screws (4) and withdraw cylinder (5) from its seat, using a rubber mallet to help free it, if necessary. Remove only those parts which are to be overhauled or renewed

Fig. 2487

7.

Detach (15) and (20) and extract the rod (18) from the cylinder body (16). Recover all seals and O-rings (13, 14, 17, 19, 21 and 22) from the cylinder rod and end caps.

Fig. 2488

Assembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. Install new oil seals (13, 14, 17, 19, 21 and 22) on rod (18) and on cylinder end caps (15) and (20). Insert rod (18) in cylinder body (16) and fit end caps (15) and (20).

Fig. 2489

2.

Fit ball joints (3) and (6) to the ends of rod (18), tightening them with a torque wrench to the specified torque.

Fig. 2490

30-595

Method of intervention 3.

Apply the recommend sealant to the threads of screws (4). Fit and tighten retaining screws (4) of cylinder end caps (5) to the specified torque

Fig. 2491

4.

IMPORTANT: The end caps (15) and (20) must adhere perfectly to the cylinder (16). Hold the end caps (15) and (20) against the cylinder (16) and tighten down the retainer screws (4) to the specified torque.

Fig. 2492

5.

IMPORTANT: Check that the gap between the end caps and the cylinder is no more than 0.1 mm. Use a 0.1 mm feeler gauge; it must not be able to fit between the end caps and the cylinder.

Fig. 2493

6.

Apply the recommend sealant to the threads of screws (4). Fit and tighten retaining screws (4) of cylinder end caps (5) to the specified torque

Fig. 2494

30-596

Method of intervention 7.

Fit pipe unions (25) to steering cylinder end caps (15) and (20).

Fig. 2495

8.

Fit bulkhead unions (23) to the axle beam assembly and tighten to the specified torque.

Fig. 2496

9.

Attach the pipes (24) and (26) to the unions (23) in the axle assembly and in the steering cylinder end caps.

Fig. 2497

10.

NOTE: It is necessary to unscrew lock nut (2) to carry out this operation. NOTE: Repeat the above operations on the opposite side.

11.

Position steering knuckle (11) in line with the axle. Screw in tie-rod (1) a sufficient distance to be able to insert its ball joint end in the relative location on steering knuckle (11).

Fig. 2498

Insert the ball joint of tie-rod (8) in the relative location on steering knuckle (9) Fit and tighten retaining nut (10) with a torque wrench to the specified torque. Repeat the above operations on the opposite side.

Fig. 2499

30-597

Method of intervention 12.

Do not tighten nuts (2) and (7) of tie-rods (1) and (8) until the toe-in has been adjusted. See para. 30.8.1 - Toe-in/steering angle/... - page 30-590

Fig. 2500

30.8.3 - Axle shaft assembly

Fig. 2501 - Axle beam assembly 1. 2. 3. 4. 5.

Axle shaft and double U joint assembly Axle beam Cover Oil seal Bush

30-598

Method of intervention Disassembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. Withdraw the two (one of the left and one on the right) double U joints (1) from the axle beam (2).

Fig. 2502

2.

NOTE: This operation will destroy the cover.

Remove cover (3) from the two double U joints (1).

Fig. 2503

3.

NOTES: This operation will destroy the oil seals (4).

Remove oil seals (4) from axle beam (2) using a puller. IMPORTANT: Take care not to damage the bush seats.

Remove bushes (5) from axle beam (2) only if they are worn and require renewal.

Fig. 2504

30-599

Method of intervention Assembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. Install bearing (5) in axle beam (2) using drift 5.9035.161.0 and a hammer. Install oil seal (4) in axle beam (2) using drift 5.9035.162.0 and a hammer.

Fig. 2505

2.

IMPORTANT: Orient oil seal (4) as shown in the figure.

Fig. 2506

3.

IMPORTANT: Do not damage the oil seal (4).

Insert double U joint assembly (1) in axle beam (2).

Fig. 2507

4.

NOTE: Install the right way round as shown

Fit cover (3) from the side of the short shaft of the double U joint using drift 5.9035.166.0 (b).

Fig. 2508

30-600

Method of intervention 30.8.4 - Flange assembly

Fig. 2509 - Flange assembly 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Screw Washer Shim Flange Cover Oil seal O-ring Washer Pinion shaft Differential carrier

Disassembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. Remove screw (1) from pinion shaft (9). Recover washer (2) and shims (3).

Fig. 2510

30-601

Method of intervention 2.

Withdraw flange (4) from pinion shaft (9). Remove cover (5) from flange (4).

Fig. 2511

3.

NOTE: This operation will destroy oil seal (6).

Remove oil seal (6) from differential carrier (10). Remove O-ring (7) and washer (8).

Fig. 2512

Assembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. NOTE: Do not install O-ring (7).

Install washer (8) on pinion shaft (9). Install a new oil seal (6) in differential carrier (10) using service tool 5.9035.160.0 and a hammer. 2.

Fig. 2513

Fit cover (5) to flange (4). Assemble flange (4) to pinion shaft (9).

Fig. 2514

30-602

Method of intervention 3.

Check that the flange is snug and measure the distance Q from the end of the pinion shaft to the contact surface for washer (3).

Fig. 2515

4.

Select shims (3) of thickness (S) from those available to bring the play within the indicated range: Q-S= 0.00 to 0.05 mm

Table 358 GAMMA SPESSORI - SHIMS RANGE

Thickness - mm 0.05 Quantity -

0.10 -

0.20 Fig. 2516

5.

Remove screw (1), washer (2) and flange (4). Lubricate a new O-ring (7) and install it on pinion shaft (9). Install flange (4).

Fig. 2517

6.

Install shims (3) and washer (2). Fit screw (1) to pinion shaft (9). Tighten screw (1) to the specified torque.

Fig. 2518

30-603

Method of intervention 30.8.5 - Differential assembly - carrier

Fig. 2519 - Differential carrier assembly 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Axle beam Locating dowel Locating dowel Differential cage Screw Adjuster ringnut Bearing Differential carrier Bush Screw Screw Bearing O-ring O-ring Adjustment nut

30-604

Method of intervention Disassembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. Drain all the oil from the differential. IMPORTANT: Support differential carrier (8) using a hoist or a suitable stand. Unscrew and remove the screws (10) and withdraw the differential carrier (8). Fig. 2520

2.

Measure the total preload T0 of the bearings (crown wheel/pinion system), using a dynamometer and a string wrapped around the splined end of the pinion shaft.

Fig. 2521

3.

Before removing ringnuts (6) and (15), make indelible reference marks on the nuts and differential carrier (8) to ensure correct positioning on reassembly.

Fig. 2522

4.

Remove screws (5) and (11).

Fig. 2523

30-605

Method of intervention 5.

NOTES: Adjuster ringnuts (6) and (15) are not identical; note which way round the nuts are installed relative to the crown wheel. Unscrew adjuster ringnuts (6) and (15) with special wrench 5.9035.025.0.

Fig. 2524

6.

Remove adjuster ringnuts (6) and (15).

Fig. 2525

7.

Remove the cones of bearings (7) and (12) using a lever in the positions indicated.

Fig. 2526

8.

Remove O-rings (13) and (14) from adjuster ring (15).

Fig. 2527

9.

Remove the differential cage (4).

Fig. 2528

30-606

Method of intervention Assembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. IMPORTANT: If new bearings are not fitted, make sure that the cones are not inverted but reinstalled in their original positions. Install bearing (7) on adjuster ring (6) using service tool 5.9035.158.0

Fig. 2529

2.

Lubricate and install O-rings (13) and (14) on adjuster ring (15).

Fig. 2530

3.

Install bearing (12) on adjuster ring (15) using service tool 5.9035.158.0

Fig. 2531

4.

IMPORTANT: Check that the crown wheel is installed the right way round.

Install the differential cage on differential carrier (8). Shift the differential cage so as to bring the crown wheel into contact with the bevel pinion.

Fig. 2532

30-607

Method of intervention 5.

Install adjuster ring (6) on differential carrier (8) from the crown wheel side.

Fig. 2533

6.

Install adjuster ring (15) on the differential carrier (8).

Fig. 2534

7.

NOTE: Check that differential bearings are properly seated, tapping them gently with a rubber mallet if necessary. Tighten adjuster rings (6) and (15) onto the differential carrier using service tool 5.9035.025.0 to take up the play and apply a slight preload to the differential bearings.

Fig. 2535

8.

Position a dial gauge with a magnetic stand on the differential carrier, so that the contact point is at 90° to the side of a tooth on the crown wheel.

Fig. 2536

30-608

Method of intervention 9.

While holding the pinion firm, rotate the crown wheel alternately in opposite directions and note the pinion/crown wheel backlash shown on the dial gauge. Measure the backlash at two or more points (teeth) by turning the crown wheel, and take the average value. Check if the value is within the prescribed limits: 0.15 to 0.20 mm Adjust the backlash by turning the adjuster rings (6) and (15) with service tool 5.9035.025.0. Fig. 2537

10.

Adjust the ringnuts (6) and (15), remembering that: (A) - if the measured backlash is below the specified minimum value, unscrew adjuster ring (6) and screw in adjuster ring (15) by the same amount; (B) - if the measured backlash is greater than the specified maximum value, unscrew adjuster ring (15) and screw in adjuster ring (6) by the same amount.

Fig. 2538

11.

Repeat the entire sequence of operations until the prescribed conditions are met.

Fig. 2539

12.

NOTE: Use this method only if the bearings have already been run in. Once the correct crown wheel/pinion backlash has been established, measure the total preload Tm of the bearings (crown wheel/pinion system), using a dynamometer and a string wrapped around the splined end of the pinion shaft. The measured value must be equal to the initial value: Tm = T0

Fig. 2540

30-609

Method of intervention 13.

If new bearings have been installed, measure the total bearing preload Tm (crown wheel/pinion system), using a dynamometer and a string wrapped around service tool 5.9035.021.0 installed on the splined end of the pinion shaft.

Fig. 2541

14.

IMPORTANT: Acceptable values with new bearings.

The total preload Tm is measured on service tool 5.9035.021.0 (calibrated diameter Dm= 104.4 mm). The measured value must be within the following range: Tm = (Pm+29) to (Pm+34) N

15.

where Pm is the effective preload measured on service tool 5.9035.021.0 (calibrated diameter Dm= 104.4 mm) See para. 30.8.9 - Bevel pinion assembly - page 30-628

Fig. 2542

If the measured value is not within the specified range, check carefully that all the components are correctly installed and adjust the differential carrier adjuster rings (6) and (15): (A) - if the measured preload is below the specified minimum value, screw in both adjuster rings (6) and (15) by equal amounts, maintaining the crown wheel /pinion backlash unchanged; (B) - if the measured preload is exceeds the specified maximum value, unscrew both adjuster rings (6) and (15) by equal amounts, maintaining the crown wheel /pinion backlash unchanged. Fig. 2543

16.

NOTE: Apply the recommend adhesive to the threads of the screws.

IMPORTANT: Only turn the adjuster rings (6) and (15) the minimum amount necessary to allow insertion of retaining screws (5) and (11). After completing all the adjustment operations, install the adjuster ring retaining screws (5) and (11). Tighten the adjuster ring retaining screws (5) and (11) with a torque wrench to the specified torque.

30-610

Fig. 2544

Method of intervention 17.

Apply oil at a pressure of 13 to 15 bar at the differential engagement inlet for a period of 3 minutes and check for oil leaks

Fig. 2545

18.

NOTE: Check that the dowels (2) and (3) are located correctly.

Before bringing the machined surfaces of parts into contact, check that there are no contaminants present and clean thoroughly using specific detergents. Apply a film of sealant to the contact surfaces of axle beam (1) and the differential carrier (8). Fig. 2546

19.

Fit differential carrier (8) to axle beam (1), securing it with the screws (10) tightened to the specified torque.

Fig. 2547

30-611

Method of intervention 30.8.6 - Checking the bevel gear pair 1.

NOTE: To check the tooth contact pattern of the bevel gear pair, coat the crown wheel with minium and rotate to identify the tooth contact pattern. The tooth contact pattern should always be checked on both sides of the teeth of the crown wheel.

Fig. 2548

2.

OK -> Correct tooth contact: If the bevel gear pair is correctly adjusted, the tooth contact pattern will be regular. Z -> Excessive contact at top of tooth: Bring the pinion closer to the crown wheel and then move the crown wheel away from the pinion to adjust the backlash. X -> Excessive contact at bottom of tooth: Move the pinion further away from the crown wheel and then bring the crown wheel closer to the pinion to adjust the backlash. Fig. 2549

3.

Corrections: 3.1. move the pinion to correct tooth contact type X. 3.2. move the pinion to correct tooth contact type Z.

Fig. 2550

30-612

Method of intervention 30.8.7 - Differential disassembly

Fig. 2551 - Differential unit 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.

Bearing cup Dowel Fixing bolt Crown wheel Differential cage Planetary reduction gear Cross gate Planet gear Thrust washer Planet carrier pin Planet carrier pin Dowel Planetary reduction gear Spacer Pressure plate Disc O-ring O-ring Piston Washer O-ring Cover Fixing bolt Oil seal O-ring Spacer O-ring Oil seal Washer Bearing cup 30-613

Method of intervention Disassembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. See para. 30.8.5 - Differential assembly ... - page 30-604

Fig. 2552

2.

NOTE: This operation will destroy the oil seal.

Remove oil seal (28).

Fig. 2553

3.

Withdraw the bearing cups (1) and (30) from the crown wheel (4) and from differential case (22) using a puller. Remove the washer (29).

Fig. 2554

4.

Remove the spacer (26). Remove the O-rings (25) and (27) from the spacer (26).

Fig. 2555

30-614

Method of intervention 5.

NOTE: This operation will destroy the oil seal.

Remove oil seal (24).

Fig. 2556

6.

Unscrew all fixing screws (23) from cover (22).

Fig. 2557

7.

Remove cover (22) and relative O-ring (21).

Fig. 2558

8.

Withdraw piston (19) and washer (20). Recover O-rings (17) and (18) from the differential lock piston (internal and external).

Fig. 2559

9.

NOTE: Separate, carefully clean and examine all the removed components, checking them for wear and functionality. Remove from differential case (5): pressure plates (14), pressure plates (15), disks (16) and planet gear (13).

Fig. 2560

30-615

Method of intervention 10.

NOTE: Examine all the removed components, checking them for wear and condition. Using a pin punch, drive the dowels (12) out of their holes and remove planet pins (10) and (11) along with the cross gate (7). Disassemble and recover all the parts from differential case: planet gears (8), thrust washers (9), planet gear (6). Fig. 2561

Assembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. Install the pins (10) and (11), the cross gate (7), planet gears (8) and thrust washers (9) on the differential case (5). Mount the dowels (12).

Fig. 2562

2.

Install differential side gear (13).

Fig. 2563

3.

Fit the spacer (19) and pressure plate (15).

Fig. 2564

30-616

Method of intervention 4.

Install first disc (16).

Fig. 2565

5.

Install other discs (16) and pressure plates (15).

Fig. 2566

6.

Lubricate new O-rings (17) and (18) and install them on piston (19).

Fig. 2567

7.

Install piston (19).

Fig. 2568

30-617

Method of intervention 8.

Lubricate oil seal (24) and install it in cover (22).

Fig. 2569

9.

Lubricate new O-rings (25) and (27) and install them on spacer (26).

Fig. 2570

10.

Install spacer (26) in cover (22).

Fig. 2571

11.

Insert spacer (26) in cover (22) using service tool 5.9035.032.0.

Fig. 2572

30-618

Method of intervention 12.

Lubricate and install oil seal (28).

Fig. 2573

13.

Install washer (29) in cover (22).

Fig. 2574

14.

Install cup of bearing (30) with service tool 5.9035.154.0.

Fig. 2575

15.

Lightly grease the seat of differential lock pressure plate (20).

Fig. 2576

30-619

Method of intervention 16.

Install differential lock pressure plate (20) in cover (22) with a thin smear of grease.

Fig. 2577

17.

Lubricate a new O-ring (21) and install it in cover (22).

Fig. 2578

18.

Fit cover (22).

Fig. 2579

19.

Apply the prescribed sealant to fixing screws (23). Insert fixing screws (23).

Fig. 2580

30-620

Method of intervention 20.

Tighten the screws (23) to the specified torque.

Fig. 2581

21.

Lubricate the lips of oil seals (24) and (28).

Fig. 2582

22.

Fit crown wheel (4) and pin (2).

Fig. 2583

23.

Insert screws (3) and tighten to the specified torque.

Fig. 2584

30-621

Method of intervention 24.

Install the cup of bearing (1) with service tool 5.9035.154.0.

Fig. 2585

30.8.8 - Axle pivot bearings assembly

Fig. 2586 - Axle pivot bearings assembly 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

Grease nipple Drilled screw Rear pivot bracket Bush O-ring Bush Oil seal Bush Washer Axle beam Thrust washer Bush Bush Oil seal Drilled screw Grease nipple

30-622

Method of intervention

Fig. 2586 - Axle pivot bearings assembly 17. 18.

Front pivot bracket Bush

Disassembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. Remove grease nipple (1) only if necessary. Withdraw rear pivot bracket (3) from the differential carrier.

Fig. 2587

2.

NOTE: This operation will destroy the O-ring.

Remove O-ring (5) from rear pivot bracket (3).

Fig. 2588

30-623

Method of intervention 3.

Unscrew and remove drilled screw (2). Remove bush (6) from rear pivot bracket (3).

Fig. 2589

4.

NOTE: This operation will destroy the oil seal.

Remove oil seal (7).

Fig. 2590

5.

Remove bushes (4) from rear pivot bracket (3).

Fig. 2591

6.

NOTE: It is advisable to cut bush (8) with a chisel; this operation will destroy the bush. Only if necessary, remove bush (8) and thrust washer (9) from the differential carrier.

Fig. 2592

7.

Loosen drilled screw (15). Withdraw front pivot bracket (17) from axle beam (10).

Fig. 2593

30-624

Method of intervention 8.

Remove grease nipple (16). Unscrew screw (15). Remove bush (13) from front pivot bracket (17).

Fig. 2594

9.

NOTE: This operation will destroy the oil seal.

Remove oil seal (14).

Fig. 2595

10.

NOTE: It is advisable to cut bush (12) with a chisel; this operation will destroy the bush. Only if necessary, remove bush (12) and thrust washer (11) from axle housing (10). Fig. 2596

11.

Remove bushes (18) from rear pivot bracket (17).

Fig. 2597

30-625

Method of intervention Assembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. NOTE: If necessary, use a drift and hammer to install bush (8).

Install thrust washer (9) on the differential carrier. Heat bush (8) to 110 - 120°C and install it on the differential carrier. Fig. 2598

2.

Apply sealant to the contact surfaces of the bushes (4). Install bushes (4) in rear pivot bracket (3) using a drift and hammer.

Fig. 2599

3.

IMPORTANT: Position bush (6) so the screw hole is aligned with the screw hole in the pivot bracket. Install bush (6) in rear pivot bracket (3). Install drilled screw (2). Install grease nipple (1) Fig. 2600

4.

Install oil seal (7) with drift 5.9035.046.0 and lubricate it

Fig. 2601

5.

NOTE: Install the O-ring in the side of the pivot bracket shown.

Grease a new O-ring (5). Install new O-ring (5) in the bush (6) in rear pivot bracket (3)

Fig. 2602

30-626

Method of intervention 6.

IMPORTANT: Take care not to damage the O-ring (5) when fitting rear pivot bracket to the axle housing. Install rear pivot bracket (3) on the differential carrier. Tighten screw (2) to the specified torque.

Fig. 2603

7.

NOTE: If necessary, use a drift and hammer to install bush (12).

Install thrust washer (11) in its seat on the front pivot bracket. Heat bush (12) to 110 - 120°C and install it on axle housing (10). Fig. 2604

8.

Apply the prescribed sealant to the contact faces of bushes (18). Install bushes (18) in front pivot bracket (17) using a drift and a hammer.

Fig. 2605

9.

Install oil seal (14) with drift 5.9035.167.0 and lubricate it.

Fig. 2606

10.

IMPORTANT: Caution: position bush (13) so the screw hole is aligned with the screw hole in the pivot bracket (17) Install bush (13) in front pivot bracket (17) using a suitable drift and a hammer. Fit screw (15). Install grease nipple (16). Fig. 2607

30-627

Method of intervention 11.

Fit front pivot bracket (17) to axle beam. Tighten screw (15) to the specified torque.

Fig. 2608

30.8.9 - Bevel pinion assembly

Fig. 2609 - Bevel pinion assembly 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Bevel pinion Shim Bearing Washer Collapsible spacer Washer Differential carrier Bearing Lock washer Nut

30-628

Method of intervention Disassembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. See previous sections before disassembling the bevel pinion assembly. Remove the differential assembly. See para. 30.8.5 - Differential assembly ... - page 30-604

Fig. 2610

2.

Hold the differential assembly in a vice. Unscrew nut (10) using service tools 5.9035.002.0 and 5.9035.007.0. NOTE: This operation will destroy nut (10).

Fig. 2611

3.

Remove nut (10) and recover lock washer (9).

Fig. 2612

4.

Tap the end of the shaft with a rubber mallet to drive out bevel pinion (1). IMPORTANT: Do not allow bevel pinion (1) to fall.

Recover washers (4) and (6), collapsible spacer (5) and cones of bearings (3) and (8).

Fig. 2613

30-629

Method of intervention 5.

Remove the cups of bearings (3) and (8) from differential carrier (7) using a drift and a hammer.

Fig. 2614

6.

To remove the cone of roller bearing (3) from bevel pinion (1), use a commercial puller. Recover the cone of bearing (3) and underlying shim (2).

Fig. 2615

7.

Inspect the condition of all the components of the bevel pinion assembly. IMPORTANT: Nut (10) and collapsible spacer (5) must be renewed on reassembly.

Fig. 2616

30-630

Method of intervention Assembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. See following sections before assembling the assembly. Place differential carrier (7) on the workbench. Seat the cups of bearings (3) and (8) using service tools 5.9035.039.0 and 5.9035.005.0 and a hammer.

Fig. 2617

2.

Install the cones of bearings (3) and (8) in their respective seats. Install the dummy pinion 5.9035.037.0 (a1) and nut (10). Tighten the nut until all bearing play is taken up.

Fig. 2618

3.

Install the dummy differential cage (a2) 5.9035.018.0 and (a3) 5.9035.004.0 as shown in the figure.

Fig. 2619

4.

Use a depth gauge to measure “X” (distance between the axis of the differential cage bearings and the contact point on the pinion).

Fig. 2620

30-631

Method of intervention 5.

To determine the thickness (S) of the shim required between the head of the pinion and the bearing, subtract the value (V) stamped on the pinion face (V= prescribed bevel pinion distance) from the measured distance (X). S=X-V mm

Fig. 2621

6.

Select a shim of thickness (S) from those available and install it on the pinion shaft under the head of the pinion. NOTE: Take care to install the shim the right way round.

Table 359 SHIM THICKNESSES

2.5 -

7.

2.6 -

2.7 -

2.8 -

2.9 -

3.0 -

3.1 -

3.2 -

3.3 -

3.4 -

Fig. 2622

Remove service tools 5.9035.018.0 and 5.9035.004.0 from differential cage (7). Remove nut (10), dummy pinion 5.9035.037.0 (a1) and the cones of bearings (3) and (8).

Fig. 2623

8.

After having selected shim (2) and installed it with the chamfered side facing the gear, install bearing (3) on pinion shaft (1) using a press and service tool 5.9035.038.0, making sure it is correctly seated. Install washers (4) and (6) and a new collapsible spacer (5). NOTE: Always fit a new spacer (5).

Fig. 2624

30-632

Method of intervention 9.

Install preassembled bevel pinion assembly (1) in differential carrier (7) and bearing cone (8) on the pinion shaft, as shown in the figure. To seat bearing (8), use drift 5.9035.038.0 and a hammer.

Fig. 2625

10.

Install lock washer (9) tighten a new nut (10) onto the pinion shaft.

Fig. 2626

11.

Tighten pinion nut (10) using special wrench 5.9035.002.0 and pinion shaft holder 5.9035.007.0. IMPORTANT: The tightening torque is determined by measurement of the preload on the bearings; tighten nut (10) progressively. NOTE: If the nut is overtightened, collapsible spacer (5) will have to be renewed and the procedure repeated.

12.

When checking the preload, it is a good idea to tap the end of the pinion shaft with a soft mallet to help seat the bearings.

Fig. 2627

To measure preload Pm on taper roller bearings (3) and (8), use a dynamometer and a string wrapped around the splined end of the pinion shaft (1). NOTE: Use this method only if the bearings have already been run in, otherwise see point [13]. The measured value must be equal to the initial value (see D.10.1.1): Pm = P0 See point [15].

Fig. 2628

30-633

Method of intervention 13.

If new taper roller bearings are used, to measure the preload Pm use a dynamometer and a string wrapped around service tool 5.9035.021.0 installed on pinion shaft (1).

Fig. 2629

14.

The effective preload Pm is measured on service tool 5.9035.021.0 (calibrated diameter Dm= 104.4 mm). The measured value must be within the following range: Pm = 31 to 45 N IMPORTANT: Acceptable values with new bearings.

Fig. 2630

15.

To adjust the preload, tighten nut (10) gradually, taking not to tighten it beyond the require amount. IMPORTANT: All preloads must be measured without oil seals installed.

After obtaining the prescribed preload, stake pinion nut (10) using a punch and hammer.

Fig. 2631

30-634

Method of intervention 30.8.10 - Planetary reduction gear assembly

Fig. 2632 - Planetary reduction gear assembly 1. 2. 3. 4. 5. 6. 7.

Fixing bolt Planet carrier O-ring Circlip Planetary reduction gear Bearing Cap

Disassembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. Drain all the oil from the planetary reduction gear.

Fig. 2633

30-635

Method of intervention 2.

Unscrew and remove the two planet carrier (2) retainer screws (1).

Fig. 2634

3.

Remove planet carrier (2) from the wheel hub and recover the relative Oring (3). Place planet carrier (2) on a suitable surface and inspect for wear.

Fig. 2635

4.

NOTE: Remove bearing (6) from gear (5). If a gear has to be replaced, replace the pair. Only if necessary: Remove the circlips (4) from the planet carrier (2) and use a puller to remove the planet gears (5) complete with bearings (6).

Fig. 2636

30-636

Method of intervention Assembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. Assemble the bearing (6) with tool 5.9035.149.0.

Fig. 2637

2.

-

Fig. 2638

3.

NOTE: Make sure the chamfered side of the bearings (6) is oriented towards the planet carrier (2). Fit the complete gears (5) to the planet carrier (2) along with circlips (4).

Fig. 2639

4.

Install a new O-ring (3) on the wheel hub. Install the planetary gear assembly on the wheel hub.

Fig. 2640

30-637

Method of intervention 5.

NOTE: Rotate the pinion to move the double “U” joint

Apply a circlip to hold the planet carrier assembly tight against the wheel hub, as shown in the figure, then rotate the assembly back and forth using a lever to mesh the gears of the planetary unit with the double “U” joint and the wheel hub ring gear. Fit retaining screws (1) and tighten to the specified torque. Fig. 2641

6.

Fill the wheel hub with oil. Fit plug (7) to planet carrier (2) and tighten to the specified torque.

Fig. 2642

30.8.11 - Wheel hub assembly

Fig. 2643 - Wheel hub assembly 1. 2. 3. 4. 5. 6.

Circlip Bush Fixing bolt Ring gear carrier Bearing Stud

30-638

Method of intervention

Fig. 2643 - Wheel hub assembly 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

Wheel hub Bearing Oil seal Lower kingpin Fixing bolt Oil seal Bearing Steering knuckle Bearing Oil seal Shim Fixing bolt Kingpins Upper kingpin Screw Bearing Stop ring Oil seal Axle beam Bush

30-639

Method of intervention Disassembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. IMPORTANT: Take care not to damage the double U joint

Insert a lever between the axle beam and steering knuckle (14) and in between the elements of the double “U” joint on the axle shaft. Lever the double U joint towards the wheel hub in order to remove circlip (1). 2.

Fig. 2644

Remove lock ring (1) from the axle halfshaft.

Fig. 2645

3.

Unscrew and remove the retaining screws (3) of the ring gear carrier hub (4).

Fig. 2646

4.

Remove hub (4). Recover bush (2).

Fig. 2647

30-640

Method of intervention 5.

NOTE: Recover the cone of bearing (5).

Withdraw hub (7) using levers and a hammer to facilitate removal.

Fig. 2648

6.

NOTE: This operation will destroy oil seal (9).

Place hub (7) on a flat surface and remove oil seal (9) with a lever. Withdraw the bearing cups (5) and (8) using a drift and a hammer.

Fig. 2649

7.

Remove bearing cone (8) from the steering knuckle shank (14) using a commercial puller.

Fig. 2650

8.

NOTE: Recover the shims and note down their sizes.

Remove the elements of the sensor assembly as previously described in this manual. See para. 30.11.2 - Steering position sens... - page 30-686 Fig. 2651

30-641

Method of intervention 9.

DANGER: Danger: Before removing kingpins (19) and (10), attach steering knuckle (14) to a hoist with a sling or rope or employ another system to support its weight; implement all established operator safety precautions. Unscrew and remove retaining screws (18) and (11) of the upper (20) and lower kingpins (10)

Fig. 2652

10.

NOTE: Mark and note down the number of shims mounted on each side. Remove kingpins (19) and (10). Recover shims (17).

Fig. 2653

11.

NOTE: This operation will destroy the oil seals (12) and (16).

Only if necessary, remove the cones of bearings (13) and (15) and seals (12) and (16) from the kingpins (10) and (19).

Fig. 2654

12.

Only if necessary, remove the bearing cups (13) and (15) from axle beam (25).

Fig. 2655

13.

Withdraw the steering knuckle (14) from the axle beam and from the shorter shaft of the double U joint assembly.

Fig. 2656

30-642

Method of intervention 14.

NOTE: This operation will destroy the oil seal.

Place steering knuckle (14) on a flat surface and withdraw oil seal (24) using a lever .

Fig. 2657

15.

Remove stop ring (23). Turn the steering knuckle (14) over and remove bearing (22) using a suitable drift and a hammer.

Fig. 2658

Assembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. NOTE: Do not tighten nut (20) until the steering angle has been adjusted See para. 30.8.1 - Toe-in/steering angle/... - page 30-590 Fig. 2659

2.

Seat bearing (22) in steering knuckle (14) using tool 5.9035.151.0 and a hammer or press.

Fig. 2660

30-643

Method of intervention

30-644

Method of intervention 8.

The special “Set Right” bearings (5) and (8) do not require any specific preload or play adjustments. In any case, before installing new parts, check the dimensions indicated. A= 23.150 ÷ 23.200 mm B= 77.275 ÷ 77.325 mm C= 27.000 ÷ 27.100 mm Fig. 2666

9.

NOTE: Do not lubricate the seal ring (9).

Seat the cups of the taper roller bearings (8) and (5) on wheel hub (7) using service tool 5.9035.041.0 and a press or hammer. Install oil seal (9) on wheel hub (7) using tool 5.9035.150.0 and a hammer.

Fig. 2667

10.

Install the cone of taper roller bearing (8) on steering knuckle (14) with service tool 5.9035.153.0. Install the wheel hub (7) on steering knuckle (14) and locate bearing cone (5)

Fig. 2668

11.

Grease two new O-rings and install on the wheel hub assembly (4) in the position shown.

Fig. 2669

30-645

Method of intervention 12.

NOTE: Align the locating holes on ring gear carrier (4) and on steering knuckle (16); the locating holes are identified by punch marks. Install ring gear carrier assembly (4).

Fig. 2670

13.

NOTE: Do not tighten screws (3).

Screw in screws (3) to seat ring gear carrier assembly (4) against wheel hub (7).

Fig. 2671

14.

DANGER: Secure the steering knuckle/wheel hub assembly with a rope. Lubricate the lips of the steering knuckle seal ring and use tool 5.9035.168.0. Fit the half axle into the steering knuckle and assemble the knuckle/hub assembly to the axle beam.

Fig. 2672

15.

Insert service tool 5.9035.168.0 (a) in the axle shaft of the double U joint assembly.

Fig. 2673

16.

Grease the surface of the upper kingpin. Insert the assembled upper kingpin. Fit pairs of U shims between the kingpin and the steering knuckle to obtain the minimum play Z (measure with dial gauge). Screw the fixing screws in loosely.

Fig. 2674

30-646

Method of intervention 17.

Grease the surface of the lower kingpin. Insert the assembled lower kingpin. Tighten down the lower kingpin bolts to the specified torque.

Fig. 2675

18.

Lever the double U joint towards the wheel hub to insert and complete the assembly.

Fig. 2676

19.

Remove tool 5.9035.168.0. Fit spacer (2) into the half axle of the double U joint and ring gear carrier (4).

Fig. 2677

20.

Tighten retaining screws (3) to the specified torque.

Fig. 2678

30-647

Method of intervention 21.

Insert a lever between the axle beam and steering knuckle (14) and in between the elements of the double “U” joint on the axle shaft. Lever the double U joint towards the wheel hub to facilitate installation of the circlip (1).

Fig. 2679

22.

NOTE: Make sure that circlip (1) is seated correctly.

Install circlip (1) on the end of the splined hub and press it into its groove. Push the double U joint by hand to its end position and check that the circlip seats.

Fig. 2680

23.

Position a magnetic base dial gauge on the axle beam trumpet. Place the gauge contact point against the top of the upper kingpin. Insert a lever between the axle beam trumpet and the steering knuckle. Move the lever back and forth vertically and read the resulting play Z on the dial gauge.

Fig. 2681

24.

Unscrew bolts (18), raise the upper kingpin and remove the shims. Fit pairs of shims between the upper kingpin and the steering knuckle according to the measured play Z. Caution: Make sure to fit each pair of shims in such a way as to alternate the position of the slit. Make up shim (W) from the available shims by using the following formula: W=[U-Z-(0.7÷0.9)] mm where 0.7÷0.9 is the bearing preload. Tighten the screws (18) to the specified torque. Fig. 2682

30-648

Method of intervention 25.

Make up shim (W) from the available shims by using the following formula:

Table 360 GAMMA SPESSORI - SHIMS RANGE

Thickness - mm 0.15 Quantity -

0.20 -

0.50 -

Fig. 2683

26.

NOTE: Assemble the elements of the sensor assembly as described previously in this manual. See para. 30.11.2 - Steering position sens... - page 30-686

Fig. 2684

30.8.12 - Brake assembly

Fig. 2685 - Brake assembly 1. 2. 3. 4.

Planet carrier Wheel hub Circlip Pressure plates 30-649

Method of intervention

Fig. 2685 - Brake assembly 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Pressure plates Brake disc Fixing bolt Ring gear carrier Ring gear O-ring Fixing bolt Pressure plate Screw Screw Circlip Circlip Brake piston O-ring O-ring Bush Spacer Washer Spacer Spring Washer

30-650

Method of intervention Disassembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. Remove the planet carrier (1) from the wheel hub (2). See para. 30.8.10 - Planetary reduction ge... - page 30-635

Fig. 2686

2.

Unscrew and remove the retaining screws (7) of the ring gear carrier (8).

Fig. 2687

3.

NOTE: Use two screws (7) in holes “A” as extractors.

Remove ring gear carrier (8) complete with the ring gear (9).

Fig. 2688

4.

Remove the two O-rings (10).

Fig. 2689

30-651

Method of intervention 5.

Remove the bolts (11) securing the pressure plate (12).

Fig. 2690

6.

NOTE: Recover all the components of the self-adjust kit.

Remove the bolts (13) and (14) of the self-adjust kit along with the pressure plate (12).

Fig. 2691

7.

Remove circlip (15) and separate ring gear carrier assembly (8) from ring gear (9).

Fig. 2692

8.

Only if necessary, remove the steel circlip (16) from ring gear (9).

Fig. 2693

30-652

Method of intervention 9.

To remove brake piston (17) fit service tool 5.9035.169.0 (s1) and the two screws (7) used previously for removal of the ring gear retaining hub, as shown in the figure. Screw in screws (7) to withdraw brake piston (17). Remove the O-rings (18, 19) from the piston (17). Inspect the removed parts for wear.

Fig. 2694

Assembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. Fit two new O-Rings (18, 19) on piston (17). Insert piston (17) in ring gear retaining hub (8).

Fig. 2695

2.

NOTE: Mark all components to facilitate re-assembly.

Temporarily mount the pressure plate (12) on the ring gear carrier (8) using the bolts (11) to align the marks “a” between the two plates and the ring gear (9) as a template.

Fig. 2696

3.

NOTE: Fit the circlip in the 2nd seat.

If previously removed, fit the steel circlip (16) into the ring gear (9).

Fig. 2697

30-653

Method of intervention 4.

Press bushes (20) into the seats indicated in the ring gear carrier (8) until flush with the inner contact surface of pressure plate (12) using service tool 5.9035.065.0.

Fig. 2698

5.

Fit the ring gear carrier (8) into the ring gear (9) and secure with the steel circlip (15).

Fig. 2699

6.

Insert the other parts of the self-adjust kit as shown in the figure.

Fig. 2700

7.

NOTE: Make sure to align the marks.

Assemble the brake pressure plate (12) to the ring gear carrier (8) with the bolts (11).

Fig. 2701

8.

NOTE: The self-adjust kit must be assembled as shown in the figure. Finish the assembly with the bolts (13) and (14) of the selfadjust kit. Tighten fixing screws (13) and (14) of the self-adjust kit to the specified torque.

Fig. 2702

30-654

Method of intervention 9.

Grease two new O-rings (10) and fit to ring gear carrier (8) in the position shown.

Fig. 2703

10.

Install the ring gear carrier assembly on wheel hub (2). Follow the indicated procedure with care

Fig. 2704

11.

IMPORTANT: In the case of renewal of the brake disc only, drive the pressure plate (12) into its seat using a drift (p1) and a hammer. NOTE: Position the drift with care to avoid damaging the piston.

Fig. 2705

12.

Insert brake disc (6) and brake pressure plates (4) and (5) in ring gear (9). Secure the discs with circlip (3).

Fig. 2706

30-655

Method of intervention 13.

Install the planet carrier (1) on the wheel hub. See para. 30.8.10 - Planetary reduction ge... - page 30-635

Fig. 2707

30-656

Method of intervention 30.9 - G0 - Bodywork - Cab - Platform 30.9.1 - Handbrake adjustment Adjustment 1.

Check that the handbrake indicator light activator button under the lever in the cab is set in an intermediate position.

Fig. 2708

2.

Install the reaction plate on the carriage and the return spring between the reaction plate and the mechanism lever.

Fig. 2709

3.

Completely unscrew the fastener nut at the end of the Bowden cable to permit installation of the reaction bracket.

Fig. 2710

4.

Tighten the Bowden cable fastener nut onto the reaction bracket with a 19 mm wrench.

Fig. 2711

30-657

Method of intervention 5.

Place the reaction bracket over the threaded holes on the transmission and tighten the three fastener screws with a 13 mm wrench.

Fig. 2712

6.

Insert the connector pin between the fork on the Bowden cable ferrule and the mechanism lever on the carriage.

Fig. 2713

7.

With the handbrake lever completely lowered, adjust the two tie-rods so that the free play between the screw and the shim is no more than 1 mm.

Fig. 2714

8.

For versions with pneumatic braking. Lower the handbrake lever completely and turn the braking valve control lever downwards.

Fig. 2715

30-658

Method of intervention 9.

Adjust the length of the control tie-rod so that it will fit onto the ball joints.

Fig. 2716

30.9.2 - Supplementary heater - Webasto - Troubleshooting General information

This paragraph described the procedure for troubleshooting problems with the Thermo 90 S and Thermo 90 ST heater. WARNING These troubleshooting procedures require a thorough understanding of the structure and operation of the individual components of the heater, and can therefore only be performed by suitably trained personnel. In case of doubt, see the chapter “Supplementary heating - Webasto - General description” or “Supplementary heating - Webasto Description of operation” for explanations of the operating principles. WARNING The scope of troubleshooting is generally limited to identifying the faulty components causing the problem. The following causes of malfunctions are not taken into consideration by the troubleshooting procedures, and must therefore be checked specifically to rule them out as the reason for a malfunction: l l l l l l

corroded pins spurious pin contact incorrectly crimped pins corrosion on cables and fuses corrosion on battery terminals excessively high ambient temperature

After identifying and resolving each fault, turn the heater off and on again and perform a functional test of the vehicle.

Generic fault symptoms Possible symptoms of generic faults are listed in the following table.

Table 361 Fault symptom

Possible cause

Solution

Heater switches off auto- No combustion after starting and after repeated ECU in fault lockout state. Switch the heater off and matically start attempt on again. Flame extinguishes during operation If the heater still does not work, contact a Webasto technical support centre Heater overheats due to lack/loss of coolant Top up the coolant Loss of voltage lasting more than 20 seconds Check fuses, pin connectors and state of charge of the battery Combustion not detected when system started Check flame detector and relative connections In many cases, the probable cause of the malfunction is the burner. Inspect the burner visually as indicated in the section “Visual inspection of burner”.

30-659

Method of intervention Fault symptoms in case of automatic shutdown due to fault In the case of a switch operated heater, the type of fault is indicated while the heater is operating in inertial mode by a flashing code indicated by the power-on lamp. To determine the error code, count the number of long flashes following the initial sequence of five short flashes. On the Thermo 90 S heater with standard timer, the error is indicated on the timer display. The following table is given as a guideline only.

Table 362 Fault symptom

Possible cause

Heater not working at all

Wiring loom, fuses

1 flash (failed start)

ECU faulty Fuel system Combustion air/exhaust gas pipe

Burner 2 flashes (fuel delivery cut off during Fuel delivery system operation) 3 flashes (undervoltage)

Burner Electric power feed

4 flashes (flame sensor permanently Flame sensor faulty in hot state) 5 flashes (flame sensor faulty) Wiring loom Flame sensor faulty 6 flashes (temperature sensor faulty) Wiring loom Temperature sensor faulty 7 flashes (metering pump faulty/ Coolant circuit overheat protection device faulty) Wiring loom Metering pump faulty 8 flashes (combustion air fan faulty) Wiring loom 9 flashes (glow plug faulty)

Combustion air fan faulty Wiring loom

10 flashes (overheat) 11 flashes (circulation pump faulty)

Glow plug faulty Heater overheating Wiring loom Circulation pump faulty

Solution

Check fuses Check battery connections: + on 12 / – on 9 / + on 3, pin X12 (Thermo 90 S) + on 12 / – on 9 / + on 3, pin X8 (Thermo 90 ST) Replace ECU Check fuel level Check fuel filter Bleed the fuel system Inspect the combustion air/exhaust gas pipe and, if necessary, clean and remove any foreign objects Clean burner or replace if necessary Check fuel level Check fuel filter Bleed the fuel system Clean burner or replace if necessary Check battery Check electrical connections Replace flame sensor Check wiring loom for damage, lost continuity circuits Replace flame sensor Check wiring loom for damage, lost continuity circuits Replace temperature sensor Check coolant level Bleed the coolant circuit Check wiring loom for damage, lost continuity circuits Replace metering pump Check wiring loom for damage, lost continuity circuits Replace combustion air fan Check wiring loom for damage, lost continuity circuits Replace glow plug Check coolant level and top up if necessary Check wiring loom for damage, lost continuity circuits Replace circulation pump

or short or short

or short or short or short

or short

Visual inspection of burner The burner and the evaporator of the heater have very specific characteristics; when replaced, these must be installed correctly to prevent malfunction. The following criteria must be checked.

30-660

Method of intervention Burner housing The starter air hole must not be obstructed. If it is obstructed, the heater will not start.

1

9

2

8

3

7

4 6

5

Fig. 2717 - Visually inspect the rear wall of the burner Key 1. 2. 3. 4. 5. 6. 7. 8. 9.

Fuel pipe Gasket washer Flame sensor Insulation Glow plug Body Screw Bracket Start air hole

Corrective action Carefully clean out the start air hole to remove foreign objects or contamination (for example, use a 1.5 mm diameter metal wire). Remove the glow plug beforehand.

30-661

Method of intervention Rear wall with metal evaporator The outlet hole of the pilot flame (1) must not be obstructed. If it is obstructed, the heater will not start.

1

Fig. 2718

Corrective action Replace the burner. Cracks, flaking material or discolouration (black deposits or other marks) on the evaporator are not a sign of burner failure and may therefore be considered insignificant. It is normal for coke deposits to form on the surface of the evaporator, but not on the outlet aperture of the pilot flame. Normally, the burner self-cleans when switching between full and partial load. Combustion chamber The combustion chamber (1) must not show any signs of damage such as dents, for example. Dents in the combustion chamber may cause incorrect combustion or the formation of coke deposits in the heater.

2

1

Corrective action Replace the burner. The combustion chamber ventilation holes (3) must not be obstructed with coke. Ventilation holes obstructed with coke may prevent starting or cause incorrect problems.

3 4

Fig. 2719

Corrective action Carefully scrape off the coke to clear the ventilation holes. Complete burner The cables of the glow plug and the flame sensor must be routed correctly as shown in the figure.

Fig. 2720

The screw connection between the housing and the combustion chamber (1) must be tightened securely. The housing and the combustion chamber (4) must be securely connected with no free play; check the connection by trying to wiggle the combustion tube slightly.

2

1

3 4

Fig. 2720

30-662

Method of intervention The gasket washer (5) must encircle the combustion tube fully and form a gas tight seal.

5

Fig. 2721

The gap (or free play) between the edge if the housing and the upper edge of the combustion chamber (1) must not be uniform around the entire circumference.

2

1

3 4

Fig. 2721

The insulation (6) must be fitted correctly.

6

Fig. 2722

30.9.3 - Supplementary heating - Webasto - Functional tests General information

This chapter describes the tests to be performed on the heater, either fitted in or removed from the vehicle, to test the functions and performance of the heater. CAUTION Do not operate the heater in an enclosed space (such as a garage or workshop) without an exhaust extraction system.

Settings Adjusting CO2 content The factory setting for the combustion air volume may be adjusted. To modify the setting, turn the relative adjuster screw. Adjustment procedure Turn screw clockwise to lower the CO2 value (leave the heater running for approximately 5 minutes before taking measurement). Coarse adjustment: Turn the adjuster screw completely clockwise then turn back by one turn.

30-663

Method of intervention Checking individual components Checking resistance of temperature sensor Test the temperature sensor electrically with a digital multimeter. At ambient temperature, the values measured should be as follows:

Table 363 resistance at 25 °C: test current:

990 ... 1010 Ω < 1 mA

Checking resistance of glow plug Test the glow plug electrically with a digital multimeter. The values measured should be as follows:

Table 364 glow plug resistance at 25 °C: test current:

12 Volts (red) 0.3 ... 0.6 Ω < 5 mA

24 Volts (green) 1.3 ... 1.44 Ω < 5 mA

Checking resistance of flame sensor Test the flame sensor electrically with a digital multimeter. The values measured should be as follows:

Table 365 Cold test: resistance at 25 °C: test current: Hot test: resistance at 800 ±20 °C: (approximately 20 mm length of ceramic rod incandescent) test current:

3.0 ±0.4 Ω < 5 mA 8 ±1.0 Ω < 5 mA

Replacing the combustion air fan The motor speed test must be conducted with the heater installed in the vehicle and operating within the correct operating voltage range. Listen for abnormal noise caused by wear. To perform the motor speed test, remove the fan cover. Change the gasket before refitting the cover. WARNING Take care not to break the fastener tabs. If the fastener tabs are broken, replace both the cover and the gasket.

Table 366 Min. motor speed in correct operating range: 1,800 rpm Max. motor speed in correct operating range: 5,600 rpm

(± 9 %) (± 9 %)

If the motor speed is not within the indicated range, replace the combustion air fan as described in the chapter “Supplementary heating - Webasto - Repairs - Replacing the combustion air fan”.

30.9.4 - Supplementary heating - Webasto - Maintenance General information

This chapter describes the maintenance procedures which may be performed on the heater installed in the vehicle.

Working on the heater Before performing any work on the heater, it is always advisable to disconnect the main power cable from the vehicle battery. While the heater is operating or in inertial operating mode, the main battery cable may not be disconnected as this may cause the heater to overheat, triggering the overheat protection function. If extensive work on the heater is necessary, it may be preferable to remove the heater completely from the vehicle. After performing any work on the heating circuit, add a mixture of water and antifreeze as specified by the manufacturer of the vehicle, then bleed the heating circuit carefully to expel all air. In the event of repair work requiring the mounting bracket to be replaced, follow the installation instructions for the heater and the specific instructions in the vehicle manual for installing the heater.

30-664

Method of intervention Working on vehicle CAUTION The temperature in the vicinity of the heater must never exceed 90 °C (such high temperatures are possible, for example, when painting the vehicle). See “Supplementary heating - Webasto - Technical specifications”.

Testing the heater Do not operate the heater in an enclosed space (such as a garage or workshop) without an exhaust extraction system, even if using the timer selector function.

Maintenance To ensure the safety of the heater, perform the following maintenance procedures immediately before or after each season when the heater is used: l l l l l l l

Clean the exterior of the heater (do not allow water into the heater). Check that the electric connections are securely fastened and show no signs of contact corrosion. Check that the exhaust and combustion air pipes are not damaged or obstructed. Check the seal integrity of the fuel line and filter. Check the seal integrity of the coolant circuit and circulation pump. Check that the hoses are free of cracks. Replace the fuel filter (if fitted).

30-665

Method of intervention

A

a b c d

B Fig. 2723

Key 1. 2. 3. 4. 5. 6. 7. 8. 9.

Heat exchanger, Vehicle heating system Switch for vehicle heating system fan Relay for vehicle fan Selector timer Fuse connector in vehicle Check valve with orifice for leakage recovery T union Vehicle engine Heater

30-666

Method of intervention 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Circulation pump Water pump Cooler Regulator valve Exhaust silencer Metering pump Combustion air intake pipe Thermostat ECU (user defined installation location for Thermo 90 S) ECU (installation position for Thermo 90 ST, user defined installation location for Thermo 90 S) l l l l l l

Figure A: With check valve and thermostat Figure B: Without check valve a: Cable bunch b: Fuel line c: Exhaust pipe d: Coolant circuit CAUTION The ECU of the Thermo 90 S and Thermo 90 ST is factory fitted on the combustion air fan.

Visual inspections or special instructions for installation Connection to vehicle cooling system For circuits equipped with a thermostat, only use thermostats with an initial aperture temperature less than 65 °C. The heater must be installed as low down as possible to allow the heater itself and the circulation pump to vent air naturally. This is particularly important as the circulation pump is not self-priming. The heater must be connected to the cooling system of the vehicle as shown in figure 801. The circuit must contain at least 6 litres of coolant. Wherever possible, preferably use the coolant lines supplied by Webasto together with the heater. If this is not possible, the lines used must at least comply with the standard DIN 73411. Flexible hoses must be laid out without bends and preferably with an upward gradient to ensure effective elimination of air. Hose connections must be secured with pipe fastener clamps. The pipe fastener clamps must be tightened to 4 Nm. Before operating the heater for the first time, or after changing the coolant, bleed the cooling system thoroughly to vent all air. The heater and the hoses must be installed appropriately to ensure static venting of air. If the system is vented correctly, the circulation pump will run almost silently. Connection to vehicle fuel system Fuel must be received from the vehicle fuel tank or from a separate fuel tank. For the permitted pressure values at the fuel inlet point, see the following table.

Table 367 Permitted height for fuel inlet H (m) 0.00 1.00 2.00 Permitted height of fuel pickup S (m) 0.00 0.50 1.00

with maximum permitted overpressure (bar) in fuel line 0.20 0.11 0.03 with maximum permitted negative pressure (bar) in fuel tank – 0.10 – 0.06 – 0.02

For ADR only: Observe ADR indications for fuel tanks. There must be a warning on the fuel filler indicating that the heating system must be closed before filling the tank with fuel.

30-667

Method of intervention

Fig. 2724 - Fuel delivery system Fuel pickup Vehicles with diesel engines Fuel must be received from the vehicle fuel tank or from a separate fuel tank.

30-668

Method of intervention

1

3 2

4

B

A

5

6

C Fig. 2725

Key 1. 2. 3. 4. 5. 6.

Layout of holes The tank pickup device may only be used with metal fuel tanks Plastic fuel tank O-ring O-ring Fuel tank connection l l l

A: Webasto tank pickup device B: Fuel pickup from plastic fuel tank (fuel collected from fuel tank drain screw) C: Fuel pickup from plastic fuel tank (fuel collected from fuel tank connection)

The connection must be fabricated from sheet metal. After cutting the tank pickup device with a saw, grind the cut edge and remove all swarf carefully. Vehicles with petrol engines With carburettor fuelled engines or fuel injection engines with a fuel return line, the fuel connection for the heater must be in the return line. With carburettor fuelled engines with no fuel return line, the fuel connection for the heater must be in the delivery line, between the fuel tank and the vehicle fuel pump. l

The fuel delivery line may usually be identified by the fact that it has an incorporated fuel filter. 30-669

Method of intervention l

If the vehicle fuel system includes a fuel vapour venting system, the fuel connection for the heater must be upstream of the vapour vent system.

Installations where fuel is collected from the delivery or return line may only be made using the specific Webasto fuel pickup device. The fuel pickup device must be installed accordingly to allow air or gas bubbles to rise naturally towards the fuel tank. Air or gas bubbles may form in the fuel line in the event of leakage from the carburettor or vehicle fuel pump, or at ambient temperatures above the fuel evaporation point. The fuel connection for the heater should not be made near the engine as heat from the engine may cause gas bubbles to form in the fuel line, compromising the combustion process. When installing the heater in vehicles with fuel injection, determine if the fuel pump is situated inside or outside the fuel tank. If the fuel pump is installed inside the fuel tank, fuel for the heater may only be collected from the return line provided that the line almost reaches the bottom of the tank and is not controlled by a check valve. Otherwise, the return line must be extended accordingly. If the fuel pump is installed outside the fuel tank, the fuel connection for the heater must be made between the tank and the pump.

from tank

to engine to metering pump

Fig. 2726 - Webasto fuel pickup device Fuel lines Fuel lines may only be made from steel, copper or PA 11/PA 12 light and temperature stabilised soft plastic (such as Mecanyl RWTL) in accordance with standard DIN 73378. When cutting lines in Mecanyl, take care not to leave sharp edges and not to crush the lines themselves. Do not cut with clippers. As it is generally not possible to route lines with a continuously upward gradient, the internal diameter of the lines themselves must not exceed a certain limit. Lines with internal diameters of 4 mm and larger allow air or gas bubbles to accumulate, which will cause malfunctions if there are bends in the line or if the lines are routed with a downward gradient. Using lines with diameters within the limits indicated will prevent the formation of bubbles which may compromise the operation of the heater. Avoid routing lines with a downward gradient between the metering pump and the heater. All unsupported lines must be fastened to prevent the risk of bending. Lines must be routed to afford protection against stones and heat (e.g. protected from heat produced by exhaust pipe). Fuel lines must be fastened at all connection points with pipe clamps. 30-670

Method of intervention Connection between 2 lines with flexible hose The figure shows an example of a correct fuel line connection with a flexible hose. CAUTION

1

Check seal tightness 2

3

Fig. 2727

Metering pump with silencer The metering pump is a combined delivery, metering and cut-off system, and is subject to specific installation criteria.

Fig. 2727

30-671

Method of intervention Metering pump, installation position and fasteners - 12 V and 24 V – petrol and Diesel DP2

Fig. 2728

Metering pump, installation position and fasteners - 12 V and 24 V – diesel only DP 30.2 - Horizontal installation position

Fig. 2729

Installation position Before installing the metering pump, check that the maximum pressure measured at the pickup point is less than 0.2 bar. Preferably install the pump in an area of the vehicle not exposed to high temperatures. The ambient temperature must not exceed +20 °C (for petrol heaters) or +40 °C (diesel heaters) in any operating condition. The metering pump and the fuel lines must not be installed in areas exposed to radiant heat produced by hot components of the vehicle. Install a heat shield if necessary. Preferably install close to the fuel tank. Installation and fastening The metering pump must be fastened with an anti-vibration mount. To ensure that the pump vents air bubbles naturally, it must be installed in a position complying with indications given in the figure. Fuel filter If there is a possibility of contamination in the fuel, use only Webasto filters (Part No. 487 171). Preferably install in a vertical position. If this is not possible, install in a horizontal position. Install in the correct position as indicated and ensure that the direction of fuel flow is correct. Combustion air delivery The combustion air must never be aspirated from an enclosed area occupied by persons. The combustion air intake aperture must not face forwards, but must be oriented appropriately to prevent fouling or obstruction with dirt or snow and prevent the aspiration of water splashes. The air intake pipe (min. internal diameter 30 mm) may measure between 0.5 m and 5 m in length, and may include multiple curvatures not exceeding a total angle of 360°. Minimum curvature radius: 45 mm. The combustion air intake must not be situated above the exhaust pipe. If it is not possible to install the combustion air intake pipe in a downwards facing position, a 4 mm diameter water drain hole must be made at the lowest point of the pipe. If the heater is installed near the fuel tank in the same compartment, the combustion air must be aspirated from the exterior and the exhaust gases must also be ducted to the exterior. The air and exhaust passages must be protected against water splashes. If the heater is installed in an enclosed container, a ventilation hole measuring at least 6 cm2 must be made in the container. If the temperature in the container exceeds the maximum permitted ambient temperature for operating the heater (see technical specifications), the ventilation aperture must be enlarged accordingly. Exhaust pipe The exhaust gas pipe (internal diameter 38 mm) may measure between 0.5 m and 5 m in length, and may include multiple curvatures not exceeding a total angle of 360° and with a minimum curvature radius of 85 mm. The exhaust pipe silencer is mandatory and must 30-672

Method of intervention be installed near the heater. To ensure an angle of 90° ± 10°, the fastener point must not be further than 150 mm from the end of the exhaust pipe. The outlet of the exhaust pipe must not face forwards. The outlet of the exhaust pipe must be oriented appropriately to prevent obstruction with snow or mud. The exhaust pipe must be made from rigid steel or steel alloy with a minimum wall thickness of 1.0 mm, or from flexible piping (in steel alloy only). The exhaust pipe must be fastened appropriately to the heater, using a pipe clamp, for example. Refer to the applicable legislation for all other requisites.

Fig. 2730

For ADR only: comply with the requisites with ADR legislation for installing the exhaust pipe.

Disassembly and assembly The only disassembly or assembly procedures permitted on the heater installed in the vehicle, provided that the cover is accessible and removable and that there is sufficient space for the operations themselves, are as follows: l l l l l

Replacing circulation pump Replacing temperature limiter Replacing temperature sensor Replacing the combustion air fan Replacing the ECU (Thermo 90 S/Thermo 90 ST)

Removal of the heater 1. Disconnect the battery. With the Thermo 90S heater with ECU mounted on the combustion air fan with a flange, only disconnect pin connectors X12 and X13 on the ECU. 2. Remove the top cover 3. Detach the cable harness connector plug from the heater 4. Disconnect the fuel inlet connector from the heater 5. Loosen the pipe clamps and remove the flexible coolant hoses from the heater 6. Disconnect the combustion air inlet and exhaust gas outlet connections from the heater 7. Remove the three screws and the washers from the heater mount 8. Remove the heater Refitting the heater 1. Fit the heater in the installation position and fasten with the 3 screws and the washers 2. Fit the flexible coolant hoses and fasten with pipe clamps. Tighten the clamps to 5 Nm 3. Fasten the fuel inlet connector to the heater 4. Fasten the combustion air inlet and exhaust gas outlet connections to the heater With the Thermo 90S heater with ECU mounted on the combustion air fan with a flange, reconnect pin connectors X12 and X13 on the ECU. 5. Connect the cable harness connector plug to the heater 6. Fit and fasten the top cover 7. Reconnect the battery 8. Bleed the fuel system 9. Bleed the coolant circuit Replacing circulation pump The procedure for replacing the circulation pump is the same whether the heater is installed in the vehicle or removed from the vehicle. Perform the replacement procedure described in the paragraph “Supplementary heating - Webasto - Repairs - Replacing circulation pump”. 30-673

Method of intervention Replacing temperature limiter The procedure for replacing the temperature limiter is the same whether the heater is installed in the vehicle or removed from the vehicle. Perform the replacement procedure described in the paragraph “Supplementary heating - Webasto - Repairs - Replacing temperature limiter”. Replacing temperature sensor The procedure for replacing the temperature sensor is the same whether the heater is installed in the vehicle or removed from the vehicle. Perform the replacement procedure described in the paragraph “Supplementary heating - Webasto - Repairs - Replacing temperature sensor”. Replacing the combustion air fan The procedure for replacing the combustion air fan is the same whether the heater is installed in the vehicle or removed from the vehicle. Perform the replacement procedure described in the paragraph “Supplementary heating - Webasto - Repairs - Replacing combustion air fan”.

Commissioning After installing the heater, bleed the coolant circuit and the fuel system thoroughly. Follow the respective procedures indicated by the manufacturer of the vehicle. During the functional test, check the seal integrity of all the coolant and fuel connections and check that the connections are correctly fastened. If the heater malfunctions during the test, troubleshoot the fault as indicated in the chapter “Supplementary heating - Webasto - Troubleshooting”.

30.9.5 - Supplementary heater - Webasto - Disassembly and reassembly General information

This chapter described the repair procedures permitted with the heater removed from the vehicle. Performing any disassembly procedure other than those described herein will void the warranty. For reassembly, use only the original spare parts contained in the respective kit. Procedures on disassembled components In general, all seals and gaskets between disassembled components must be discarded and replaced. Screening and winnowing Clean all disassembled components. Visual inspection Check all components and replace any damaged parts (with cracks, deformation, wear etc.). Check pins and wires for corrosion, poor electrical contact, incorrect crimping etc., and repair if necessary. Check that the pin contacts show no signs of corrosion and that all contacts are fastened correctly. Repair if necessary.

30-674

Method of intervention Electrical connections (Thermo 90 S)

1

3

2

4

Fig. 2731 - Electrical connections (Thermo 90 S) Key 1. 2. 3. 4.

Top cover Removal tool Retainer wedge Retainer tab (12 pieces)

Disconnecting electrical connections (X1 pin connector) All electrical connections are contained within this plug. Before removing a component, disconnect the relative electrical connections. With the Thermo 90 S heater with mounting flange on the combustion air fan, disconnect the X1 pin connector of the heater and the X12 pin connector of the ECU; reconnect only after restoring the relative electrical connections. 1. 2. 3.

Remove the top cover of the heater. Remove the retainer wedge from the pin connector, using the hook on the removal tool. Press and hold the retainer tab with the screwdriver part of the removal tool and pull the wire out of the plug connector.

Preparing electrical connections 1. 2. 3.

Push the wire into the contact hole until it locks in place. Fit the retainer wedge in the pin connector with the screwdriver part of the removal tool, and push until it locks into place. Refit the top cover

30-675

Method of intervention Replacing circulation pump

1

2

3

4

Fig. 2732 - Replacing circulation pump Key 1. 2. 3. 4.

O-ring Circulation pump Clamp Screw (2)

The Thermo 90 ST heater is shown in the figure. In the case of the Thermo 90 S heater, the ECU may also be mounted on the combustion air fan; the position of the ECU does not influence the procedure for replacing the circulation pump. Disassembly 1. 2. 3. 4. 5.

Remove the heater (see “Maintenance”). Disconnect the electrical connectors. Remove screws (4). Remove the clamp (3) and the circulation pump. Perform the procedures necessary on the disassembled components

Reassemble 1. 2. 3. 4. 5.

Spread non-acid grease (petroleum jelly) on the seal ring (1). Fit the circulation pump (2) in the installation position and fasten with the clamp (3) and the screws (4). Tighten the screws (4) to 3 Nm ± 10 %. Prepare the electrical connections. Install the heater (see “Maintenance”).

30-676

Method of intervention Replacing temperature limiter 1

2

3

6 5

4

Fig. 2733 - Replacing the temperature limiter and temperature sensor Key 1. 2. 3. 4. 5. 6.

Protective cap Clamp Temperature limiter Heat exchanger Gasket ring Temperature sensor

The Thermo 90 ST heater is shown in the figure. In the case of the Thermo 90 S heater, the ECU may also be mounted on the combustion air fan; the position of the ECU does not influence the procedure for replacing the temperature sensor. Disassembly Only remove the temperature limiter if it must be replaced with a new component. Perform the functional test with the temperature limiter installed. 1. 2. 3. 4. 5.

Remove the heater (see “Maintenance”). Disconnect the electrical connections. Remove the clamp (2) and remove the protective cap (1). Lift the spring with the screwdriver and remove the temperature limiter (3). Perform the procedures necessary on the disassembled components

Once removed, the temperature limiter must always be replaced with a new component.

30-677

Method of intervention Reassemble If this component is not installed correctly, the heat exchanger will overheat and be irreparably damaged. 1.

Fit the new temperature limiter (3) in the heat exchanger (4) and push the spring into its seat. m The spring must seat perceptibly and audibly into the relative groove. Only once the spring is securely fitted is the temperature limiter installed correctly. m If the spring does not seat perceptibly in the groove: m clean the mating surface for the temperature limiter on the heat exchanger. m clean the groove in the heat exchanger. m check that the retainer tabs at the two sides of the spring are not missing. If necessary, replace the temperature limiter. Fit the protective cap (1) and fasten with the clamp (2). Tighten the clamp (1) to 1 Nm ± 10 %. Prepare the electrical connections. Install the heater (see “Maintenance”).

2. 3. 4. 5.

Replacing temperature sensor Disassembly 1. 2.

Remove the heater (see “Maintenance”). Disconnect the electrical connectors. m Warning - risk of scalding caused by escaping hot coolant. Unscrew the temperature sensor (6) and remove together with the gasket ring (5) Perform the procedures necessary on the disassembled components

3. 4.

Reassemble 1. 2. 3. 4.

Spread non-acid grease (petroleum jelly) on the gasket ring (5). Screw the temperature sensor (6), complete with seal ring (5), into the heat exchanger (4) and tighten to 1.5 Nm ±10 %. Prepare the electrical connections. Install the heater (see “Maintenance”).

Replacing the combustion air fan

2

3

4 1 5

Fig. 2734 - Replacing the combustion air fan 30-678

Method of intervention Key 1. 2. 3. 4.

Combustion air fan Screw (2) Shaped gasket ring Burner head

Disassembly 1. 2. 3. 4. 5.

Remove the heater (see “Maintenance”). Disconnect the electrical connectors. Remove screws (2). Ease the combustion air fan (1) out of the burner head (4), and remove together with the gasket ring (3). m In the case of Thermo 90 S/Thermo 90 ST heaters with the ECU mounted on a flange, also remove the ECU. Perform the procedures necessary on the disassembled components

Reassemble Fit the shaped gasket ring correctly (3), applying grease (e.g. petroleum jelly) and taking care not to crush the ring itself. 1. 2. 3. 4.

Fit the combustion air fan (1) in the installation position complete with the new gasket ring (3), and fasten with the screws (2). Tighten the screws (2) to 3 Nm ± 10 %. m In the case of Thermo 90 S/Thermo 90 ST heaters with the ECU mounted on a flange, also fit the ECU. Prepare the electrical connections. Install the heater (see “Maintenance”).

30-679

Method of intervention Replacing the burner, the flame sensor and the glow plug 1 13 12

11

6

7 8 10

9

2 5

4

3

Fig. 2735 - Replacing the burner, the flame sensor and the glow plug Key 1. 2. 3. 4. 5. 6. 7. 8.

Burner Helical membrane Burner head Washer Screw Glow plug Flame sensor Bracket

30-680

Method of intervention 9. 10. 11. 12. 13.

Insulation Nut (2) Sheath Sheath Sheath

While a Thermo 90 ST heater is illustrated in this figure, the figure is also applicable for the Thermo 90 S heater. Disassembly 1. 2. 3. 4. 5. 6. 7. 8. 9.

Remove the heater (see “Maintenance”). Remove the combustion air fan Remove the screw (5) and the washer (4). Remove the nuts (10) and remove the bracket (8). Remove the sheaths (11 and 12) from the notches on the body of the burner tube (3). Detach the sheath (13) and the burner (1) from the burner head, and remove together with the helical membrane (2). Detach and remove the flame sensor (7) and the glow plug (6) from the burner (1). Visually inspect the burner to assess its state (see “Troubleshooting”). Perform the procedures necessary on the disassembled components

Reassemble 1. 2. 3.

Fit the helical membrane (2) on the burner (1). Carefully fit the flame sensor (7) and the glow plug (6) fully into their respective seats in the burner, then push the sheaths (11 and 12) into the notches in the body of the burner tube (3). Fit the burner (1) and the sheath (13) on the burner head (3). m During the following procedure, ensure that the cables of the flame sensor (7) and the glow plug (6) are laid out correctly as shown in the figure.

6

7 Fig. 2736

1. 2. 3. 4. 5.

Push the insulation (9) onto the bracket (8) and fit the bracket in the installation position. m Lay out the cables of the flame sensor and the glow plug correctly as shown in the figure. Fasten the bracket (8) with the nuts (10). Tighten the nuts to 3 Nm ±10 %. Secure the fuel cable with the screw (5) and the relative washer (4). Tighten the screw to 3 Nm ±10 %. Fit the combustion air fan. Prepare the electrical connections. 30-681

Method of intervention 6.

Install the heater (see “Maintenance”).

Replacing the burner head

3 2

1

Fig. 2737 - Replacing the burner head Key 1. 2. 3.

Burner head V clamp Heat exchanger

Disassembly 1. 2. 3. 4. 5. 6.

Remove the heater (see “Maintenance”). Remove the combustion air fan Remove the burner, the flame sensor and the glow plug. Remove the screw fastening the V clamp (2) and remove the clamp. Ease out and remove the burner head (1) from the heat exchanger (3). Perform the procedures necessary on the disassembled components

Reassemble The burner head outlet or exhaust gas connection may also be straightened during installation in the vehicle. 1. 2. 3. 4. 5.

Fit the burner head (1) in the heat exchanger (3), adjust if necessary and fasten with the V clamp (2). If necessary, tighten the fastener screw of the V clamp to 3 Nm ±10 %. Fit the burner, the flame sensor and the glow plug. Fit the combustion air fan. Install the heater (see “Maintenance”).

30-682

Method of intervention Replacing the heat exchanger Disassembly 1. 2. 3. 4. 5. 6. 7. 8. 9.

Remove the heater (see “Maintenance”). Remove the circulation pump. Remove the temperature limiter. Remove the temperature sensor Remove the combustion air fan Remove the burner, the flame sensor and the glow plug. Remove the burner head. Remove the pin and the pin housing. Perform the procedures necessary on the disassembled components

Reassemble 1. 2. 3. 4. 5. 6. 7. 8.

Fasten the pin housing onto the heat exchanger and fit the pin in its housing. Fit the burner head. Fit the burner, the flame sensor and the glow plug. Fit the combustion air fan. Fit the temperature sensor Fit the temperature limiter. Fit the circulation pump. Fit the heater.

30-683

Method of intervention 30.10 - H0 - Hydraulic system

30.10.1 - Tightening the hydraulic power steering unit fastener screws Purpose

This assembly standard (939451 - 06/05/2013 - rev0) defines the correct tightening torque to be applied to the hydraulic power steering unit fastener screws.

Installation Tighten in two steps as follows: l l

tighten in a crossed pattern, applying 50% of the torque indicated in the table tighten in a crossed pattern, applying the definitive torque indicated in the table

1

939451

Fig. 2738 - Tightening the hydraulic power steering unit fastener screws Legend 1.

Screw

30-684

Method of intervention Table 368 Screw

M8 (class 8.8) M8, M10 (class 10.9)

CS

20 + - 10% 30 + - 10%

30-685

Method of intervention 30.11 - L0 - Electrical system 30.11.1 - Fitting BDS cables 1.

Fit the BDS on the machine, tightening the nuts to the specified torque while preventing the BDS itself from turning.

Fig. 2739

2.

Fit the battery cables and tighten the nuts to a torque of 18 Nm.

Fig. 2740

3.

DANGER The BDS terminal pins must be connected with the correct polarity. The terminal pin which is connected to the battery is identified by a red stamp or symbol.

Fig. 2741

30-686

Method of intervention 30.11.2 - Steering position sensor assembly

Fig. 2742 - Sensor assembly 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Cap Drilled screw Washer Sensor pin Screw Pin Pump housing Bearing Screw Sensor Sensor cover Bush Electrical wiring Bush Rubber grommet Gudgeon pin Connector Sheath Cap Axle beam

30-687

Method of intervention Disassembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. Unscrew and remove plug (1).

Fig. 2743

2.

Unscrew and remove drilled screw (2).

Fig. 2744

3.

Remove washer (3).

Fig. 2745

4.

Remove washer (3). Remove sensor pin (4).

Fig. 2746

30-688

Method of intervention 5.

Remove steering knuckle (7). See para. 30.8.11 - Wheel hub assembly - page 30-638

Fig. 2747

6.

Cut wires (13) on the side of wiring connector (17) and recover rubber bush (14).

Fig. 2748

7.

Remove screws (9). Detach sensor (10) and sensor cover (11).

Fig. 2749

8.

Withdraw sensor wires (13) and recover the rubber bush (12).

Fig. 2750

30-689

Method of intervention Assembly 1.

Some figures may not show the axle exactly as it is on your tractor, but the procedure described remains unchanged. Assemble the sensor cover (11) as shown in the figure.

Fig. 2751

2.

Remove plug (19). Grease the hole for wires (13).

Fig. 2752

3.

Fit rubber bush (12) on the new wires (13). Apply sealant to bush (12) and wires (13).

Fig. 2753

4.

Insert the three wires (13) in sheath (18) in the axle housing. Push the wires in as far as they will go.

Fig. 2754

30-690

Method of intervention 5.

Carefully pull wires (13) out through the exit hole.

Fig. 2755

6.

Locate the rubber bush (12) and sensor (10).

Fig. 2756

7.

Apply the prescribed sealant to screws (9). Fit screws (9) and tighten to the specified torque.

Fig. 2757

8.

Fit plug (19) and tighten to the specified torque. Install bearing cup (8) in axle beam (20) using drift 5.9035.163.0 and a hammer. Grease the kingpin seat with the prescribed grease.

Fig. 2758

9.

Fit rubber bush (14) on wires (13). Fit rubber grommets (15) and pins (16) on wires (13).

Fig. 2759

30-691

Method of intervention 10.

Disassemble the new connector (17). Insert the three wires(13) into connector (17)

Fig. 2760

11.

Assemble each pin (16) to the connector (17) respecting the position indicated.

Fig. 2761

12.

NOTE: Insert a rubber grommet (15) in position (h) to close the hole.

Wiring diagram.

Fig. 2762

13.

Assembly diagram.

Fig. 2763

30-692

Method of intervention 14.

Fit steering knuckle (7). See para. 30.8.11 - Wheel hub assembly - page 30-638

Fig. 2764

15.

Fit sensor pin (4).

Fig. 2765

16.

Fit washer (3).

Fig. 2766

17.

Apply the prescribed sealant to screw (2). Finger-tighten screw (2).

Fig. 2767

18.

Adjust the position of the sensor using a screwdriver, as shown in the figure. During the adjustment, the wheels on the axle should be in the straightahead position and the sensor should be receiving a 5V power supply

Fig. 2768

30-693

Method of intervention 19.

The sensor is positioned correctly when the sensor output voltage is with the specified range: 2,5±0.2 V

Fig. 2769

20.

Tighten screw (2) to the specified torque. Apply the prescribed sealant to the threads of plug (1). Fit plug (1) and tighten to the specified torque.

Fig. 2770

30-694

Method of intervention 30.12 - R0 - Rear lift

30.12.1 - 939272 - Pulling force sensor (23/11/2010)

Fig. 2771 l

A: Efective direction of the sensor for pulling force.

30-695

Method of intervention 30.13 - S0 - Wheels

30.13.1 - 939267 - Tyre fitting (23/11/2010) Assembly instructions

A

Fig. 2772 l

Screws of the bracket must not touch inside of the tyres. Otherwise, displace bracket! Distance, at least 25 mm

After assembling of the left and right front tyres, you have to check that no assembly component (bolt, nut and bracket) is in contact with the inside of the tyres and will damage the tyre by driving.

30-696

40 - Wiring diagrams

40-1

Wiring diagrams 40.1 - Introduction 40.1.1 - Introduction

For easier consultation, this unit has been divided into the following chapters: l

l

l

l

Introduction m Contains a brief description of the terminology used, the procedures to follow for troubleshooting and repairs, and the instruments required for fault diagnosis. Components list m Contains the components of the electrical systems, organised by type. m Indicates the system code, the component code and description, the technical data required for functional testing and a description of the pin-outs of the ECUs. Systems m Contains the wiring diagrams of the tractor’s systems. Wiring harnesses m Contains the layouts, the wiring diagrams and the positions of connectors on the tractor.

Introduction This section of the workshop manual is intended as a practical guide to fault diagnosis of the tractor’s electrical and electronic systems. The following pages provide the technician with all the necessary information regarding the tractor’s systems and components. Due to the possible time difference between the introduction of technical modifications (in line with our policy of continuous product improvement) and the corresponding amendment of our printed documentation, the data contained in this document are subject to modification and as such are not binding. Definition of components and symbols To prevent any misunderstanding or ambiguity, definitions for some of the key terms used in this unit are listed below.

Table 369 TERM

Connector Temperature sensor Pressure sensor Position sensor Pressure switch Thermostat Switch Solenoid valve

DESCRIPTION

Element used to connect two components (e.g. wiring-switch, wiring-wiring) Electrical component that converts the temperature of a medium (air, water, oil, etc.) into a voltage or resistance Electrical component that converts the pressure of a medium (air, water, etc.) into a voltage or resistance Electrical component that converts an angular or linear position into a voltage Switch that changes state (opens or closes a contact) according to the operating pressure in the circuit in which it is installed Switch that changes state (opens or closes a contact) according to the temperature of the medium (air, water, etc.) in which it is immersed. Mechanical component that opens or closes one or more electrical contacts. Valve operated by applying electrical current to a coil (or solenoid)

Chapter “Components” shows the wiring diagrams for certain switches and buttons. The following symbols are used for ease of interpretation: Contact between pins CLOSED (stable switch position) Contact between pins CLOSED (unstable switch position) Indicator LED

Indicator light

40-2

Wiring diagrams Diode

General rules The inspection, maintenance, fault diagnosis and repair operations are essential to ensure that the tractor continues to operate correctly over time and to prevent malfunctions and breakdowns. This paragraph describes repair procedures and aims to help improve the quality of repairs. Modification of the tractor’s electrical/electronic circuits The manufacturer prohibits any modification or alteration of the electrical wiring for the connection of any non-approved electrical appliances or components. In particular, if the electrical system or a component is altered without the Manufacturer’s authorisation, the Manufacturer will accept no liability for any damage to the vehicle and the vehicle warranty will be invalidated. Main wiring faults Bad contact between connectors l

The main causes of poor contact between connectors are incorrect insertion of the male into the female connector, deformation of one or both connectors, and corrosion or oxidisation of the pin contact surfaces.

Defective pin soldering or crimping l

The pins of the male and female connectors make good contact in the crimped or soldered area, but the wires are subjected to excessive strain, leading to breakage of the insulation and a poor connection or breakage of the wire.

Disconnecting wiring l

If connectors are disconnected by pulling on the cables, or if components are removed with the wires still connected, or if the wiring is subject to impact by a heavy object this could damage the soldering or crimping of wires on the pins and some wires may break.

Penetration of water inside connectors l

The connectors are designed to prevent penetration of liquids (water, oil etc.); however, when cleaning the tractor with pressure washers or steam washers water could penetrate or condense in the connectors. As the connectors are designed to prevent liquid penetration, any water that does get in will be unable to drain out, and thus may cause short circuits across the pins. It is therefore good practice to dry the connectors with a low pressure jet of compressed air after washing the tractor.

Oil or dirt on connectors l

If the connectors or pin contact surfaces show signs of oil or grease contamination, this will prevent the passage of current (oil and grease are electrical insulators) creating a poor contact. Clean the connectors thoroughly using a dry cloth or a low pressure jet of compressed air and use specific products (deoxidising sprays, etc.) to degrease the contacts. Important Take care not to bend the pins when cleaning them. Use dry oil-free compressed air.

Removal, refitting and drying of connectors and wiring When disconnecting wiring, pull on the connectors rather than on the wires themselves. For connectors that are held in position with screws or levers, fully loosen the screws, then pull on the connector. For connectors that are clipped together, fully depress the clip then pull the connector apart. After disconnecting connectors, apply water proof covers to prevent contamination of the contacts with dirt or moisture. Connecting the connectors. Check the condition of the connectors: l l l l l

Make sure the pin contact surfaces are free of water, dirt or oil. Check that the connectors are not deformed and that the pins are not corroded or oxidised. Check that the connector casings are not damaged or split. If a connector is contaminated with oil or grease, or if moisture has penetrated the casing, clean it thoroughly. If a connector is damaged, deformed or broken, replace it with a new one.

When connecting connectors, make sure they are properly aligned before applying force. For connectors with clips, insert the two halves until they clip together. Cleaning and drying wiring

40-3

Wiring diagrams l

l l

When wiring is dirty or contaminated with oil or grease, clean it with a dry cloth, or, if necessary, with water or steam. If the wiring must be cleaned with water, avoid directing the water or steam jet on the connectors; if water penetrates the connector, clean it thoroughly. Check that the connector is not short circuited due to the presence of water by testing for continuity across the pins. After checking that the connector is good condition, degrease the contacts using a deoxidising product.

Renewal of damaged electrical components. l l

l

l

When replacing electrical components (fuses, relays, etc.), use only original parts supplied by the manufacturer. When replacing fuses, check that the new fuse conforms to DIN 72581 or ISO 8820 standards, and in particular: m fuse F1 (100A) DIN 72581/2 m bayonet fuse (F2, F3, etc.) DIN 72581/3C m fuse F51 (100A) and F52 (200A) ISO 8820. The fitting of replacement fuses that do not comply with these standards will invalidate the warranty with immediate effect and release the manufacturer from all liability. When replacing relays, make sure that the new relay conforms to the standards marked on the original relay.

Diagnostic instruments For the correct diagnosis of any faults in the tractor’s electrical system, the following instruments are required: l

l l

Digital multimeter with the following minimum characteristics: m AC VOLT 0-600 m DC VOLT 0-600 m OHM 0-32M m AC AMP 0-10 m DC AMP 0-10 All Round Tester or computer with “PCTESTER” software installed SDF Analyzer

Wire colour codes Table 370

COLOUR CODES

A B S G H L M N R S V Z

Light blue White Orange Yellow Grey Blue Brown Black Red Pink Green Purple

40.1.2 - Basic electronics for mechanics (1/2) What is electronics?

The name of this branch of electrical science is derived from the word “ELECTRON”, the name given to a small electrically charged particle. The movement of electrons produces electrical current, which we know more about for its effects - heat, light, magnetism, electrolysis, etc. - than for its actual nature. While electrical engineering is concerned with these external effects of electrical current, electronics deals with way materials react to the gain or loss of electrons. Electrons in fact move from (-) to (+), but according to a convention that was established before the emergence of modern atomic theory, electric current flows in the opposite direction from (+) to (-). Using electronics it is possible to program complex logical processes, which could not be achieved in other ways. The various applications of electronics on our tractors can be divided into two groups: l

40-4

Invisible electronics, which operate without requiring any intervention of the driver, (voltage regulation, rectification of the current produced by the alternator, timing, etc.);

Wiring diagrams l

Visible electronics, ranging from the visible and audible information to made available to the driver via the vehicle’s instruments and signalling systems, to the control systems that serve to optimise work processes (Performance Monitor, SBA System, I-Monitor, etc.).

Logical development of the electronics As mentioned previously, electronics is generally viewed as a branch of electrical science, even though in certain aspects they are quite independent. Whereas electrical engineering generally deals with large amounts of current, electronics is more concerned with very low levels of current. Electronic applications are based on the movement of electrons and thus exploit the different degrees to which different materials conduct electrical current: l l l

Conductors, Insulators, Semiconductors

We therefore need to know what happens “electrically” inside the material. All matter is composed of tiny particles called atoms. The atom can be likened to a planetary system which has at its core a nucleus, comprised of protons and neutrons, around which rotate the electrons in different orbits, or shells.

Fig. 2773

Under certain conditions, electrons can move from one atom to another. If the number of electrons in an atom is the same as the number of protons, the atom is neutral (it has no charge). If the number of electrons exceeds the number of protons, the atom is negatively charged, while if it loses electrons it will become positively charged.

40-5

Wiring diagrams Atomic structure of matter The atom is the smallest particle of a simple element that can combine with other atoms to form molecules.

Fig. 2774

The composition of the nucleus and the number of electrons present in an atom determine which element it belongs to.

Fig. 2775

The structure of an atom can be compared to that of the solar system: 1. 2.

Electron (Planet) Nucleus (Sun)

Fig. 2776

Electrical charges of the same sign (1) repel each other while charges of opposite signs (2) attract.

Fig. 2777

40-6

Wiring diagrams 40.1.3 - Basic electronics for mechanics (2/2) Conductors, Insulators and Semiconductors

The behaviour exhibited by different materials in response to electricity derives from their atomic structure: 1. 2.

In conductors (generally metals), electrons are able to move freely from one atom to another; In insulators (generally metalloids) electron movement is restricted to varying degrees, depending on the type of material. Their atoms are not able to acquire electrons. Semiconductors (germanium, silicon, selenium, etc.), are materials which in their pure state may act as insulators, but with the addition of precisely calibrated amounts certain impurities, they can become conductors. Their electrical properties thus lie somewhere in the range between insulators and conductors. If these materials in their pure state are subjected to a technical process known as “doping” (the addition of impurities with a certain number of atoms with free electrical charges), they become positively or negatively charged, depending on the specific process.

3.

Electrical voltage We have talked about “external causes” that can provoke the movement of electrons in atoms. One of these external causes is “voltage” or “potential difference”, which exerts a “force” on electrical charges, causing them to start moving. This force is known as electromotive force; the force supplied by electrical sources (battery, dynamo, alternator). The concept of voltage or potential difference is illustrated by the example shown here. l

The levels in A and B are equal if the valve is open.

Fig. 2778

The concept of voltage or potential difference is illustrated by the example shown here. l

l

For water to flow from A to B, there must a difference in level “h” when the valve closed. The difference between the height of water in A and that in B creates a difference in pressure.

Fig. 2779

When the valve is opened, water flows from A to B until the point where the two pressures are equalised. The same happens with electrical current: l

to obtain current flow, there has to be potential difference at one of the conductor (caused by the presence of electrical charge).

Fig. 2780

40-7

Wiring diagrams Resistance The water model can also be used to explain the concept of electrical resistance. If water encounters obstacles when flowing through a pipe the the flow rate will slow or the direction of flow will change . The same applies to electrical current; obstacles of an electrical nature reduce the flow of electrons. Every material offers some degree resistance to the flow of electrons; the level of this resistance will depend on its atomic structure and its dimensions. Obstacles in a water course will slow down or change the direction of the water flow. Electrical resistance can be compared to a restriction in the conductor or scaling on the inside of a water pipe.

Fig. 2781

The electrical resistance of a material can be defined as the opposition it presents to the flow of electrons and varies according to the nature of the material and its dimensions.

Electrical continuity Staying with the water analogy, let’s examine how to obtain a continuous flow of water in a circuit. 424For the flow to be continuous, the water must be returned to basin 1. In this hydraulic circuit, the function of the pump (2) is to return the water to basin or tank (1).

Fig. 2782

Similarly, for current to flow continuously in an electrical circuit, the electrons must return from the positively charged terminal to the negatively charged terminal, in order to maintain a potential difference between the two terminals. This is the job of the electrical power source.

Electrical power supply An electrical power source can be defined as a system capable of separating and initiating the motion of a number of electrons. A battery, for example, has two metal terminals, one positive and one negative. Inside the battery, a chemical process causes free electrons to flow to the negative terminal to create a negative charge and a corresponding positive charge to build at the positive terminal. This process will continue inside the battery until the actions which caused it are balanced by the forces of attraction between the electrons and the positive charges. If the electrons could flow to the positive terminal, the initial neutral status could be restored, but as there is internal connection between the two terminals, this can only be achieved if there is an external connection between B and A. We can therefore state that a difference in potential, or voltage, has been created between the two terminals A and B. If we now connect an external load between B and A, the electrons concentrated at terminal A (+) will starting moving towards terminal B, thereby pushing along the free electrons present in the connecting conductor. An electrical current is thus created, (which by convention is deemed as flowing from A to B), and this current will continue to flow as long as there remains a difference in potential between the two terminals. 40-8

Wiring diagrams Schematic representation of a electrical power source A = Positive terminal B = Negative terminal G = Generator

Fig. 2783

Electromotive force (e.m.f.) Taking a simple electrical circuit , let’s see what happens to the voltage at the terminals of the power source when the circuit is closed (in this example, the power source is a battery, but the same result would be obtained with a different source of power, such as an alternator). Simple circuit with switch “I “open: no current flow. The same situation occurs if we replace the battery with an alternator in rotation. A voltage (e.g. 12V) is present at the terminals of the power source, which can be measured with a voltmeter. This no-load voltage is known as the electromotive force. R = resistance of a load.

Fig. 2784

Simple circuit with switch “I” closed. The battery powers the resistance R. A voltage drop occurs between the terminals of the power source, caused by the circulation of current in the source itself, which has its own internal resistance. Vd = r × A r = internal resistance of the power source in series with the other elements of the circuit A = current flowing through the circuit

Fig. 2785

The following relationship is therefore true for every power source: Available voltage = Electromotive force - Internal resistance x Current V=E-(r×I)

Direct Current (DC) and Alternating Current (AC) Electrical current can be either direct or variable: with direct current, the electrons always flow only one direction; with variable current, the direction and intensity of electron flow varies over time in accordance with the laws of trigonometry. If this change in direction is regular over time, the current is described as “alternating”. Alternating current changes cyclically from positive values to zero and from zero to negative values and so on. On a tractor, the battery supplies direct current voltage, and therefore direct current flows through the connected circuits. The alternator produces alternating current, which, as we shall see, must be converted into direct current by a bridge rectifier before it can be used. The graph below illustrates the behaviour of a sinusoidal alternating current. The voltage increases from zero volts up to the maximum positive value and then decreases to zero volts . The polarity is then inverted and the the voltage rises to the maximum negative 40-9

Wiring diagrams value before returning once again to zero. This complete sequence is referred to as one “cycle”. If a cycle is performed once every second, then the frequency of the alternating current is said to be 1 Hertz. In domestic electrical supplies, the frequency of the supply is 50 Hz. Frequency is thus the number of complete cycles performed in one second. A period is defined as the time required for an alternating sine wave to complete one cycle, i.e. from zero to a positive peak to zero to a negative peak and back to zero. This time period is expressed in seconds and is denoted by the letter T. The alternating current wave form illustrated in the graph is called sinusoidal. T = 1 period A = Amplitude B = Positive voltage C = Negative voltage

Fig. 2786

The number of cycles per second is the FREQUENCY and is expressed in Hertz and denoted with the letter “f”. f=1÷T T=1÷f An AC current with a frequency of 50 Hertz therefore has a period of 1 ÷ 50 = 0.02 seconds.

Electrical values: Current and Voltage CURRENT Symbol A Value: Amount of electrical charge that passes through a conductor in a given unit of time. Units: amperes. Instrument: ammeter. Connection to circuit: In series. Basic electrical circuit incorporating a voltmeter and an ammeter. Resistance is present in the conductors (R), in the loads (Ri1) and in the power source (Ri2). The inclusion of an ammeter (unlike a voltmeter) requires a modification to the circuit, in that the circuit must be opened at some point by cutting a conductor and the instrument must be then connected between the open ends of the conductor.

Fig. 2787

The inclusion of an ammeter (unlike a voltmeter) requires a modification to the circuit, in that the circuit must be opened at some point by cutting a conductor and the instrument must be then connected between the open ends of the conductor.

Fig. 2788

40-10

Wiring diagrams VOLTAGE Symbol V Voltage: Difference in potential; (emf); force that causes electrons to flow Units: Volts Measuring instrument: Voltmeter. Connection to circuit: in parallel.

Resistance In an electrical circuit, voltage and current are both dependent on RESISTANCE, i.e. the opposition to the flow of electrons in a material. We have already mentioned how the motion of electrons occurs as a result of forces produced by the collision of these minute particles. This phenomenon generates heat and is this reason why materials heat up when current passes through them. The greater the current (the greater the number of electrons in motion) the more heat is produced. As the temperature increases, the movement of the electrons also increases, and the electrons find it more difficult to move under the influence of the voltage. In some materials, this resistance is minimal; these materials are good conductors of current (conductors: copper, aluminium, silver, etc.). In others, the resistance is so high that it is difficult for electrons to move (insulators: mica, porcelain, glass, paper, etc.) In addition to the nature of the material, resistance is also affected by its dimensions: l l

l

LENGTH: the greater the length of the conductor the greater the number of collisions between atoms and free electrons. CROSS-SECTIONAL AREA; the greater the cross-sectional area, the greater the number of free electrons. Resistance is inversely proportional to cross-sectional area. TEMPERATURE, the motion of atoms and consequently the probability of collision with free atoms increases proportionally with the temperature, thus increasing also the resistance.

The electrical circuits on the tractor are generally comprised of wire conductors with a cross-sectional area that is negligible in comparison with their length.

Fig. 2789 - Load connection cables 1. 2. 3. 4. 5. 6. 7.

Single colour. Spiral striping with max. pitch 50 mm Horizontal striping. With narrow-spaced coloured rings. With wide spaced rings. With rings in groups of 2 of same or different colours, depending on use. With coloured rings in groups of 3

RESISTANCE Symbol R ( Omega ) Resistance: Opposition to the flow of electrons. 40-11

Wiring diagrams Units: Ohm (Omega ). Measuring instrument: Ohmmeter (tester), or voltmeter and ammeter when in presence of voltage.

The resistance of different materials - Resistivity It has been determined experimentally that the resistance of a wire conductor is given by: R = p × ( l ÷ S ) = ohms in which: p = (Greek letter pronounced “rho”) is a proportional coefficient that varies according to the nature of the material and is known as “resistivity” or “specific resistance”. l = length, expressed in metres S = sectional area, expressed in mm² This formula can also be written: p=(R×S)÷l so we can state that the unit of measurement of resistivity (p) represents a resistance of 1 ohm of a conductor of the material in question, with a length 1 metre, and sectional area of 1 mm², at a temperature of 0°C. While for conductors resistivity is measured in ohms per mm²/m, for insulators it is almost always expressed in mega ohms/mm, which is the resistance in millions of ohms of a cube with a side length of 1 m. Variation of resistance with temperature (temperature coefficient) For most metals, resistivity increases with the temperature (positive temperature coefficient); this is why when talking about resistivity there must always be a reference to temperature. There are exceptions to this rule, such as, for example, chromium and carbon, in which resistivity decreases with the temperature (negative temperature coefficient) and some alloys in which resistivity does not vary, which have temperature coefficient of 0. This increase or decrease in the resistance per degree of temperature and per ohm of resistance is termed the “temperature coefficient” , and is denoted with the Greek letter a (alpha). If the initial resistance is R0, at a temperature t0 (ambient temperature), and the temperature difference is t = t1 - t0, the variation in resistance will be: R×t×a and the final resistance is: Rt = R0 + R0 × t × a Rt = R0 (1 + a × t0) This formula is of great practical importance as it allows us to calculate the final temperature of a coil or resistor using the resistance variation method. The temperature coefficient is used (positive or negative) to characterise thermistors (PTC = Positive Temperature Coefficient and NTC = Negative Temperature Coefficient)

The interdependence of electrical values In an electrical circuit, the relationship between current, voltage and resistance is given by the formula: V=IxR Volts = ohms x amps If any of these values is unknown, it can be calculated, providing the other two values are known, simply by applying one of the following formulae: R=V÷I I=V÷R V=IxR

Power The power developed or dissipated is given by the formula: Power = Voltage x Current Watt (W) = Volts x Amps In mechanical engineering, power is still commonly expressed in terms of horsepower: hp The relationship between horsepower and Watts is given in the following equation: 40-12

Wiring diagrams 1 hp = 736 W = 0.736 kW 1 kW = 1.36 hp Dissipated power, in electrical terms, is power transformed into heat and is given by: Power = Voltage x Current = Resistance x Current x Current given that: W=V×I V=R×I then: W = R × I × I = R × I²

Multiples and submultiples of electrical values Table 371

Multiples and submultiples of units of measurement Prefix Name Symbol

megakilohectodecadecicentimillimicronanopico-

M k h da D S M µ N P

Multiply by

Divide by

1,000,000 1000 100 10 -

10 100 1.000 1,000,000 1,000,000,000 1,000,000,000,000

40.1.4 - Electrical and electronic components (1/2) Electrical and electronic components

Electronic components are used in circuits to modulate (vary, modify), control and regulate electrical values or to protect other devices. In particular, electronic semiconductor components exploit the various reactions of electrons to heat, magnetism, and light in order to generate small electrical signals. These electrical signals, when suitably modified, can be used by signalling devices or to control other components. Components can be classified on the basis of the functions they perform; components used to control or amplify power signals are deemed ACTIVE; components which neither control nor amplify power are deemed PASSIVE.

Resistors* Components of various design comprised of a conductor with a known resistivity that when included in a circuit causes a voltage drop. They are therefore used to change voltage and current; they come in different shapes and sizes, depending on their type, ohmic resistance value, tolerance and heat dispersion characteristics.

Table 372 TYPES OF RESISTORS

FIXED

VARIABLE

wirewound film -

wirewound film Linear or non-linear variation

THERMALLY SENSITIVE RE- LIGHT SISTORS TORS Thermistors: LDR NTC PTC -

SENSITIVE

RESIS-

All resistors are defined by their dimensions and characteristics: ohmic value, and maximum operating temperature. * N.B. To avoid confusion, in this manual the term RESISTANCE is used for the value expressed in ohms which represents the opposition to the flow of electrical current. The term RESISTOR is used for the component used to introduce “resistance” into an electrical circuit. Resistors are of two types: fixed or variable. (the term “resistance” is also often used for the component).

40-13

Wiring diagrams Fixed resistors How to determine the ohmic value of a resistor In wirewound resistors, the value is printed with decimal point (or comma) and the omega symbol. If the value of the resistor is 10.5 ohms, the marking will be: 10.5 ohms sometimes the letter R is used in place of the decimal separator (point or comma): 10 R5 On resistors with values measured in thousand of ohms, the printed value will include the letter “k”, which stands for thousand (1000): 10.5 kohms (10,500 ohms)

Fig. 2790

Potentiometers (Variable resistors) This a resistor with a sliding contact that varies the resistance as it is moved along the resistor. The symbols used in schematics for a variable resistor or potentiometer are shown in the figure on the right:

Fig. 2791

Use of a variable resistor as a voltage divider Divides the voltage into two or three parts in a specific ratio. V1 = Applied voltage, P = Potentiometer, U = Load, V2 = Required voltage (obtained by moving the sliding contact) < V1

Fig. 2792

Use of a variable resistor as an electrical resistance of absolute value All the current flows through the sliding contact. This means that the sliding contact must be held securely in place, otherwise the voltage V2 will change.

Fig. 2793

40-14

Wiring diagrams Preventing arcing between the resistor and sliding contact. The figure shows a way to prevent the arcing between the resistor and the sliding contact that may occur in the case of poor contact. This connection allows some of the current to flow through the full length of the resistor. The voltage drop between the sliding contact and the resistor is less than V1, thus reducing the possibility of arcing. The resistor of the rheostat can be sized so that the resistance can be varied in both a linear and a non-linear way.

Fig. 2794

Voltage divider Voltage dividers with fixed resistors or potentiometers are used whenever circuits require electrical power below the standard voltages available on the tractor (12 Volts with engine off and 14.5 Volts with engine running). Voltage dividers are found in the voltage regulator of the alternator and in the electronic control units. Thermistors (Thermally Sensitive Resistors) These are semiconductor resistors in which the resistance decreases as the temperature rises, ranging from just a few ohms at 0 °C to tens of thousands of ohms at 100 °C; they are used to detect changes in temperature. They may be either self-heating, if the heat is produced by the current flowing through them, or externally heated, if sensitive to the temperature of the environment or the component on which they are mounted. There are two types: PTC (Positive Temperature Coefficient) and NTC (Negative Temperature Coefficient) With PTC thermistors, resistance increases with the temperature, while with the NTC type, resistance decreases as the temperature rises. NTC types are available with resistance values ranging from just a few ohms to several hundred kohms. Operating characteristics of NTC thermistors

Fig. 2795

Operating characteristics of PTC thermistors Note the linearity of the variation.

Fig. 2796

Thermistors are used in cab heating and climate control systems.

40-15

Wiring diagrams Capacitor This component consists of a pair of conductors, generally in the form of flat plates, separated by an insulator (dielectric). Its function to store electrical charge from a power supply. This charge can then be given as and when required. Symbol

Fig. 2797

Capacitor in a circuit with a generator.

Fig. 2798

The amount of electrical charge that a capacitor can store is referred to as its “capacitance” (C), and is measured in farads (F). In practice, however, the farad is too large for general use so the following units are used instead: mF = millifarad = 1/1,000 F µF = microfarad = 1/1,000,000 F nF = nanofarad = 1/1,000,000,000 F On closing the switch, the electrons start moving but their flow is impeded by the dielectric. Electrons will therefore accumulate in the plate connected to the negative terminal (-) of the generator, causing negative charge to build up. In the meantime the positive plate loses electrons, thereby becoming positively charged. A potential difference is thus created across the plates of the capacitor, and this increases until it equals the potential difference of the generator. The capacitance of the capacitor is therefore proportional to the applied voltage and to the surface area of the plates and is inversely proportional to the distance “d” between the plates. It also depends on the type of dielectric used. The process described above is known as charging the capacitor, and is complete when the capacitor is fully charged. If a resistor or a load of another type is connected to the capacitor, the latter discharges as electrons flow in opposite direction and the potential difference between the plates decreases to zero.

Diodes A diode can be defined simply as a junction between two semiconductors, one made of P-type material and the other made of N-type material.

40-16

Wiring diagrams A diode is a junction between two semiconductors, one made of P type material and the other made of N type material.

Fig. 2799

The contact between the two semiconductors in different situations of electrical charge forms a barrier to electrical current flow at the junction. This barrier prevents the current from flowing through the diode.

Fig. 2800

Rectification, isolation, (switch), discharge and protection.

Fig. 2801

The diode symbol and the designations of its terminals.

Fig. 2802

The situation at the junction between the two semiconductors changes when a voltage is applied across the anode and cathode; the diode is polarised, as shown in the figure. When a voltage is applied to the diode, it polarises in the two ways indicated.

40-17

Wiring diagrams (A) = Direct polarisation (forward biasing) ( - ) = Cathode ( + ) = Anode

Fig. 2803

(B) = Reverse polarisation (reverse biasing) ( - ) = Cathode ( + ) = Anode

Fig. 2804

With forward biasing (positive connected to the anode and negative to the cathode) the resistance to current flow is significantly reduced and the diode allows current to flow, providing that the applied voltage exceeds the threshold value, i.e. the voltage required to initiate the process by which the barrier is reduced. If the polarity of the diode is reversed, there is no electron flow except for the very weak current that crosses the junction. If the reverse voltage applied to the diode exceeds a certain value (thousand of Volts) the reverse current flowing through the diode will increase rapidly to the point where the junction is damaged. The function of the diode is therefore to allow current flow in one direction only, from the anode (+) to the cathode ( - ). It this way it acts as an electrical one-way valve. Forward biased diode allows current flow. The lamp illuminates,

Fig. 2805

40-18

Wiring diagrams Reverse biased diode blocks current flow. The lamp does not illuminate.

Fig. 2806

The main function of the diode is to act as an electrical one-way valve.

Fig. 2807

Zener diode We have already mentioned how diodes do not tolerate reverse voltage, as when this reaches a certain level, the reverse current flow will increase significantly to the point where the diode itself is damaged. The Zener diode is specifically designed to allow a certain amount of reverse current flow without damage to the junction. It is also possible to make this reverse current flow occurs at a certain reverse voltage, known as “zener voltage”. A zener diode can therefore be defined as semiconductor with a special PN junction with controlled reverse bias properties. If forward biased, the Zener diode behaves just like a normal diode, while if reverse biased, it prevents current flow until the voltage reaches the critical level, which is defined as the “Zener point”. At this point the current increases rapidly.

40-19

Wiring diagrams

Fig. 2808

The behaviour of the Zener diode can thus be compared to that of a pressure relief valve in a hydraulic circuit. a) current and water flow b) no current or water flow, c) the water flows when it overcomes the opposing force of the valve spring. Likewise, the current flows when the voltage reaches the zener point.

LED (light emitting diode) A LED is a special diode with two terminals; it allows current flow in one direction only and emits light when low-voltage current passes through it. The polarity of the terminals is very important, and the cathode is marked to facilitate identification. The light emitted is monochromatic; the colours red, yellow, green and orange are available. Operating characteristics of a LED and its symbol.

Fig. 2809

40-20

Wiring diagrams LED 1. 2. 3. 4.

Light beam emitted Diode Transparent plastic cap PIN terminals

Fig. 2810

LEDs are often used for signal lamps as their power consumption is very low, they require only low levels of reverse current and they are impact resistant. A typical application is as an indicator lamp, which, unlike a conventional bulb, can be flashed on and off repeatedly without failing. They are also used to display segmented symbols and alphanumeric digits.

40.1.5 - Electrical and electronic components (2/2) Transistors

A transistor is semiconductor which has three junctions. It can be distinguished from a diode by its three leads, whereas a diode only has two.

Fig. 2811 - Schematic diagram and symbol of the transistor. As you can see from the schematic, there two possible configurations: PNP (with a N semiconductor in the centre) or NPN (with a P semiconductor in the centre). The central part is known as the “base”. The lateral parts are doped with impurities and are termed the “collector” and the “emitter”. On the symbol, note that the emitter is marked with an arrow, which indicates the direction of current flow between the base and the emitter. Inside the transistor, there are two opposing barriers to current flow: if voltage is applied at one end of the semiconductor (E-C), one if the barriers is eliminated while the other is strengthened and consequently no current flows; the same result is obtained if the polarity of the applied voltage is reversed.

40-21

Wiring diagrams When voltage is applied across terminals (E) and (C), no current flows through the transistor.

Fig. 2812

If a weak voltage is applied simultaneously to the base terminal, the transistor becomes a conductor and current flows between the emitter and collector. When voltage is also applied to the base terminal, the transistor allows current flow.

Fig. 2813

When the voltage applied to the base terminal is modified, the current flow between the emitter and collector will also vary proportionally. From this behaviour are derived the two main characteristics of the transistor: 1.

Current does not flow through the transistor if the circuit between the emitter and collector is interrupted, i.e. no voltage applied. The current flowing through the transistor is directly proportional to current that flows through the emitter-base circuit, within the operating limits of the transistor. This means that the base current (the current that flows between the emitter and base) is proportional to the collector current (the current flow between the emitter and the collector) and therefore the latter increases.

2.

Given these two characteristics, a transistor can function as a switch (by removing the voltage at the base) or as an amplifier. With a transistor, a weak current flowing from the emitter E to the base B (PNP transistor) or from the base to the emitter (NPN transistor), can be used to control a strong current flow from the emitter to the collector (PNP) or from the collector to emitter (NPN). This is the most useful characteristic of the transistor, which can be summarised in the equation: a = ( Ic ) ÷ ( Ib ) This parameter, however, varies according to the collector current and voltage, as well as the temperature of the transistor. The difference between NPN-type and PNP-type transistors lies solely in the direction of the current flow. The operating limits of transistors are: l l

40-22

the maximum collector current, maximum voltage from collector to emitter.

Wiring diagrams

Fig. 2814 - Operation schematic Schematic showing operation of a PNP transistor and an NPN transistor when voltage is applied at the base. The current Ic can flow from E to C only if it flows from E to B (1) or from B to E (2). Ic is amplified relative to Ib.

Fig. 2815

Typical connection of a transistor. The resistor R limits the current and protects the transistor.

40-23

Wiring diagrams

Fig. 2816

Typical connection of a transistor. The resistor R limits the current and protects the transistor.

Fig. 2817

The transistor as a current amplifier

Use of a transistor as a switch or relay Thanks to their amplifying properties, transistors can be used in place of relays (electromagnetic switches) as they can perform the same function, but with the advantage that they use static components rather than moving parts. The figure shows two electrical circuits, one controlled by a relay and the other by a transistor. In the relay circuit, when the switch is closed in the relay control circuit, the contacts close the main circuit (drawn with the thick black line); i.e. a relatively small current (0.2 A) can be used to control a much larger working current (8A). The transistor circuit works in exactly the same way. When the switch in the control circuit is closed, the current flows from the positive pole of the battery through the emitter; the base terminal of the transistor is polarised and the transistor allows current flow (EC) thus allowing current to flow in the main circuit.

40-24

Wiring diagrams

Fig. 2818

Circuit diagrams show use of an electromagnetic relay (B) and use of a transistor as a relay (A). U = Load in main circuit.

40-25

Wiring diagrams 40.2 - Components

40.2.1 - 2.8519.134.0/50 - HLHP control unit Connector M003 pins

5

6

73

82

94

1

2

7

16

28

3

Fig. 2819

Table 373 Pin

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

Voltage

+12V 0V +12V 0V +12V 0V 0V

Description

Battery positive (+30) Battery negative Battery positive (+30) Battery negative Battery positive (+30) Battery negative Negative power feed for rear hitch UP control solenoid valve Battery positive (+15) Sensors negative Hydraulic oil reservoir temperature sensor signal input Auxiliary distributor control button (up) signal input Auxiliary distributor control button (down) signal input Brakes circuit pressure signal input Front axle rpm sensor signal input Front PTO speed sensor signal input Radar signal input ISO 9141 interface LH damper position sensor signal input RH damper position sensor signal input Semiactive cab suspension button signal input Rear hitch position sensor signal input CANBUS interface (CAN-L) CANBUS interface (CAN-H) Negative power feed for rear hitch DOWN control solenoid valve CANBUS distributor interface (CAN-L)

Table 374 Pin

31 32 33 34 35 36 37

40-26

Voltage

0V

Description

Sensors negative CANBUS distributor interface (CAN-H) Steering angle sensor signal input Front axle suspension position sensor signal input Front hitch position sensor signal input RH draft sensor signal input

Wiring diagrams Pin

38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

Voltage

Description

LH draft sensor signal input Operator presence signal input EPB lever signal input Hitch down button signal input Hitch up button signal input Hydraulic steering circuit pressure signal input Hydraulic circuit pressure signal input Rear PTO speed sensor signal input (USA) CANBUS vehicle interface (CAN-H) CANBUS vehicle interface (CAN-L) Positive power feed for rear hitch UP control solenoid valve

0V

Sensors negative

PTO speed selection signal input Front ground-operated hitch “Up” control buttons signal input Front ground-operated hitch “Down” control buttons signal input

Table 375 Pin

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

Voltage

Description

A/C condenser ON signal input Safety switch signal input (NO contact) Safety switch signal input (NC contact)

+5V +5V +5V

Positive power feed for sensors Positive power feed for sensors Positive power feed for sensors Positive power feed for rear hitch DOWN control solenoid valve Differential lock control solenoid valve power Front axle DOWN coil power Positive power feed for front axle speed sensor LH damper positive power RH damper positive power Front PTO control solenoid valve power Front axle suspension Load Sensing control solenoid valve Front axle “Up” control solenoid valve power EPB Limp Home signal

Ground-operated PTO control buttons signal input

Table 376 Pin

91 92 93

Voltage

Description

LH damper negative power 40-27

Wiring diagrams Pin

94

Voltage

Description

RH damper negative power

40.2.2 - 2.8519.133.0/20 - Transmission control unit Connector M001 pins

1

4

7

10

13

16

2

5

8

11

14

17

3

6

9

12

15

18

Fig. 2820

Table 377 Pin

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Voltage

Description

Signal input for clutch pedal position sensor 0V

Shuttle lever power feed

Connector M001a pins

1

4

7

10

13

16

2

5

8

11

14

17

3

6

9

12

15

18

Fig. 2821

40-28

Wiring diagrams Table 378 Pin

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Voltage

Description

Brake pedal sensor power feed Shuttle lever NEUTRAL signal input Shuttle lever REVERSE signal input Shuttle lever forward signal input RH brake pedal pressed signal input LH brake pedal pressed signal input

Connector M001b pins

1

4

7

10

13

2

5

8

11

14

3

6

9

12

15

Fig. 2822

Table 379 Pin

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Voltage

Description

CANBUS vehicle interface (CAN-L) CANBUS vehicle interface (CAN-H) PTO 1400 solenoid valve power feed PTO 540 solenoid valve power feed

12V 0V 12V

PTO 1000 solenoid valve power feed Proportional PTO engagement solenoid valve power feed Battery positive (+15) Rear PTO signal input Battery negative Battery positive (+30) ISO 9141 serial interface

40-29

Wiring diagrams Connector M001c pins

1

4

7

10

13

16

2

5

8

11

14

17

3

6

9

12

15

18

Fig. 2823

Table 380 Pin

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Voltage

0V 5V 0V 5V 5V 5V

Description

Accelerator pedal position sensor negative power feed SMART WHEEL negative power feed Accelerator pedal position sensor signal input Battery negative SMART WHEEL signal input Brakes circuit pressure sensor positive Brakes circuit pressure sensor negative Brakes circuit pressure signal input Accelerator pedal position sensor positive power feed Clutch pedal position sensor positive power feed Clutch pedal position sensor signal input SMART WHEEL positive power feed

CANBUS vehicle interface (CAN-H) CANBUS vehicle interface (CAN-L)

40.2.3 - Engine control unit Connector M002 pins

5

6

3

4

1

2

75

91

58

74

41

57

24

40

7

23

Fig. 2824

Table 381 Pin

1 2

40-30

Voltage

+12V 0V

Description

Battery positive (+30) Battery negative

Wiring diagrams Pin

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

Voltage

+12V 0V +12V 0V

Description

Battery positive (+30) Battery negative Battery positive (+30) Battery negative

Ambient temperature sensor

+5V

Hand throttle position sensor power feed

+5V

Not used Accelerator pedal position sensor power feed

Water in fuel sensor signal input Signal input for accelerator pedal position sensor Hand throttle position sensor signal input

Table 382 Pin

32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61

Voltage

Description

Engine oil pressure sensor signal input

Negative power feed for Visco Clutch

Not used

Not used Ambient temperature sensor HOLD button signal input Not used

0V

Positive power feed for engine coolant level sensor Battery negative

40-31

Wiring diagrams Pin

62

Voltage

Description

Engine coolant level sensor signal input

Table 383 Pin

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

Voltage

Description

Engine start signal input (+50) +12V

Battery positive (+30)

GND

Hand throttle position sensor power feed Water in fuel sensor power feed

+12V

Infocenter power feed (+15) Positive power feed for Visco Clutch

GND

Negative power feed for engine coolant level sensor CANBUS engine interface (CAN-H) CANBUS engine interface (CAN-L) Accelerator pedal position sensor power feed CANBUS vehicle interface (CAN-H) CANBUS vehicle interface (CAN-L)

Connector M002a pins

85 64

105 84

43

63

22

42

1

21

Fig. 2825

Table 384 Pin

1 2 3 4 5 6 7 8

40-32

Voltage

Description

Positive power feed for urea pump Relay negative power feed Inverter valve power feed

Wiring diagrams Pin

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Voltage

Description

Urea level sensor signal input Intake air temperature sensor signal input Engine coolant temperature sensor signal input Urea temperature sensor signal input Exhaust gas temperature sensor signal input Negative power feed for RAIL pressure sensor Positive power feed for urea pressure sensor +5V

Positive power feed for sensors Cylinder 4 injector power feed Cylinder 5 injector power feed Cylinder 6 injector power feed Proportional solenoid valve power Urea dosing valve

Not used

Table 385 Pin

32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62

Voltage

Description

+5V

Sensors negative power RAIL pressure sensor power feed Positive power feed for urea return line heater relay

Positive power feed for urea pump power relay Exhaust restrictor solenoid valve power feed Common power feed for cylinder 4, 5 and 6 injectors Common power feed for cylinder 4, 5 and 6 injectors Common power feed for cylinder 4, 5 and 6 injectors Proportional solenoid valve power Urea dosing valve Not used Not used

Low fuel pressure sensor signal input Urea pressure sensor signal input Preheating activation signal input PWM signal for urea pump Positive power feed for urea delivery line heater relay Positive power feed for urea dispensing module heater relay

Table 386 Pin

63 64

Voltage

Description

Preheating relay power feed Cylinder 1 injector power feed 40-33

Wiring diagrams Pin

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 96 97 98 99 100 101 102 103 104 105

40-34

Voltage

Description

Cylinder 2 injector power feed Cylinder 3 injector power feed

Power feed for urea level/temperature sensor Oil pressure sensor signal input Intake air pressure sensor signal input Power feed for intake air temperature sensor Speed sensor shielding CANBUS engine interface-2 (CAN-H) RAIL pressure sensor signal input Positive power feed for urea pick-up line heater relay Inverter valve signal input Common power feed for cylinder 1, 2 and 3 injectors Common power feed for cylinder 1, 2 and 3 injectors Common power feed for cylinder 1, 2 and 3 injectors Power feed for exhaust restrictor solenoid valve and preheat relay Negative power feed for urea pump Urea tank heater valve Starter motor command Starter motor command CANBUS engine interface-2 (CAN-L) Negative power feed for camshaft speed sensor Positive power feed for camshaft speed sensor Negative power feed for crankshaft speed sensor Positive power feed for crankshaft speed sensor

Wiring diagrams 40.2.4 - Main power relay switch (TGC/RME-SA1) Field of application

Main power relay switch for disconnecting battery from 12V vehicle electrical system, intended for use in agricultural vehicles.

Definitions Table 387 Code

TGC/RME-SA1 Activation Deactivation S (ON-OFF) Status LED tAB tAC tDC tAUX t1stON tACrefrac tEMEdetect tEMErefrac TX dcX TERREPET tERFILTER TA

SW

Description

Version 1 (1) of bistable, mechanically retained (/RM) main power relay switch (TGC) with electronic system control board (E) for specific client (SA). Normal operating state of device, with battery connected to vehicle electrical system. Rest state of device, with battery isolated from vehicle electrical system. Remote electric command with two stable states (ON - OFF) for switching device on and off. Indicator lamp or LED installed on exterior of device to indicate status of device itself. Coil power feed time. Controlled switch on time Time elapsing between operation of ON control by user and effective closure of main contact. Controlled switch off time Time elapsing between operation of OFF control by user and effective aperture of main contact. Duration of AUX line activation pulse. Duration of first status LED pulse on closure of main contacts. Time interval during which device inhibits all manoeuvres following a failed power on command. Maximum time interval during which user must complete manoeuvre on the SON-OFF control to trigger emergency disable state. Time interval during which device inhibits activation following emergency disable. Period or duration of status LED flash during state X (state X for different cases defined in document). Duty cycle, or duration of status LED pulse during state X (state X for different cases defined in document). Repeat period of pulse sequence indicating active error code. Time period for which fault condition relative to control signal channels must persist in order to be indicated. General ambient conditions: • Temperature: 23°C (±5°C), • Atmospheric pressure: 960 mbar (±100 mbar), • Relative humidity: 60% (±15%). Device management software.

Notes This document contains frequent references to: l l

the electrical wiring diagram contained in the paragraph “Electrical Connections”, and the paragraph relative to the “Pin List”.

General description The TGC/RME-SA1 is a device used to disconnect batteries from the vehicle electrical system. The device consists of a pair of fixed contacts, connected to the battery and the electrical system respectively, and a mobile contact (main contact), which connects the two fixed contacts. The mobile contact is moved by a relay switch which, when powered briefly, moves the contact from the position in which it connects the fixed contacts into the position in which the fixed contacts are disconnected, and vice versa. Due to the cam shape of the mobile core, both positions of the mobile contact are mechanically stable. This prevents the mobile contact from returning to the previous position once it has moved. The device is subdivided into the following parts: l

l

Power section: bistable relay switch with one main contact for disconnecting the battery positive terminal from the electrical system of the vehicle. Electronic control unit (ECU): for managing functions of complete device. 40-35

Wiring diagrams l

Wiring loom, which includes: 1. an auxiliary positive power feed line available for external utilities (AUX); 2. the ground line of the device (GND); 3. two lines (CH1 and CH2) for connection to the remote electric control (SON-OFF), for commanding device activation and deactivation states; 4. status LED driver line, for indicating status of device (in normal and fault conditions) (LIGHT) 5. the power line for the aforementioned command and status LED lines (COM+) 6. a line for reading the ignition switched power signal (+15).

The electric control (SON-OFF) is managed with two lines (CH1 and CH2) to: l l

minimise the possibility of spurious command signals; enable diagnosis of faults relative to the control itself.

The electric control used consists of a deviator switch (see connection diagram), which switches the positive power feed received from COM+ to CH1 and CH2 to command deactivation and activation states respectively. As a result, both commands are associated with a clearly defined voltage, which minimises the risk of misinterpreting a fault state caused by an interruption or short circuit in the line as a command signal. The device may be interfaced with an external indicator lamp (status LED driven from LIGHT line) to indicate the status of the device itself. In the connection diagram given here, the status LED is integrated in the control.

Description of function Normal operation Activation Switching the control SON-OFF from OFF to ON, with the TGC/RME-SA1 device in deactivated state: l l l

the LIGHT line (t1stON) activates for a prolonged period and then flashes (flash mode parameters: TON and dcON); the AUX line is activated with a single pulse with the duration tAUX; the main contact is closed, after a delay time of tAC.

The tAC delay time covers the wake-up cycle from sleep mode, which is in effect when the device is in deactivated state (see next paragraph), and the read and filter operations relative to the command signal channels CH1 and CH2. This sequence is performed completely independently of the ignition switch (+15) state identified. The LIGHT line continues to produce a flashing signal uninterruptedly until the next change in state requested by the user. The AUX line pulse is generated after the change in state of the main contact, to permit utilities operating with ignition switched power to be disabled (from an external relay) and prevent the possibility of the contact closing while under power. This condition applies if the user requests activation with the ignition switch (+15) on and with the relative utilities (e.g. lights and fans) already connected. The activation sequence is illustrated in the following diagram:

40-36

Wiring diagrams t AC

MAIN C.

Closed Open

COIL DRIVE t 1stON

LIGHT

t AUX

AUX S ON-OFF +15

LED Blink

ON OFF DO NOT CARE

Fig. 2826

Note 1: If the device is powered with the SON-OFF control already switched to ON, no change in state is implemented. In this case, the control must first be returned to OFF and then switched back to ON to activate. This condition applies primarily in the event of installation or maintenance of the device, when the battery is connected to the device with the lever on the control inadvertently left in the ON position. Note 2: If the manoeuvre to close the main contact fails, the device repeats the attempt to perform the manoeuvre a number of times, extending the duration of the AUX line activation pulse. This pulse remains active until the repeat attempts are concluded, whether they successfully lead to the closure of the contact or not. Note 3: If the repeat attempts to close the main contact (see previous note) conclude without success, and the device remains in deactivated state, the SON-OFF control is locked out for a period tACrefrac, during which no more attempts of the manoeuvre may be performed. At the end of this period, if the control was switched to ON, it must first be switched to OFF and then to ON again to perform a new closure manoeuvre. Note 4: With reference to Note 2 and Note 3, concerning a situation in which the manoeuvre to close the main contact fails, see the detailed explanations in the paragraph relative to the management of fault states, and the error table. Deactivation Switching the control SON-OFF from ON to OFF, with the TGC/RME-SA1 device in activated state and with the ignition switch (+15) OFF: l

the main contact is opened after a delay tDC. 40-37

Wiring diagrams l

During the delay time tDC, the LIGHT line flashes (flash mode parameters TOFFdelay and dcOFFdelay).

In addition to covering the read and filter operations relative to the command signal channels CH1 and CH2, the delay time tDC is set long enough to also allow the electronic control units of the vehicle to perform all the operations necessary before disconnection of the system from the battery pack. If the user restores the initial status of the control (by switching SON-OFF back to ON) during the tDC delay time, the deactivation sequence is interrupted and the active state is restored, as indicated by the flashing LIGHT line. The main contact remains closed. The deactivation sequence described above is illustrated in the following diagram:

t DC

MAIN C.

Closed Open

COIL DRIVE LED delay Blink

LIGHT S ON-OFF +15

ON OFF

OFF

Fig. 2827

If, however, the ignition switch state (+15) is on when the user requests deactivation, the LIGHT line generates a warning flash (flash mode parameters TOFF&KEY and dcOFF&KEY), and the command is NOT executed. The LIGHT line continues to flash for as long as the fault condition persists: in other terms, for as long as the battery disconnect request exists with the ignition switch in on state (+15 active). This also applies if the ignition switch state changes to active during the delay time tDC - in this case, the sequence is interrupted, the main contact remains closed and the warning flash signal described above is generated. Once the deactivation sequence is completed, the device enters sleep mode, minimising battery current absorption. Emergency deactivation With the TGC/RME-SA1 in activated state and in any ignition switch state (+15), performing: l l l

2 consecutive ON-OFF-ON manoeuvres on the SON-OFF control followed by an ON-OFF manoeuvre within a maximum time period of tEMEdetect

: l l l

40-38

the current flash mode of the LIGHT line stops immediately, the main contact opens immediately, and the SON-OFF control is locked out completely by the device for a period tEMErefrac.

Wiring diagrams This is an emergency main contact aperture sequence and must therefore only be performed in situations of real emergency where the battery must be disconnected as quickly as possible without implementing the normal delayed procedure. l l

This sequence may also be performed with the ignition switch on. Immediately after opening the contact, this sequence causes a state in which, for a period of time (tEMErefrac), device activation is locked out, with the contact forced open.

Therefore, if the lever on the SON-OFF control is returned to ON while performing the final ON-OFF manoeuvre in the emergency sequence, the device remains in the deactivated state and may not be activated again until the lock-out period elapses. Once this period has elapsed, the control must first switched to OFF and then to ON again to activate the device. Conversely, if the user only performs the first two ON-OFF-ON manoeuvres in the emergency sequence and fails to perform the third within the time limit tEMEdetect, the second of these manoeuvres is considered a normal deactivation request and the device implements the normal sequence described in the previous paragraph. The emergency deactivation sequence described above is illustrated in the following diagram:

MAIN C.

Closed Open

COIL CMD LIGHT S ON-OFF +15

Blink

ON OFF


t EMErefrac

DO NOT CARE

Fig. 2828

Fault state management The TGC/RME-SA1 device is capable of identifying and indicating certain fault states. In certain cases, the user is notified of the fault state by the status LED (LIGHT signal). This occurs in the form of a repeated sequence of a number of flashes corresponding to the active error code. There are only two cases in which the device itself implements corrective action upon identifying a fault. l

l

In the event of a fault concerning the aperture or closure of the main contact, before generating the error state signal, the device performs a number of attempts to repeat the manoeuvre and resolve the fault. The error state continues to be indicated until a new status LED flash mode is necessary. If a short circuit to ground in the AUX line is detected, the device instantaneously deactivates the line via both the protection circuit integrated in the hardware driver and via the device management SW, which switches off the driver itself.

In all other cases, the fault is indicated only, with no corrective action implemented by the device. The fault continues to be indicated for as long as the fault state itself persists. 40-39

Wiring diagrams For details on error codes and the conditions in which they are generated, see the paragraph relative to the error table. Descriptions of faults, organised by type, are given as follows. See para. 20.5.8 - Alarm List, Electronic... - page 20-497 Control faults (COM) These are faults concerning the control and recognition of the control status by the device. Control status recognition is made possible by dual channels for reading control status (CH1 and CH2). Any permanent status not recognised as valid generates an error code. See the COM errors listed in the error table for details. See para. 20.5.8 - Alarm List, Electronic... - page 20-497 Faults relative to the status of the main contact (MCO) These are faults relative to the status of the main contact - in other terms, conditions where the main contact does not maintain or fails to attain the expected status. See the MCO errors listed in the error table for details. See para. 20.5.8 - Alarm List, Electronic... - page 20-497 Faults relative to the auxiliary power line status (AUX) These are faults associated with short circuits on the AUX line. See the AUX errors listed in the error table for details. See para. 20.5.8 - Alarm List, Electronic... - page 20-497 Electrical connections The electrical diagram for the connection of the TGC/RME-SA1 device to the vehicle electrical system is given below:

40-40

Wiring diagrams LOAD POSITIVE LINE

PCB

Vbat

ON OFF

IGNITION KEY SON-OFF

8 7 6 5 4 3 2 1

Vbat

CH2 COM+

4 3 2 1

OFF ON

Vbat

OFF

+15

LOAD

LIGHT CH1

ON

GND AUX

L2 (OPT)

uC & Drivers

Battery Disconnecting Switch (TGC/RME-SA1) BATTERY POSITIVE LINE BATTERY

+ -

BATTERY NEGATIVE (To Chassis)

Fig. 2829

Pin list The table relative to the 8 pin connector, with details of the respective pin functions, is given as follows. See the relative paragraph later in this document for electrical characteristics.

Table 388 Pin No.

Pin type

Label

2 3 4

Power - IN Input signal Output signal

GND CH1 LIGHT

5

Power - OUT

COM+

6 7 8

Input signal Input signal /

CH2 +15 /

1

Power - OUT

AUX

Description of function

Positive power output switched by device SW and with short circuit protection. For generic external electronic device. General device GROUND. First input line for reading remote control status. Active negative driver signal for external indicator lamp (status LED) Permanent positive power output, protected against short circuiting by PTC. For small external utility. Second input line for reading remote control status. Ignition switch state reading line. Not used.

40-41

Wiring diagrams 40.2.5 - A - Starting and charging Table 389 Sys- P/N tem

A001

A004 A005 A006 A007 A008 A009 A010

04504666 04504666 04504666 04504666 04504666 04504666 04258670

Description

Characteristics/Notes

Alternator “B+”

Alternator “D+” Cylinder 1 injector Cylinder 2 injector Cylinder 3 injector Cylinder 4 injector Cylinder 5 injector Cylinder 6 injector Preheating device

Power supply: 12V Total resistance at 20°C: 0.061 ohms

Link to system

Link to wiring

40-210 40-469 40-469 40-210 40-469 40-210 40-144 40-106 40-106 40-106 40-106 40-106 40-106 40-116

40-514 40-514 40-512 40-512 40-589 40-589 40-576 40-592 40-592 40-592 40-592 40-592 40-592 40-589

Link to system

Link to wiring

40-407 40-388 40-116 40-487 40-469 40-250 40-397 40-379 40-210 40-210 40-469 40-178 40-450 40-469 40-210 40-450 40-178

40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514

40.2.6 - B - Fuses Table 390 Sys- P/N tem

Description

B001

Fuse (250A)

B002

Fuse (200A)

B003

Fuse (40A)

B004

Fuse (15A)

B005 B006

Not used Fuse (15A)

B007 B008

Not used Fuse (3A)

40-42

Characteristics/notes

40-450 40-178 40-216 40-168 40-231 40-469 40-156 40-331 40-297 40-116 40-366 40-144

Wiring diagrams Table 391 Sys- P/N tem

Description

B008

Fuse (3A)

B009 B010

Fuse (15A) Fuse (10A)

B011 B012 B013

Fuse (10A) Not used Fuse (15A)

B014

Fuse (30A)

B015

Fuse (20A)

Characteristics/Notes

Link to system

Link to wiring

40-106 40-422 40-147 40-431 40-210 40-442 40-120 40-207 40-216 40-231 40-297 40-465 40-106 40-120 40-231 40-216 40-297 40-207 40-465 40-120 40-210 40-469 40-210 40-469 40-465 40-207

40-514 40-514 40-514 40-514 40-514 40-514 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518

Link to system

Link to wiring

40-231 40-480 40-112 40-216 40-469 40-331 40-210 40-321 40-297 40-480 40-216 40-321 40-231 40-297 40-331 40-112 40-487 40-407 40-397 40-388 40-379 40-487 40-388 40-407 40-397 40-379 40-250 40-116

40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-589

Table 392 Sys- P/N tem

Description

B016

Fuse (30A)

B017

Fuse (30A)

B018

Fuse (50A)

B019

Fuse (30A)

B020

Pre-heating relay supply fuse (150A)

Characteristics/Notes

40-43

Wiring diagrams Sys- P/N tem

B021

Description

Characteristics/Notes

Fuse (30A)

Link to system

Link to wiring

40-210 40-321 40-469

40-514 40-514 40-514

Link to system

Link to wiring

40-469 40-349 40-210 40-231 40-250 40-469 40-297 40-480 40-210 40-321 40-216 40-331 40-196 40-200 40-216 40-250 40-210 40-231 40-297 40-469 40-450 40-178 40-450 40-178 40-207 40-297 40-231 40-465 40-250 40-216

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-465 40-207 40-349 40-200 40-196 40-418 40-207 40-465 40-207 40-465 40-450 40-216 40-465 40-207 40-231 40-297 40-250

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Table 393 Sys- P/N tem

Description

Characteristics/Notes

15A Fuse - Lights fuse and power outlet socket (F3/1, +30) 3A Fuse - Work Display Fuse (F3/2, +30)

7.5A Fuse - Air conditioning compressor fuse (F3/3) 5A fuse - Tierra fuse (F3/4, +30)

15A Fuse - Rear work light fuse (F3/5) 15A Fuse - Rear work light fuse (F3/6) 5A fuse - Tierra fuse (F3/7, +15)

Table 394 Sys- P/N tem

Description

5A fuse - Fuse (F3/8, +15) 7.5A Fuse - Air conditioning fuse (F3/9, +15)

15A Fuse - U.S.A. trailer lights fuse (F3/10, +15) 10A Fuse - ISO 11786 (F1A/1, +15)

40-44

Characteristics/Notes

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

5A Fuse - EPB (F1-A/2, +15)

15A Fuse - Windscreen wiper (F1-A/3, +15)

Link to system

Link to wiring

40-112 40-207 40-297 40-331 40-465 40-321 40-216 40-231 40-250 40-147 40-465

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-422 40-431 40-341 40-156 40-207 40-297 40-116 40-231 40-147 40-250 40-331 40-144 40-106 40-133 40-156 40-465 40-125 40-422 40-120 40-480 40-168 40-207 40-366 40-321 40-216 40-442 40-431

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-196 40-200 40-133 40-125 40-366 40-207 40-465 40-474 40-315 40-141

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Table 395 Sys- P/N tem

Description

Characteristics/Notes

15A Fuse - Windscreen wiper (F1-A/3, +15)

3A Fuse - Cluster (F1-A/4, +15)

3A Fuse - Cluster (F1-A/4, +15)

3A Fuse - Cluster (F1-A/4, +15)

Table 396 Sys- P/N tem

Description

7.5A Fuse - HLHP control unit (F1-A/5, +15)

Characteristics/Notes

40-45

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

7.5A Fuse - HLHP control unit (F1-A/5, +15)

7.5A Fuse - Pneumatic seat (F1-A/6, +15) 7.5A Fuse - Engine (F1A/7, +15) 15A Fuse - EU/USA emergency lights (F1-A/8, +15)

Link to system

Link to wiring

40-216 40-231 40-336 40-309 40-194 40-144 40-250 40-321 40-297 40-207 40-465 40-349 40-106 40-207 40-465 40-465 40-442 40-168 40-207

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-216 40-487 40-207 40-277 40-268 40-250 40-231 40-407 40-388 40-373 40-379 40-371 40-286 40-465 40-397 40-245 40-407 40-397 40-388 40-487 40-379 40-465 40-207 40-349 40-465 40-207 40-465 40-349 40-207 40-341

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-207 40-480 40-321 40-465

40-571 40-571 40-571 40-571

Table 397 Sys- P/N tem

Description

Characteristics/Notes

3A Fuse - iMonitor + MMI (F1-A/9, +15)

3A Fuse - iMonitor + MMI (F1-A/9, +15)

3A Fuse - ISOBUS 11783 (F1-A/10, +15)

7.5A Fuse - Rear view mirrors (F1-A/11, +15) 10A Fuse - Rear windscreen wiper (F1-A/12, +15)

Table 398 Sys- P/N tem

40-46

Description

15A Fuse - Brake lights (F1-A/13, +15)

Characteristics/Notes

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

3A Fuse - Work light display (F1-A/14, +15)

3A Fuse - Work light display (F1-A/14, +15)

5A Fuse - Transmission (F1-A/15, +15)

5A Fuse - Transmission (F1-A/15, +15)

Link to system

Link to wiring

40-147 40-156 40-297 40-231 40-216 40-349 40-112 40-465 40-465 40-450 40-431 40-422 40-178 40-207 40-250 40-465 40-366 40-207 40-480 40-231 40-250 40-297 40-216 40-474 40-125 40-133 40-309 40-321

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-474 40-336 40-250 40-231 40-216 40-315 40-465 40-297 40-309 40-207 40-231 40-125 40-250 40-297 40-133 40-465 40-216 40-207 40-349 40-465 40-346 40-207 40-207 40-349 40-465 40-349 40-418 40-207 40-465

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Table 399 Sys- P/N tem

Description

7.5A Fuse - Radar/PTO/ distributors (F1-A/16, +15)

5A Fuse - SGR Transmission (F1-A/17, +15)

5A Fuse - Radio (F1-A/18, +15) 7.5A Fuse - External electric power outlet sockets (F1-A/19, +15) 3A Fuse - Ignition key (F1A/20, +15)

Characteristics/Notes

40-47

Wiring diagrams Table 400 Sys- P/N tem

Description

Characteristics/Notes

20A fuse - Webasto (heater) (F4/1-4, +30) 20A Fuse - Low rear work light relay protection (F4/25, +30) 20A Fuse - Seat/brakes (F4/3-6, +15) 20A Fuse - Rear defrost (F4/8-11) 30A fuse - Heating unit (F4/13-14, +30) 40A Fuse - Heating system (F4/17-18, +30) 15A Fuse - Front work lights (R6/1-5) 15A fuse - ABS trailer socket (R6/2-6, +15) 15A Fuse - Front work lights (R6/4-8)

Link to system

Link to wiring

40-469 40-210 40-418 40-178 40-210 40-469 40-450 40-331 40-207 40-349 40-465 40-349 40-210 40-469 40-200 40-469 40-210 40-196 40-210 40-200 40-196 40-469 40-450 40-178 40-207 40-321 40-465 40-450 40-178

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-366 40-133 40-210 40-125 40-297 40-216 40-469 40-250 40-231 40-196 40-216 40-469 40-231 40-200 40-210 40-297 40-250 40-418

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Table 401 Sys- P/N tem

Description

7.5A Fuse - SGR Transmission (F1-A/1, +30)

7.5A Fuse - Air conditioning system fuse (F1/2, +30)

40-48

Characteristics/Notes

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

5A Fuse - Transmission control unit (F1-B/3, +30)

5A Fuse - Transmission control unit (F1-B/3, +30)

Link to system

Link to wiring

40-125 40-210 40-297 40-309 40-231 40-216 40-480 40-366 40-321 40-469 40-133 40-250 40-474

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-469 40-349 40-210 40-210 40-469 40-480 40-144 40-321 40-366 40-346 40-210 40-469 40-422 40-431 40-156 40-210 40-147 40-469 40-277 40-379 40-469 40-286 40-371 40-268 40-210 40-373 40-487 40-397 40-231

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-407 40-388 40-245 40-216 40-250 40-431 40-156 40-147 40-422 40-210 40-469

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Table 402 Sys- P/N tem

Description

Characteristics/Notes

15A Fuse - Turn indicator relay protection (F1-B/4, +30) 15A Fuse - Armrest (F1B/5, +30)

5A Fuse - Radio (F1-B/6, +30) 15A Fuse - Lights relay protection (F1-B/7, +30)

15A Fuse - iMonitor (F1B/8, +30)

15A Fuse - iMonitor (F1B/8, +30)

Table 403 Sys- P/N tem

Description

15A Fuse - iMonitor (F1B/8, +30)

15A Fuse - Lights relay protection (F1-B/9, +30)

Characteristics/notes

40-49

Wiring diagrams Sys- P/N tem

Description

Characteristics/notes

7.5A Fuse - Left hand sidelights (F1-B/10, +30)

7.5A Fuse - Left hand sidelights (F1-B/10, +30) Bf011

5A Fuse - Road lights/Top lights relay protection (F1B/11, +30)

Link to system

Link to wiring

40-200 40-178 40-147 40-194 40-422 40-341 40-196 40-349 40-474 40-450 40-431 40-156 40-315 40-309 40-210 40-147 40-147 40-469

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-431 40-156 40-422 40-465 40-156 40-422 40-147 40-422 40-147 40-156 40-431 40-210 40-431 40-469 40-422 40-147 40-156 40-210 40-349 40-469 40-465 40-210 40-469 40-112 40-207 40-349 40-469 40-210 40-178

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Table 404 Sys- P/N tem

Bf011

Description

5A Fuse - Road lights/Top lights relay protection (F1B/11, +30) 5A Fuse - Lights (F1-B/12, +15) 7.5A Fuse - Right hand sidelights (F1-B/13, +30) 15A Fuse - Sidelights relay protection (F1-B/14, +30)

3A Fuse - Cab lights (F1B/15, +30) 15A Fuse - Ignition key (F1-A/16, +30)

10A Fuse - Hitch relay protection (F1-B/17, +30)

40-50

Characteristics/notes

Wiring diagrams Table 405 Sys- P/N tem

Description

Characteristics/Notes

15A Fuse - Work light display (F1-A/18, +30)

15A Fuse - Work light display (F1-A/18, +30) 5A fuse - Webasto (thermo call) (F1-B/19, +30) 15A Fuse - Trailer lights relay protection (F1-B/20, +30) 20A Fuse - Tractor electric power outlet sockets (F2/1-4, +30) 20A Fuse - Cab electric power outlet sockets (F2/2-5, +30) 20A Fuse - HLHP control unit (F2/3-6, +30)

Link to system

Link to wiring

40-231 40-147 40-250 40-297 40-156 40-112 40-216 40-178 40-210 40-469 40-422 40-450 40-431 40-418 40-210 40-469 40-178 40-469 40-450 40-210 40-210 40-349 40-469 40-349 40-210 40-469 40-315 40-250 40-133

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-216 40-309 40-144 40-194 40-196 40-336 40-141 40-125 40-297 40-469 40-349 40-366 40-321 40-200 40-210 40-480 40-231 40-474 40-168 40-210 40-469 40-442 40-469 40-210 40-450 40-178

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Table 406 Sys- P/N tem

Description

20A Fuse - HLHP control unit (F2/3-6, +30)

20A Fuse - HLHP control unit (F2/3-6, +30)

20A Fuse - EU/USA emergency lights (F2/7-10, +30) 20A Fuse - Front work lights relay protection (F2/8-11)

Characteristics/Notes

40-51

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

20A Fuse - Steering (F2/912, +30)

Link to system

Link to wiring

40-250 40-216 40-210

40-571 40-571 40-571

Link to system

Link to wiring

40-397 40-469 40-231 40-120 40-210 40-297 40-231 40-216 40-250 40-469 40-116 40-144 40-106 40-112 40-210 40-465 40-469 40-207 40-469 40-465 40-210 40-207

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-469 40-210 40-112 40-474 40-168 40-309 40-156 40-331 40-133 40-315 40-141 40-474 40-349 40-321 40-168 40-147 40-422 40-349 40-450 40-442 40-422 40-125 40-366

40-498 40-498 40-498 40-583 40-576 40-576 40-576 40-576 40-576 40-576 40-583 40-576 40-583 40-583 40-583 40-583 40-583 40-576 40-583 40-576 40-576 40-576 40-576

Table 407 Sys- P/N tem

Description

Characteristics/Notes

20A Fuse - Steering (F2/912, +30) 30A Fuse - Engine (F2/1314, +30)

30A Fuse - Engine (F2/1314, +30) 40A Fuse - Ignition key relay protection (F2/15-16) 40A Fuse - Ignition key relay protection (F2/17-18)

40.2.7 - C - Grounds Table 408 Sys- P/N tem

Description

C001 2.9559.047.0

Battery negative terminal

C002

Engine ground

C002

Engine ground

40-52

Characteristics/notes

Wiring diagrams Sys- P/N tem

C002

Description

Characteristics/notes

Engine ground

Link to system

Link to wiring

40-388 40-250 40-407 40-379 40-487 40-397 40-418

40-512 40-512 40-512 40-512 40-512 40-512 40-576

Link to system

Link to wiring

40-112 40-216 40-120 40-465 40-231 40-297 40-207 40-431 40-210 40-331 40-379 40-407 40-487 40-388 40-397 40-341 40-469 40-309 40-297 40-156 40-336 40-442 40-231 40-216 40-178 40-144 40-106 40-480

40-498 40-518 40-518 40-518 40-518 40-518 40-518 40-583 40-498 40-583 40-510 40-510 40-510 40-510 40-510 40-583 40-498 40-571 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583

Link to system

Link to wiring

40-156 40-250 40-397 40-268 40-474 40-286 40-147 40-194 40-196 40-309

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Table 409 Sys- P/N tem

Description

C002

Engine ground

C002

Engine ground

C002

Characteristics/notes

Engine ground

Table 410 Sys- P/N tem

C003

Description

Cab ground

Characteristics/notes

40-53

Wiring diagrams Sys- P/N tem

Description

C003

Cab ground

C003

Cab ground

Characteristics/notes

Link to system

Link to wiring

40-336 40-373 40-297 40-141 40-231 40-379 40-133 40-442 40-216 40-450 40-487 40-178 40-210 40-200 40-321 40-321 40-315 40-125 40-116 40-388

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-528 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-144 40-465 40-349 40-120 40-112 40-106 40-366 40-407 40-422 40-431 40-480 40-250 40-450 40-371 40-341 40-349 40-315 40-321 40-474 40-216 40-168 40-245 40-178 40-231 40-200 40-442 40-116 40-480 40-196 40-133

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Table 411 Sys- P/N tem

Description

C003

Cab ground

C003

Cab ground Cab ground

Cab ground

40-54

Characteristics/notes

Wiring diagrams Table 412 Sys- P/N tem

Description

Characteristics/Notes

Cab ground

Cab ground

C004 2.9559.064.0

Cab ground Negative terminal of the auxiliary battery

C005

Cab ground (roof)

Link to system

Link to wiring

40-309 40-431 40-194 40-156 40-331 40-297 40-277 40-106 40-125 40-144 40-422 40-268 40-286 40-147 40-366 40-277 40-112 40-297 40-480 40-321 40-231 40-216 40-331 40-349 40-346 40-341 40-178 40-418 40-450

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-580 40-580 40-580 40-580 40-580 40-580

Link to system

Link to wiring

40-442 40-156 40-147 40-156 40-422 40-133 40-431 40-341 40-125 40-147 40-168 40-168 40-442 40-341 40-431 40-422 40-125 40-133

40-571 40-496 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-496 40-496 40-571 40-496 40-496 40-496 40-496 40-496 40-496

40.2.8 - D - Intermediate connections D001

Table 413 Sys- P/N tem

D001 D001 D001 D001 D001 D001 D001 D001 D001 D001 D001 D001 D001 D001 D001 D001 D001 D001

Description

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Characteristics/notes

40-55

Wiring diagrams D002

Table 414 Sys- P/N tem

D002 D002 D002 D002

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector Wiring connector

Link to system

Link to wiring

40-469 40-469 40-210 40-210

40-514 40-571 40-514 40-571

Link to system

Link to wiring

40-422 40-147 40-168 40-156 40-168 40-156 40-147 40-431 40-431 40-422

40-566 40-524 40-524 40-524 40-571 40-571 40-571 40-566 40-571 40-571

Link to system

Link to wiring

40-442 40-168 40-450 40-168 40-178 40-178 40-442 40-450

40-566 40-524 40-566 40-571 40-571 40-524 40-571 40-571

Link to system

Link to wiring

40-147 40-147 40-168 40-156 40-431 40-168 40-156 40-422 40-431 40-422

40-526 40-571 40-526 40-526 40-567 40-571 40-571 40-567 40-571 40-571

Link to system

Link to wiring

40-178 40-168 40-450 40-442 40-178

40-571 40-571 40-567 40-567 40-526

D003

Table 415 Sys- P/N tem

D003 D003 D003 D003 D003 D003 D003 D003 D003 D003

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D004

Table 416 Sys- P/N tem

D004 D004 D004 D004 D004 D004 D004 D004

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D006

Table 417 Sys- P/N tem

D006 D006 D006 D006 D006 D006 D006 D006 D006 D006

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D007

Table 418 Sys- P/N tem

D007 D007 D007 D007 D007 40-56

Description

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Characteristics/notes

Wiring diagrams Sys- P/N tem

D007 D007 D007

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector

Link to system

Link to wiring

40-168 40-442 40-450

40-526 40-571 40-571

Link to system

Link to wiring

40-125 40-418 40-431 40-422 40-200 40-366 40-168 40-133 40-480 40-315 40-144 40-474 40-194 40-349 40-216 40-250 40-331 40-156 40-231 40-297 40-309 40-147 40-315 40-442 40-196 40-309 40-349 40-321 40-147

40-576 40-576 40-576 40-576 40-576 40-576 40-576 40-576 40-576 40-576 40-576 40-576 40-576 40-576 40-576 40-576 40-576 40-576 40-576 40-576 40-576 40-576 40-571 40-576 40-576 40-571 40-571 40-576 40-571

Link to system

Link to wiring

40-250 40-331 40-196 40-156 40-297 40-231 40-480 40-321 40-418 40-133 40-442 40-168 40-422 40-366 40-144 40-431 40-200 40-474 40-194 40-216

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

D008

Table 419 Sys- P/N tem

D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Table 420 Sys- P/N tem

D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008 D008

Description

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Characteristics/Notes

40-57

Wiring diagrams Sys- P/N tem

D008

Description

Characteristics/Notes

Wiring connector

Link to system

Link to wiring

40-125

40-571

Link to system

Link to wiring

40-106 40-321 40-450 40-341 40-112 40-349 40-442 40-366 40-168 40-178 40-216 40-336 40-116 40-315 40-231 40-480 40-297 40-431 40-331 40-250 40-331 40-200 40-156 40-422 40-125 40-147 40-474 40-309 40-144 40-141

40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-571 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583

Link to system

Link to wiring

40-133 40-196 40-147 40-112 40-106 40-116 40-125 40-133 40-144 40-156 40-422 40-366 40-331 40-196 40-200 40-141 40-178 40-349 40-297 40-442 40-309

40-583 40-583 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

D009

Table 421 Sys- P/N tem

D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Table 422 Sys- P/N tem

D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 D009 40-58

Description

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Characteristics/notes

Wiring diagrams Sys- P/N tem

D009 D009 D009 D009 D009 D009 D009 D009

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Link to system

Link to wiring

40-474 40-250 40-321 40-168 40-231 40-480 40-315 40-341

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-336 40-216 40-450 40-431

40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-349

40-571

Link to system

Link to wiring

40-250 40-231 40-216 40-106 40-112 40-116 40-297 40-297 40-231 40-106 40-116 40-216 40-112 40-250

40-590 40-590 40-590 40-590 40-571 40-590 40-590 40-571 40-571 40-571 40-571 40-571 40-590 40-571

Link to system

Link to wiring

40-216 40-231 40-297 40-106 40-207 40-465 40-120 40-231 40-465 40-106 40-120 40-250 40-216 40-297

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-518 40-518 40-518 40-518 40-518 40-518 40-518

Table 423 Sys- P/N tem

D009 D009 D009 D009

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector

D010

Table 424 Sys- P/N tem

D010

Description

Characteristics/Notes

Wiring connector

D011

Table 425 Sys- P/N tem

D011 D011 D011 D011 D011 D011 D011 D011 D011 D011 D011 D011 D011 D011

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D012

Table 426 Sys- P/N tem

D012 D012 D012 D012 D012 D012 D012 D012 D012 D012 D012 D012 D012 D012

Description

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Characteristics/notes

40-59

Wiring diagrams Sys- P/N tem

D012 D012

Description

Characteristics/notes

Wiring connector Wiring connector

Link to system

Link to wiring

40-250 40-207

40-571 40-518

Link to system

Link to wiring

40-321 40-442 40-431 40-422 40-349 40-397 40-147 40-250 40-487 40-388 40-407 40-379 40-156 40-373 40-450 40-480 40-147 40-168 40-156 40-422 40-431 40-442 40-450 40-349 40-250 40-379 40-168 40-388 40-397

40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-559 40-537 40-537 40-571 40-537 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-407 40-480 40-321 40-487 40-373

40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-250 40-277 40-487 40-397 40-379 40-371 40-231 40-216 40-245 40-371 40-407

40-537 40-537 40-537 40-537 40-537 40-559 40-559 40-559 40-559 40-537 40-537

D013

Table 427 Sys- P/N tem

D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013 D013

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Table 428 Sys- P/N tem

D013 D013 D013 D013 D013

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D014

Table 429 Sys- P/N tem

D014 D014 D014 D014 D014 D014 D014 D014 D014 D014 D014 40-60

Description

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Characteristics/Notes

Wiring diagrams Sys- P/N tem

D014 D014 D014 D014 D014 D014 D014 D014 D014 D014 D014 D014 D014 D014 D014 D014 D014 D014

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Link to system

Link to wiring

40-373 40-407 40-371 40-487 40-388 40-286 40-250 40-268 40-277 40-286 40-397 40-388 40-268 40-379 40-373 40-231 40-371 40-216

40-559 40-571 40-571 40-571 40-537 40-571 40-571 40-571 40-571 40-537 40-571 40-571 40-537 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-245 40-297 40-297

40-571 40-571 40-571

Link to system

Link to wiring

40-250 40-286 40-277 40-268 40-250 40-268 40-277 40-286 40-250

40-537 40-537 40-537 40-537 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-418 40-250 40-216 40-297 40-200 40-196 40-231 40-216 40-196 40-297 40-231 40-418 40-250 40-200

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-556 40-556 40-556 40-556 40-556 40-556 40-556

Table 430 Sys- P/N tem

D014 D014

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector

D015

Table 431 Sys- P/N tem

D015 D015 D015 D015 D015 D015 D015 D015

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Configuration connector

D016

Table 432 Sys- P/N tem

D016 D016 D016 D016 D016 D016 D016 D016 D016 D016 D016 D016 D016 D016

Description

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Characteristics/Notes

40-61

Wiring diagrams D021

Table 433 Sys- P/N tem

D021 D021 D021 D021 D021 D021 D021 D021 D021 D021

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Link to system

Link to wiring

40-231 40-297 40-250 40-349 40-216 40-349 40-297 40-216 40-231 40-250

40-571 40-571 40-571 40-571 40-571 40-535 40-535 40-535 40-535 40-535

Link to system

Link to wiring

40-442 40-168 40-442

40-528 40-571 40-571

Link to system

Link to wiring

40-422 40-156 40-336 40-178 40-168 40-442 40-321 40-315 40-431 40-147 40-349 40-178 40-450 40-309 40-147 40-315 40-156 40-309 40-336 40-168 40-442 40-431 40-422 40-321 40-349 40-450

40-520 40-520 40-520 40-520 40-520 40-520 40-520 40-520 40-520 40-520 40-520 40-571 40-520 40-571 40-571 40-571 40-571 40-520 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-349 40-349 40-341

40-571 40-580 40-580

D022

Table 434 Sys- P/N tem

D022 D022 D022

Description

Characteristics/Notes

Wiring connector Configuration connector Configuration connector

D023

Table 435 Sys- P/N tem

D023 D023 D023 D023 D023 D023 D023 D023 D023 D023 D023 D023 D023 D023 D023 D023 D023 D023 D023 D023 D023 D023 D023 D023 D023 D023

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D024

Table 436 Sys- P/N tem

D024 D024 D024 40-62

Description

Wiring connector (yellow) Wiring connector (yellow) Wiring connector (yellow)

Characteristics/Notes

Wiring diagrams Sys- P/N tem

D024 D024 D024 D024 D024 D024 D024 D024 D024

Description

Characteristics/Notes

Wiring connector (yellow) Wiring connector (yellow) Wiring connector (yellow) Wiring connector (yellow) Wiring connector (yellow) Wiring connector (yellow) Wiring connector (yellow) Wiring connector (yellow) Wiring connector (yellow)

Link to system

Link to wiring

40-450 40-418 40-346 40-450 40-418 40-178 40-346 40-341 40-178

40-580 40-580 40-580 40-571 40-571 40-571 40-571 40-571 40-580

Link to system

Link to wiring

40-341 40-178 40-346 40-349 40-349 40-450 40-341 40-346 40-178 40-450

40-580 40-580 40-580 40-580 40-571 40-571 40-571 40-571 40-571 40-580

Link to system

Link to wiring

40-450 40-156 40-147 40-168 40-321 40-349 40-178 40-336 40-442 40-315 40-309 40-309 40-450 40-156 40-147 40-336 40-178 40-442 40-349 40-315 40-168 40-321

40-522 40-522 40-522 40-522 40-522 40-522 40-522 40-522 40-522 40-522 40-571 40-522 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-450 40-450

40-569 40-569

D025

Table 437 Sys- P/N tem

D025 D025 D025 D025 D025 D025 D025 D025 D025 D025

Description

Characteristics/notes

Wiring connector (brown) Wiring connector (brown) Wiring connector (brown) Wiring connector (brown) Wiring connector (brown) Wiring connector (brown) Wiring connector (brown) Wiring connector (brown) Wiring connector (brown) Wiring connector (brown)

D026

Table 438 Sys- P/N tem

D026 D026 D026 D026 D026 D026 D026 D026 D026 D026 D026 D026 D026 D026 D026 D026 D026 D026 D026 D026 D026 D026

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D027

Table 439 Sys- P/N tem

D027

Description

Wiring connector Wiring connector

Characteristics/Notes

40-63

Wiring diagrams D028

Table 440 Sys- P/N tem

D028 D028 D028 D028 D028 D028 D028 D028

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Link to system

Link to wiring

40-178 40-442 40-450 40-178 40-442 40-178 40-450 40-178

40-505 40-569 40-569 40-526 40-567 40-503 40-567 40-526

Link to system

Link to wiring

40-450 40-450

40-568 40-568

Link to system

Link to wiring

40-178 40-178 40-178 40-450 40-442 40-442 40-450 40-178

40-524 40-504 40-502 40-566 40-566 40-568 40-568 40-524

Link to system

Link to wiring

40-144 40-133 40-125 40-116 40-106 40-422 40-231 40-450 40-366 40-442 40-331 40-216 40-178 40-168 40-366 40-321 40-431 40-156 40-147 40-216 40-297 40-297 40-321 40-422

40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-583 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-514 40-583 40-514 40-583 40-583 40-583

D029

Table 441 Sys- P/N tem

D029

Description

Characteristics/Notes

Wiring connector Wiring connector

D030

Table 442 Sys- P/N tem

D030 D030 D030 D030 D030 D030 D030 D030

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D031

Table 443 Sys- P/N tem

D031 D031 D031 D031 D031 D031 D031 D031 D031 D031 D031 D031 D031 D031 D031 D031 D031 D031 D031 D031 D031 D031 D031 D031 40-64

Description

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Characteristics/notes

Wiring diagrams Sys- P/N tem

D031 D031 D031 D031 D031

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Link to system

Link to wiring

40-178 40-450 40-331 40-156 40-125

40-583 40-583 40-583 40-583 40-583

Link to system

Link to wiring

40-106 40-168 40-116 40-442 40-133 40-144 40-147 40-431 40-231

40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583

Link to system

Link to wiring

40-469 40-231 40-216 40-331 40-297 40-321 40-112 40-210 40-480 40-231 40-469 40-112 40-210 40-480 40-216 40-321 40-297 40-331

40-583 40-518 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-518 40-518 40-518 40-518 40-518 40-518 40-518 40-518

Link to system

Link to wiring

40-321 40-216 40-331 40-331 40-321 40-480 40-112 40-231 40-112 40-480 40-216 40-231 40-297 40-297

40-518 40-583 40-518 40-583 40-583 40-583 40-583 40-583 40-518 40-518 40-518 40-518 40-518 40-583

Table 444 Sys- P/N tem

D031 D031 D031 D031 D031 D031 D031 D031 D031

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D032

Table 445 Sys- P/N tem

D032 D032 D032 D032 D032 D032 D032 D032 D032 D032 D032 D032 D032 D032 D032 D032 D032 D032

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D033

Table 446 Sys- P/N tem

D033 D033 D033 D033 D033 D033 D033 D033 D033 D033 D033 D033 D033 D033

Description

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Characteristics/notes

40-65

Wiring diagrams D034

Table 447 Sys- P/N tem

D034 D034 D034 D034 D034 D034 D034 D034 D034 D034 D034 D034 D034 D034 D034 D034 D034 D034 D034 D034

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Link to system

Link to wiring

40-178 40-178 40-147 40-168 40-156 40-147 40-168 40-442 40-321 40-431 40-480 40-422 40-450 40-156 40-321 40-431 40-442 40-450 40-422 40-480

40-507 40-583 40-507 40-507 40-507 40-583 40-583 40-509 40-583 40-509 40-509 40-509 40-509 40-583 40-507 40-583 40-583 40-583 40-583 40-583

Link to system

Link to wiring

40-336 40-297 40-336 40-231 40-216 40-231 40-297 40-216

40-516 40-583 40-583 40-583 40-583 40-516 40-516 40-516

Link to system

Link to wiring

40-431 40-178 40-147 40-196 40-422 40-349 40-156 40-106 40-450 40-200 40-178 40-450 40-147 40-196 40-200 40-156 40-431 40-422 40-106 40-349

40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-529 40-529 40-529 40-529 40-529 40-583 40-529 40-529 40-529 40-529 40-529

D035

Table 448 Sys- P/N tem

D035 D035 D035 D035 D035 D035 D035 D035

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D036

Table 449 Sys- P/N tem

D036 D036 D036 D036 D036 D036 D036 D036 D036 D036 D036 D036 D036 D036 D036 D036 D036 D036 D036 D036 40-66

Description

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Characteristics/Notes

Wiring diagrams D037

Table 450 Sys- P/N tem

D037 D037

Description

Characteristics/notes

Wiring connector Wiring connector

Link to system

Link to wiring

40-141 40-141

40-499 40-583

Link to system

Link to wiring

40-194 40-194

40-549 40-576

Link to system

Link to wiring

40-331 40-331

40-533 40-576

Link to system

Link to wiring

40-309 40-309 40-474 40-474

40-531 40-576 40-531 40-576

Link to system

Link to wiring

40-133 40-125 40-125 40-133

40-531 40-531 40-576 40-576

Link to system

Link to wiring

40-474 40-474

40-499 40-576

Link to system

Link to wiring

40-474 40-474 40-309 40-309

40-531 40-576 40-531 40-576

D038

Table 451 Sys- P/N tem

D038 D038

Description

Characteristics/notes

Wiring connector Wiring connector

D039

Table 452 Sys- P/N tem

D039 D039

Description

Characteristics/notes

Wiring connector Wiring connector

D040

Table 453 Sys- P/N tem

D040 D040 D040 D040

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector Wiring connector

D041

Table 454 Sys- P/N tem

D041 D041 D041 D041

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector

D042

Table 455 Sys- P/N tem

D042 D042

Description

Characteristics/notes

Wiring connector Wiring connector

D043

Table 456 Sys- P/N tem

D043 D043 D043 D043

Description

Wiring connector Wiring connector Wiring connector Wiring connector

Characteristics/notes

40-67

Wiring diagrams D044

Table 457 Sys- P/N tem

D044 D044 D044 D044 D044 D044 D044 D044 D044 D044 D044 D044 D044 D044 D044 D044

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Link to system

Link to wiring

40-147 40-422 40-431 40-442 40-315 40-168 40-487 40-156 40-147 40-442 40-315 40-168 40-487 40-422 40-156 40-431

40-576 40-576 40-576 40-576 40-576 40-576 40-576 40-576 40-500 40-500 40-500 40-500 40-500 40-500 40-500 40-500

Link to system

Link to wiring

40-309 40-474 40-474 40-309

40-576 40-576 40-588 40-588

Link to system

Link to wiring

40-349 40-349 40-178 40-178

40-571 40-522 40-522 40-571

Link to system

Link to wiring

40-178 40-450 40-178 40-450 40-450 40-178 40-178 40-450

40-506 40-506 40-502 40-502 40-522 40-522 40-522 40-522

Link to system

Link to wiring

D045

Table 458 Sys- P/N tem

D045 D045 D045 D045

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector Wiring connector

D046

Table 459 Sys- P/N tem

D046 D046 D046 D046

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector

D047

Table 460 Sys- P/N tem

D047 D047 D047 D047 D047 D047 D047 D047

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D048

Table 461 Sys- P/N tem

D048

40-68

Description

Not used

Characteristics/Notes

40-522

Wiring diagrams D049

Table 462 Sys- P/N tem

D049 D049

Description

Characteristics/notes

Wiring connector Wiring connector

Link to system

Link to wiring

40-178 40-178

40-544 40-522

Link to system

Link to wiring

40-349

40-520

Link to system

Link to wiring

40-450 40-178 40-178 40-450 40-178 40-450 40-450 40-178

40-501 40-520 40-501 40-506 40-506 40-520 40-520 40-520

Link to system

Link to wiring

40-422 40-431 40-156 40-147 40-422 40-147 40-156 40-431

40-520 40-520 40-520 40-520 40-496 40-496 40-496 40-496

Link to system

Link to wiring

D050

Table 463 Sys- P/N tem

D050

Description

Characteristics/notes

Not used

D051

Table 464 Sys- P/N tem

D051 D051 D051 D051 D051 D051 D051 D051

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D052

Table 465 Sys- P/N tem

D052 D052 D052 D052 D052 D052 D052 D052

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D053

Table 466 Sys- P/N tem

D053

Description

Characteristics/notes

40-520

Not used

D054

Table 467 Sys- P/N tem

D054 D054

Description

Characteristics/notes

Wiring connector Wiring connector

Link to system

Link to wiring

40-349 40-349

40-592 40-580

Link to system

Link to wiring

40-178 40-450 40-178 40-178

40-554 40-580 40-580 40-546

D055

Table 468 Sys- P/N tem

D055 D055 D055 D055

Description

Wiring connector Wiring connector Wiring connector Wiring connector

Characteristics/notes

40-69

Wiring diagrams Sys- P/N tem

D055 D055 D055 D055

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector Wiring connector

Link to system

Link to wiring

40-450 40-450 40-450 40-178

40-546 40-554 40-580 40-580

Link to system

Link to wiring

40-450 40-178 40-450 40-450 40-178 40-178 40-450 40-178

40-580 40-547 40-547 40-552 40-552 40-580 40-580 40-580

Link to system

Link to wiring

40-349 40-349

40-591 40-580

Link to system

Link to wiring

40-450 40-450 40-178 40-349 40-450 40-349 40-178 40-178 40-178 40-349 40-450 40-178 40-349 40-450 40-349 40-450 40-178 40-349 40-349 40-450 40-178 40-178 40-450 40-349

40-580 40-563 40-563 40-563 40-561 40-561 40-561 40-580 40-551 40-551 40-551 40-545 40-545 40-545 40-580 40-580 40-580 40-580 40-580 40-580 40-580 40-580 40-580 40-580

D056

Table 469 Sys- P/N tem

D056 D056 D056 D056 D056 D056 D056 D056

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D057

Table 470 Sys- P/N tem

D057 D057

Description

Characteristics/notes

Wiring connector Wiring connector

D058

Table 471 Sys- P/N tem

D058 D058 D058 D058 D058 D058 D058 D058 D058 D058 D058 D058 D058 D058 D058 D058 D058 D058 D058 D058 D058 D058 D058 D058

40-70

Description

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Characteristics/Notes

Wiring diagrams D059

Table 472 Sys- P/N tem

D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059 D059

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Link to system

Link to wiring

40-349 40-178 40-349 40-178 40-341 40-341 40-450 40-450 40-341 40-349 40-178 40-349 40-341 40-178 40-178 40-349 40-450 40-341 40-450 40-450 40-341 40-178 40-450 40-349 40-450 40-349 40-341 40-178 40-349

40-561 40-580 40-563 40-563 40-563 40-561 40-563 40-561 40-580 40-545 40-561 40-580 40-545 40-545 40-551 40-551 40-551 40-551 40-580 40-545 40-580 40-580 40-580 40-580 40-580 40-580 40-580 40-580 40-580

Link to system

Link to wiring

40-178 40-341 40-450

40-580 40-580 40-580

Link to system

Link to wiring

40-277 40-407 40-286 40-397 40-268 40-407 40-388 40-379 40-268 40-250 40-397 40-286 40-388 40-487 40-487 40-277 40-487

40-563 40-563 40-561 40-561 40-561 40-561 40-563 40-563 40-563 40-563 40-563 40-563 40-561 40-563 40-537 40-561 40-561

Table 473 Sys- P/N tem

D059 D059 D059

Description

Characteristics/notes

Wiring connector Wiring connector Wiring connector

D060

Table 474 Sys- P/N tem

D060 D060 D060 D060 D060 D060 D060 D060 D060 D060 D060 D060 D060 D060 D060 D060 D060

Description

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Characteristics/Notes

40-71

Wiring diagrams Sys- P/N tem

D060 D060 D060 D060 D060 D060 D060 D060 D060 D060 D060 D060 D060

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Link to system

Link to wiring

40-286 40-379 40-388 40-397 40-250 40-407 40-379 40-250 40-245 40-373 40-268 40-277 40-268

40-537 40-537 40-537 40-537 40-561 40-537 40-561 40-537 40-559 40-559 40-537 40-537 40-537

Link to system

Link to wiring

40-388 40-245 40-379 40-407 40-286 40-277 40-373 40-397 40-487 40-373 40-245 40-245 40-373 40-250

40-537 40-559 40-537 40-537 40-537 40-537 40-559 40-537 40-537 40-563 40-563 40-561 40-561 40-537

Link to system

Link to wiring

40-373 40-397 40-407 40-250 40-268 40-277 40-286 40-388 40-231 40-371 40-216 40-371 40-250 40-487 40-245 40-379 40-397 40-388 40-407 40-286 40-487 40-268 40-379 40-277 40-371

40-559 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-559 40-537 40-559 40-559 40-542 40-537 40-559 40-542 40-542 40-542 40-542 40-542 40-542 40-542 40-537 40-542 40-542

Table 475 Sys- P/N tem

D060 D060 D060 D060 D060 D060 D060 D060 D060 D060 D060 D060 D060 D060

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D062

Table 476 Sys- P/N tem

D062 D062 D062 D062 D062 D062 D062 D062 D062 D062 D062 D062 D062 D062 D062 D062 D062 D062 D062 D062 D062 D062 D062 D062 D062 40-72

Description

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Characteristics/Notes

Wiring diagrams Sys- P/N tem

D062 D062 D062 D062 D062

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Link to system

Link to wiring

40-373 40-231 40-371 40-216 40-245 40-250

40-542 40-542 40-542 40-542 40-542 40-537

Link to system

Link to wiring

40-250 40-277 40-286 40-407 40-268 40-277 40-250 40-268 40-286 40-407

40-540 40-540 40-540 40-540 40-540 40-537 40-537 40-537 40-537 40-537

Link to system

Link to wiring

40-388 40-277 40-286 40-487 40-250 40-268 40-407 40-379 40-487 40-277 40-286 40-268 40-250 40-388 40-379 40-407 40-397 40-397

40-537 40-537 40-537 40-512 40-537 40-537 40-537 40-537 40-537 40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-537 40-512

Link to system

Link to wiring

40-388 40-388 40-397 40-487 40-379 40-379 40-397 40-407 40-487 40-407

40-510 40-512 40-512 40-512 40-512 40-510 40-510 40-510 40-510 40-512

D063

Table 477 Sys- P/N tem

D063 D063 D063 D063 D063 D063 D063 D063 D063 D063

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D064

Table 478 Sys- P/N tem

D064 D064 D064 D064 D064 D064 D064 D064 D064 D064 D064 D064 D064 D064 D064 D064 D064 D064

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D066

Table 479 Sys- P/N tem

D066 D066 D066 D066 D066 D066 D066 D066 D066 D066

Description

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Characteristics/Notes

40-73

Wiring diagrams D067

Table 480 Sys- P/N tem

D067 D067 D067 D067 D067 D067 D067 D067 D067 D067 D067 D067 D067 D067 D067 D067 D067 D067

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Link to system

Link to wiring

40-268 40-487 40-286 40-388 40-397 40-250 40-277 40-379 40-487 40-407 40-250 40-379 40-407 40-286 40-277 40-268 40-397 40-388

40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-510 40-512 40-510 40-510 40-510 40-510 40-510 40-510 40-510 40-510

Link to system

Link to wiring

40-168 40-442 40-442

40-571 40-528 40-571

Link to system

Link to wiring

40-388 40-277 40-379 40-487 40-397 40-268 40-407 40-250 40-286 40-277 40-268 40-379 40-286 40-250 40-407 40-397 40-487 40-388

40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537

Link to system

Link to wiring

40-277 40-388 40-250

40-563 40-565 40-565

D068

Table 481 Sys- P/N tem

D068 D068 D068

Description

Characteristics/Notes

Configuration connector Wiring connector Configuration connector

D069

Table 482 Sys- P/N tem

D069 D069 D069 D069 D069 D069 D069 D069 D069

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D071

Table 483 Sys- P/N tem

D071 D071 D071 40-74

Description

Wiring connector Wiring connector Wiring connector

Characteristics/Notes

Wiring diagrams Sys- P/N tem

D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071 D071

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

Link to system

Link to wiring

40-245 40-373 40-268 40-286 40-407 40-397 40-397 40-277 40-286 40-407 40-277 40-397 40-286 40-407 40-373 40-268 40-245 40-268 40-388 40-245 40-373 40-397 40-388 40-268 40-277 40-407 40-286 40-388 40-245 40-373

40-565 40-565 40-565 40-563 40-563 40-558 40-563 40-558 40-558 40-558 40-561 40-561 40-561 40-561 40-563 40-563 40-565 40-565 40-563 40-563 40-565 40-558 40-565 40-561 40-558 40-558 40-558 40-561 40-561 40-561

Link to system

Link to wiring

D072

Table 484 Sys- P/N tem

D072

Description

Characteristics/Notes

40-559

Not used

D073

Table 485 Sys- P/N tem

D073 D073 D073

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector

Link to system

Link to wiring

40-196 40-418 40-200

40-571 40-571 40-571

Link to system

Link to wiring

40-200 40-196

40-571 40-571

Link to system

Link to wiring

40-341 40-341

40-579 40-571

D074

Table 486 Sys- P/N tem

D074 D074

Description

Characteristics/notes

Wiring connector Wiring connector

D075

Table 487 Sys- P/N tem

D075 D075

Description

Wiring connector Wiring connector

Characteristics/notes

40-75

Wiring diagrams D076

Table 488 Sys- P/N tem

D076

Description

Characteristics/notes

Wiring connector

Link to system

Link to wiring

40-349

40-571

Link to system

Link to wiring

40-297 40-297

40-571 40-571

Link to system

Link to wiring

40-297 40-250 40-216 40-231

40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-349

40-571

Link to system

Link to wiring

40-349 40-349

40-522 40-522 40-522

Link to system

Link to wiring

40-349 40-349

40-520 40-520 40-520

Link to system

Link to wiring

40-388 40-407 40-373 40-379 40-487 40-250 40-397 40-379 40-397 40-250 40-487 40-407

40-537 40-537 40-559 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537

D077

Table 489 Sys- P/N tem

D077

Description

Characteristics/Notes

Configuration connector Configuration connector

D078

Table 490 Sys- P/N tem

D078 D078 D078 D078

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector

D079

Table 491 Sys- P/N tem

D079

Description

Characteristics/Notes

Wiring connector

D080

Table 492 Sys- P/N tem

D080

Description

Characteristics/Notes

Configuration connector Configuration connector Not used

D081

Table 493 Sys- P/N tem

D081

Description

Characteristics/Notes

Configuration connector Configuration connector Not used

D086

Table 494 Sys- P/N tem

D086 D086 D086 D086 D086 D086 D086

40-76

Description

Configuration connector Configuration connector Configuration connector Configuration connector Configuration connector Configuration connector Configuration connector Configuration connector Configuration connector Configuration connector Configuration connector Configuration connector

Characteristics/Notes

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

Configuration connector Configuration connector Configuration connector

Link to system

Link to wiring

40-388 40-373

40-559 40-537 40-559

Link to system

Link to wiring

40-106 40-106

40-590 40-592

Link to system

Link to wiring

40-106 40-106

40-592 40-590

Link to system

Link to wiring

40-250

40-537

Link to system

Link to wiring

40-231 40-297 40-216 40-216 40-231 40-297

40-583 40-583 40-583 40-570 40-570 40-570

Link to system

Link to wiring

40-321 40-321

40-583 40-586

Link to system

Link to wiring

40-321 40-321

40-586 40-583

Link to system

Link to wiring

40-418 40-418

40-576 40-585 40-576

D087

Table 495 Sys- P/N tem

D087 D087

Description

Characteristics/Notes

Wiring connector Wiring connector

D088

Table 496 Sys- P/N tem

D088 D088

Description

Characteristics/Notes

Wiring connector Wiring connector

D089

Table 497 Sys- P/N tem

D089

Description

Characteristics/notes

Wiring connector

D090

Table 498 Sys- P/N tem

D090 D090 D090 D090 D090 D090

Description

Characteristics/Notes

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

D091

Table 499 Sys- P/N tem

D091 D091

Description

Characteristics/Notes

Wiring connector Wiring connector

D092

Table 500 Sys- P/N tem

D092 D092

Description

Characteristics/Notes

Wiring connector Wiring connector

D093

Table 501 Sys- P/N tem

D093 D093

Description

Wiring connector Wiring connector Not used

Characteristics/Notes

40-77

Wiring diagrams D094

Table 502 Sys- P/N tem

D094

Description

Characteristics/Notes

Wiring connector

Link to system

Link to wiring

40-346

40-580

Link to system

Link to wiring

40-250

40-512

D095

Table 503 Sys- P/N tem

D095

Description

Characteristics/Notes

Wiring connector

40.2.9 - E - On-board instruments and visual and audible indicators Table 504 Sys- P/N tem

Description

E001 2.8339.278.0/20

Instrument panel

E002 2.8339.278.0/20

Instrument panel

E002 2.8339.278.0/20

Instrument panel

E003 0.018.9908.4/40

Work Display

E004 01169304

Horn

Characteristics/Notes

Link to system

Link to wiring

40-168 40-442 40-422 40-156 40-147 40-250 40-297 40-216 40-231 40-366 40-331 40-106 40-116 40-125 40-133 40-442 40-144 40-168 40-431 40-250 40-480 40-216 40-331 40-231 40-321 40-297 40-147 40-422 40-431 40-156

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-529 40-529 40-529 40-529

Link to system

Link to wiring

40-388 40-216 40-245 40-268 40-286 40-373 40-371 40-397 40-277 40-407 40-231

40-542 40-542 40-542 40-542 40-542 40-542 40-542 40-542 40-542 40-542 40-542

Table 505 Sys- P/N tem

40-78

Description

0.019.0639.0

I-Monitor

0.019.0639.0

I-Monitor

Characteristics/Notes

Wiring diagrams Sys- P/N tem

Description

E006 04414773 E007 04414773

RH rotating beacon LH rotating beacon

0.019.0639.0

Characteristics/Notes

I-Monitor

Link to system

Link to wiring

40-388 40-373 40-371 40-407 40-397 40-349 40-349

40-542 40-542 40-542 40-542 40-542 40-592 40-591

Link to system

Link to wiring

40-349 40-431 40-422 40-147 40-156 40-422 40-168 40-442 40-147 40-156 40-422 40-431 40-422 40-442 40-168 40-147 40-431 40-156 40-422 40-422 40-431 40-156 40-147 40-156 40-422 40-431 40-147 40-431 40-422 40-147 40-156

40-571 40-567 40-567 40-526 40-526 40-567 40-526 40-569 40-524 40-524 40-566 40-566 40-566 40-568 40-524 40-529 40-529 40-529 40-529 40-529 40-529 40-529 40-529 40-529 40-529 40-529 40-529 40-529 40-529 40-529 40-529

Link to system

Link to wiring

40-450 40-178 40-450 40-178 40-349

40-529 40-529 40-529 40-529 40-529

40-450 40-178 40-450 40-178 40-349

40-529 40-529 40-529 40-529 40-529

40-349

40-522

40.2.10 - F - External lights Table 506 Sys- P/N tem

F001 F003 2.8059.039.0

F004 F004 F005 F005

2.8059.039.0 2.8059.530.0 2.8059.535.0 2.8059.039.0 2.8059.039.0

Description

Characteristics/Notes

LH carpet light RH sidelight

RH sidelight RH turn indicator RH turn indicator LH sidelight LH sidelight

2.8059.039.0 F006 2.8059.535.0 F006 2.8059.530.0 F007 2.8039.005.0

LH sidelight LH turn indicator LH turn indicator RH high beam headlight

F008 2.8039.004.0

RH low beam headlight

F009 2.8039.004.0

LH low beam headlight

F010 2.8039.005.0

LH high beam headlight

Table 507 Sys- P/N tem

F011 2.8039.305.0 F012 2.8039.305.0 F013 2.8039.307.0/20 F014 2.8039.305.0 F015 2.8039.305.0 F016 2.8039.306.0/20 F017 0.019.5137.4

Description

Rh front work light - on cowl RH centre front work light on engine cowl LH LED bar - on engine cowl LH centre front work light on engine cowl Lh front work light - on cowl RH LED bar - on engine cowl RH rear cosmetic light

Characteristics/Notes

40-79

Wiring diagrams Sys- P/N tem

F018 2.8059.534.0 F019 2.8059.532.0 F020 2.8059.531.0 F021 0.019.5138.4 F022 2.8059.534.0

Description

Characteristics/Notes

Right hand rear turn indicator RH rear brake light Right hand rear sidelight

F023 2.8059.532.0 F024 2.8059.531.0

LH rear cosmetic light Left hand rear turn indicator LH rear brake light Left hand rear sidelight

F025 2.8039.023.0 F026 04414115

Rear service light License plate light

F027 2.8039.023.0

RH lower rear work light

F028 2.8039.023.0

LH lower rear work light

Link to system

Link to wiring

40-168

40-522

40-321 40-147 40-156 40-349 40-168

40-522 40-522 40-522 40-520 40-520

40-321 40-156 40-147 40-178 40-156 40-147 40-422 40-431 40-450 40-178 40-450 40-178

40-520 40-520 40-520 40-544 40-496 40-496 40-496 40-496 40-506 40-506 40-506 40-506

Link to system

Link to wiring

40-178 40-450 40-178 40-450 40-178

40-546 40-546 40-554 40-554 40-554

40-178

40-546

40-450

40-554

40-450

40-546

40-450 40-178 40-178 40-450 40-178 40-450 40-450 40-178 40-178

40-547 40-547 40-552 40-552 40-547 40-547 40-552 40-552 40-545

40-178

40-563

40-450

40-563

40-178

40-561

40-450

40-561

40-178

40-551

40-450

40-545

Table 508 Sys- P/N tem

Description

F029 2.8039.019.0

Right hand inner rear work light (on cab roof)

F030 2.8039.032.0

Right hand outer rear work light (on cab roof) Right hand outer rear work light (on cab roof) Right hand outer rear work light (on cab roof) Right hand outer rear work light (on cab roof) Left hand inner rear work light (on cab roof) Left hand inner rear work light (on cab roof) Left hand outer rear work light (on cab roof) Left hand outer rear work light (on cab roof) Left hand outer front work light (on cab roof) Left hand inner front work light (on cab roof) Left hand inner front work light (on cab roof) Left hand inner front work light (on cab roof) Left hand inner front work light (on cab roof) Left hand outer front work light (on cab roof) Left hand outer front work light (on cab roof)

F030 2.8039.018.0 F030 2.8039.032.0 F030 2.8039.018.0 F031 2.8039.019.0 F031 2.8039.032.0 F032 2.8039.018.0 F032 2.8039.032.0 F033 2.8039.019.0 F033 2.8039.019.0 F033 2.8039.019.0 F033 2.8039.032.0 F033 2.8039.032.0 F033 2.8039.032.0 F033 2.8039.019.0

40-80

Characteristics/Notes

Wiring diagrams Sys- P/N tem

F033 2.8039.032.0 F034 2.8039.032.0 F034 2.8039.019.0 F034 2.8039.019.0 F034 2.8039.019.0 F034 2.8039.032.0

Description

Left hand outer front light (on cab roof) Left hand outer front light (on cab roof) Left hand inner front light (on cab roof) Left hand outer front light (on cab roof) Left hand outer front light (on cab roof) Left hand inner front light (on cab roof)

Characteristics/Notes

Link to system

Link to wiring

work

40-450

40-551

work

40-450

40-561

work

40-450

40-545

work

40-450

40-563

work

40-178

40-563

work

40-450

40-551

Link to system

Link to wiring

40-178

40-545

40-178

40-551

40-178

40-561

40-178

40-551

40-450 40-178 40-450 40-450 40-178 40-450 40-178

40-563 40-563 40-561 40-551 40-545 40-545 40-561

40-450

40-563

40-178

40-563

40-178

40-561

40-450

40-561

40-450

40-551

40-178

40-545

40-450

40-545

40-178

40-551

40-178 40-178 40-450 40-450 40-178 40-450 40-178

40-504 40-502 40-502 40-568 40-504 40-568 40-505

40-450

40-503

Table 509 Sys- P/N tem

F034 2.8039.019.0 F034 2.8039.032.0 F034 2.8039.032.0 F035 2.8039.032.0 F035 2.8039.019.0 F035 2.8039.032.0 F035 2.8039.019.0 F035 2.8039.032.0 F036 2.8039.019.0 F036 2.8039.019.0 F036 2.8039.032.0 F036 2.8039.032.0 F036 2.8039.032.0 F036 2.8039.019.0 F036 2.8039.019.0 F036 2.8039.032.0 F037 F037 F037 F037 F037 F037 F038

2.8039.023.0 2.8039.016.0 2.8039.016.0 2.8039.023.0 2.8039.033.0 2.8039.033.0/10 2.8039.023.0

F038 2.8039.016.0

Description

Left hand inner front work light (on cab roof) Left hand inner front work light (on cab roof) Left hand outer front work light (on cab roof) Right hand outer front work light (on cab roof) Right hand outer front work light (on cab roof) Right hand outer front work light (on cab roof) Right hand outer front work light (on cab roof) Right hand outer front work light (on cab roof) Right hand inner front work light (on cab roof) Right hand inner front work light (on cab roof) Right hand inner front work light (on cab roof) Right hand inner front work light (on cab roof) Right hand inner front work light (on cab roof) Left hand outer front work light (on cab roof) Left hand outer front work light (on cab roof) Right hand inner front work light (on cab roof) Lh front work light (on arm) Lh front work light (on arm) Lh front work light (on arm) Lh front work light (on arm) Lh front work light (on arm) Lh front work light (on arm) Rh front work light (on arm) Rh front work light (on arm)

Characteristics/Notes

40-81

Wiring diagrams Sys- P/N tem

F038 2.8039.016.0 F038 2.8039.023.0 F038 2.8039.033.0 F038 2.8039.033.0/10

Description

Rh front arm) Rh front arm) Rh front arm) Rh front arm)

Characteristics/Notes

Link to system

Link to wiring

work light (on

40-178

40-503

work light (on

40-450

40-569

work light (on

40-178

40-505

work light (on

40-450

40-569

Link to system

Link to wiring

40-178 40-450 40-450 40-178 40-442

40-502 40-502 40-501 40-501 40-522 40-522

40-442

40-520 40-520

40-431 40-156 40-431

40-566 40-524 40-566

40-431 40-156 40-431

40-567 40-526 40-567

Link to system

Link to wiring

40-349 40-349 40-349

40-571 40-571 40-580

40-349

40-580

40-349 40-349

40-580 40-580

40-349 40-349

40-571 40-571

Link to system

Link to wiring

40-480 40-144 40-366 40-321 40-231 40-297 40-106 40-216 40-250

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Table 510 Sys- P/N tem

Description

F039 2.8039.016.0

LH lower rear work light

F040 2.8039.016.0

RH lower rear work light

F041 F041 2.8059.535.0

Not used RH rear hazard warning light - USA version Not used LH rear hazard warning light - USA version Left hand repeater headlight Left hand repeater headlight Right hand repeater headlight

F042 F042 2.8059.535.0 F043 2.8039.021.0/10 F043 2.8039.022.0/10 F044 2.8039.021.0/10

Characteristics/Notes

40.2.11 - G - Interior lights Table 511 Sys- P/N tem

G001 2.8339.074.0 2.8339.074.0 G002 0.019.5437.4/10 G003 0.019.5437.4/10 G004 2.8339.231.0 G005 G006 0.019.0494.4/20 G007 0.019.0495.4/20

Description

Characteristics/Notes

Cab courtesy light Cab courtesy light Right hand courtesy light on cab roof Left hand courtesy light on cab roof Cab courtesy light Side instrument panel courtesy light Right hand ambient light Left hand ambient light

40.2.12 - H - Electrical and manual controls Table 512 Sys- P/N tem

Description

H001 0.019.2557.4/40

Armrest

0.019.2557.4/40

Armrest

40-82

Characteristics/Notes

Wiring diagrams Sys- P/N tem

Description

H002 0.018.9910.4/20

Work light switch

H002 0.018.9910.4/20

Work light switch

H003 0.018.7370.4

Shuttle control lever

0.018.7370.4

Shuttle control lever

H005 0.015.8629.4

Characteristics/Notes

H007 0.017.9597.4

Right hand electric rear view mirror control lever Left hand electric rear view mirror control lever Monitor controls

H007 0.017.9597.4

Monitor controls

H006 0.015.8629.4

Link to system

Link to wiring

40-216 40-178 40-231 40-450 40-147 40-349 40-112 40-422 40-297 40-431 40-156 40-250 40-125 40-133 40-125 40-133 40-349

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-496 40-496 40-496 40-496 40-580

40-349

40-580

40-487 40-373 40-286 40-250 40-277 40-268 40-397 40-388 40-407 40-245 40-379

40-537 40-559 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-559 40-537

Link to system

Link to wiring

40-168 40-442

40-571 40-571

40-349

40-571

40.2.13 - I - Circuit breakers Table 513 Sys- P/N tem

I001 2.7659.110.0

Description

Hazard switch

warning

Characteristics/Notes

lights 1

0 30

49

L

15 1

30 3

49 4

49a 5

1

R

6

Pin

2

15

49a

5

Pos

b 30

3 4

7

L 6

R 7

0 1 2.7659.110.0

I002 2.7659.405.0

Fig. 2830

Switch for courtesy lights on the steps

Pos

Pin

1

2

3

0 1 2.7659.405.0

Fig. 2831

40-83

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

Link to system

Link to wiring

I003 2.7649.100.0

RH brake pedal switch

40-321

40-571

I003 2.7649.100.0

RH brake pedal switch

40-480

40-571

I004 2.7649.100.0

LH brake pedal switch

40-321

40-571

I004 2.7649.100.0

LH brake pedal switch

40-480

40-571

I006 0.015.0485.4

Starter switch

Between Pin 1 and Pin 2: Normally closed (NC) contact Between Pin 3 and Pin 4: Normally open contact (NO) Between Pin 1 and Pin 2: Normally closed (NC) contact Between Pin 3 and Pin 4: Normally open contact (NO) Between Pin 1 and Pin 2: Normally closed (NC) contact Between Pin 3 and Pin 4: Normally open contact (NO) Between Pin 1 and Pin 2: Normally closed (NC) contact Between Pin 3 and Pin 4: Normally open contact (NO)

40-207 40-465 40-112

40-571 40-571 40-571

40-125 40-133 40-431 40-147 40-156 40-422

40-571 40-571 40-571 40-571 40-571 40-571

40-156 40-431

40-571 40-571

83

15

75

Pos

Pin

50

30

86s

30

15

50

75

83

0 1 2 0.015.0485.4

I007

Safety switch

I008 2.7659.376.0

Road lights switch

Fig. 2832

0 1 2

Pos

Pin

1

2

3

4

5

6

7

4

5

6

9

8

1

2

3

10

7

9

8

10

0 1 2 2.7659.376.0

I009 2.7659.377.0

Fig. 2833

Top lights switch 0 1

Pos

Pin

1

2

3

4

5

7

4

5

6

9

8

1

2

3

10

6

7

8

0 1

2.7659.377.0

Fig. 2834

40-84

Wiring diagrams Table 514 Sys- P/N tem

I009 2.7659.377.0

Description

Characteristics/Notes

Top lights switch 0

Link to system

Link to wiring

40-422 40-147

40-571 40-571

40-474 40-309 40-315 40-194

40-571 40-571 40-571 40-571

40-315

40-500

40-315

40-500

40-336

40-522

1

Pos

Pin

1

2

3

4

7

4

5

6

9

8

1

2

3

10

6

5

7

8

0 1

2.7659.377.0

I010 2.7659.380.0

PTO selector switch

I011 2.7659.379.0 I012 2.7659.378.0

Rear hitch control switch Semi-active cab control switch Front hitch DOWN control pushbutton

I013 2.7659.347.0

Fig. 2834

0 1

2 1

Pos

Pin

1

2

3

0 1 2.7659.347.0

I014 2.7659.348.0

Front hitch UP control pushbutton

Fig. 2835 1

0

2 1

Pos

Pin

1

2

3

0 1 2.7659.348.0

I015 2.7659.337.0

Fig. 2836

RH distributor DOWN button (on mudguard)

Pos

Pin

1

2

3

0 1 2.7659.337.0

Fig. 2837

40-85

Wiring diagrams Sys- P/N tem

I016 2.7659.337.0

Description

Characteristics/Notes

RH distributor UP button (on mudguard)

Pos

Pin

1

2

Link to system

Link to wiring

40-336

40-522

40-315

40-522

40-315

40-522

40-309

40-522

40-336

40-520

3

0 1 2.7659.337.0

I017 2.7659.347.0

RH rear hitch DOWN button (on mudguard)

Fig. 2837 0 1

2 1

Pos

Pin

1

2

3

0 1 2.7659.347.0

I018 2.7659.348.0

RH rear hitch UP button (on mudguard)

Fig. 2837 1

0

2 1

Pos

Pin

1

2

3

0 1 2.7659.348.0

I019 2.7659.350.0

RH rear PTO button (on mudguard)

Fig. 2837 0 1

3 2 1

Pos

Pin

1

2

0

3 270 Ohm

1

220 Ohm

2.7659.350.0

I020 2.7659.337.0

Fig. 2838

LH distributor DOWN button (on mudguard)

Pos

Pin

1

2

3

0 1 2.7659.337.0

Fig. 2838

40-86

Wiring diagrams Sys- P/N tem

I021 2.7659.337.0

Description

Characteristics/Notes

LH distributor UP button (on mudguard)

Pos

Pin

1

2

Link to system

Link to wiring

40-336

40-520

40-315

40-520

40-315

40-520

40-309

40-520

40-120

40-518

40-349

40-580

40-341

40-580

3

0 1 2.7659.337.0

I022 2.7659.347.0

LH rear hitch DOWN button (on mudguard)

Fig. 2838 0 1

2 1

Pos

Pin

1

2

3

0 1 2.7659.347.0

I023 2.7659.348.0

LH rear hitch UP button (on mudguard)

Fig. 2838 1

0

2 1

Pos

Pin

1

2

3

0 1 2.7659.348.0

I024 2.7659.350.0

LH rear PTO button (on mudguard)

Fig. 2838 0 1

3 2 1

Pos

Pin

1

2

0

3 270 Ohm

1

220 Ohm

2.7659.350.0

I025 2.7659.373.0

Fig. 2838

Battery disconnect switch 4

1

2

3

Pos

Pin

1

2

3

4

0 1 2.7659.373.0

I026 2.7659.381.0 I027 2.7659.382.0

Rear view mirror demister switch Rear screen wiper switch

Fig. 2839

40-87

Wiring diagrams Sys- P/N tem

I028 04414097 I029 2.7659.411.0 I030 2.7659.489.0

Description

Door open warning signal switch Hazard warning lights switch “Performance Steering” system activation switch

Characteristics/Notes

0 1

Pos

Pin

1

2

3

4

5

6

7

4

5

6

9

8

1

2

3

10

7

8

9

Link to system

Link to wiring

40-349

40-580

40-442

40-528

40-487 40-407 40-379 40-388 40-397

40-537 40-537 40-537 40-537 40-537

40-346 40-349

40-580 40-580

Link to system

Link to wiring

40-450 40-178 40-178 40-450 40-112 40-120 40-469 40-210 40-469 40-120 40-210 40-112 40-210 40-112 40-120 40-469 40-120

40-514 40-514 40-514 40-514 40-514 40-514 40-518 40-518 40-518 40-518 40-511 40-511 40-511 40-511 40-511 40-511 40-511 40-511 40-518

40-120

40-518

40-120

40-518

40-120

40-518

40-120

40-518

40-465 40-207 40-250 40-286 40-277 40-268

40-518 40-518 40-537 40-537 40-537 40-537

10

1 2 2.7659.489.0

I031 2.7659.471.0 I031 2.7659.471.0

Light Bar switch Light Bar switch

Fig. 2840

40.2.14 - J - Relays Table 515 Sys- P/N tem

J002 J003

J004 J005 J006 2.7659.368.0/10

J007 J008 J009 J010 J011 J012 J013

40-88

Description

Left hand work light relay (on engine cowl) Right hand work light relay (on engine cowl) Not used Not used Battery disconnect contactor

2.7659.368.0/10

Battery disconnect contactor

2.7659.368.0/10

Battery disconnect contactor AD Blue pump control relay AdBlue suction line heater power supply relay AdBlue return line heater power supply relay AdBlue delivery line heater power supply relay AdBlue system power supply relay Nox sensor power supply relay CAN-L CANBUS ISO11783 configuration relay

Characteristics/Notes

Wiring diagrams Table 516 Sys- P/N tem

Description

J014

CAN-H ISO11783 relay

J015

ISOBUS relay (50A)

J016

ISOBUS relay (30A)

J020 J021 J022 J023 J032 04216031 04216031 04216031 04216031

Stoll application relay Stoll application relay Stoll application relay Stoll application relay Preheating relay Preheating relay Preheating relay Preheating relay Ignition key relay (F3/1)

Characteristics/Notes

CANBUS configuration

hitch service light relay (R4/1) Rear defrost relay (R4/3) Same bonnet relay (R4/6)

Link to system

Link to wiring

40-286 40-277 40-250 40-268 40-397 40-407 40-388 40-487 40-379 40-397 40-487 40-407 40-379 40-388 40-250 40-250 40-250 40-250 40-250 40-116 40-116 40-116 40-116 40-465 40-207 40-349 40-178 40-349 40-147

40-537 40-537 40-537 40-537 40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-537 40-537 40-537 40-537 40-590 40-589 40-590 40-589 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-431 40-156 40-422 40-210 40-469 40-178 40-450 40-178 40-210 40-469 40-450 40-450 40-178 40-450 40-178

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

40-450 40-178 40-331

40-571 40-571 40-571

40-349 40-156 40-422 40-147 40-431

40-571 40-571 40-571 40-571 40-571

Table 517 Sys- P/N tem

Description

Same bonnet relay (R4/6) Relay for front work lights on cab roof (R6/1) Relay for rear work lights on cab roof (R6/2) Relay for low front work lights (R1-A/1) Relay for trailer electrical power outlet sockets (R1A/2) Relay for low rear work lights (R1-A/3) Trailer braking relay (R1A/4) Lights relay (R1-A/6) Road lights/Top lights relay (R3/1)

Characteristics/Notes

40-89

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

Brake lights relay (R3/2) Road lights/Top lights relay (R3/3)

Link to system

Link to wiring

40-480 40-321 40-422 40-147 40-431 40-156

40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-156 40-422 40-147 40-431 40-147 40-156 40-431 40-422 40-431 40-147 40-156 40-422 40-207 40-465 40-341

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-133 40-125 40-125

40-571 40-571 40-571

40-133

40-571

40-133

40-571

40-125

40-571

Table 518 Sys- P/N tem

Description

Characteristics/Notes

High beam relay (R3/4)

Sidelights relay (R3/5)

Low beam relay (R3/6)

Ignition key relay (R7/1) 2.8639.008.0

Front windscreen wiper relay (R7/2)

40.2.15 - K - Sensors and transmitters Table 519 Sys- P/N tem

K001 2.7099.037.0 K002 2.7099.740.0/10 K002 2.7099.740.0/10 K003 04429390/10

K003 04429390/10

40-90

Description

Characteristics/notes

Clutch pedal pressed proximity sensor Clutch pedal position sen- Pin 1 = power (Nominal 5.0V) Pin 2 = ground sor Pin 4 = analogue signal Clutch pedal position sen- Pin 1 = power (Nominal 5.0V) Pin 2 = ground sor Pin 4 = analogue signal Accelerator pedal position Sensor N°1 Pin 1 = 5.0Vdc power sensor Pin 2 = ground Pin 4 = 0.5V - 4.5V analogue signal Sensor N°2 Pin 6 = 5.0Vdc power Pin 5 = ground Pin 3 = 0.5V - 4.5V analogue signal Accelerator pedal position Sensor N°1 Pin 1 = 5.0Vdc power sensor Pin 2 = ground Pin 4 = 0.5V - 4.5V analogue signal Sensor N°2 Pin 6 = 5.0Vdc power Pin 5 = ground Pin 3 = 0.5V - 4.5V analogue signal

Wiring diagrams Sys- P/N tem

Description

Characteristics/notes

Link to system

Link to wiring

Accelerator pedal position Sensor N°1 40-106 Pin 1 = 5.0Vdc power sensor Pin 2 = ground Pin 4 = 0.5V - 4.5V analogue signal Sensor N°2 Pin 6 = 5.0Vdc power Pin 5 = ground Pin 3 = 0.5V - 4.5V analogue signal

40-571

Description

Link to system

Link to wiring

Operator present sensor Operator present sensor Water in fuel sensor Brake circuit alarm pres- Normally open contact (NO) Switching pressure: 15 bar Brake circuit alarm pres- Normally open contact (NO) Switching pressure: 15 bar EPB pressure sensor Normally closed (NC) contact Resistance between pin 1 and pin 2: closed contact: 2200 ohms open contact: 3200 ohms EPB pressure sensor Normally closed (NC) contact Resistance between pin 1 and pin 2: closed contact: 2200 ohms open contact: 3200 ohms Hitch draft sensor (LH) Pin 1 = ground Pin 2 = analogue signal Pin 3 = 8V power Signal with no implement hitched: 4V ± 0.2 V PTO speed sensor Pin 1 = ground Pin 2 = square wave signal Pin 3 = 12 V power input Resistance between Pin 2 and Pin 3: approx.18 kOhm High level: 3.5-5.5 V Low level: 0.6-1.2 V

40-125 40-133 40-106 40-321

40-571 40-571 40-583 40-583

40-480

40-583

40-480

40-583

40-321

40-583

40-315

40-583

40-474

40-583

Sys- P/N tem

Description

Characteristics/Notes

Link to system

Link to wiring

K009 04438352

PTO speed sensor

K010 2.7059.834.0

Fuel level sensor

Pin 1 = ground 40-309 Pin 2 = square wave signal Pin 3 = 12 V power input Resistance between Pin 2 and Pin 3: approx.18 kOhm High level: 3.5-5.5 V Low level: 0.6-1.2 V Resistance between pin 1 and pin 40-144 2: with tank full 177÷197 Ohm with tank half full 58.5÷66 Ohm with tank empty 3.5÷5.5 Ohm

K003 04429390/10

Table 520 Sys- P/N tem

K004 K004 K005 0.900.0942.1 K006 2.7099.670.0/10 K006 2.7099.670.0/10 K007 2.7099.009.0

K007 2.7099.009.0

K008 2.7099.982.0

K009 04438352

Characteristics/Notes

Table 521 40-583

40-583

40-91

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

K010 2.7059.834.0

Fuel level sensor

K011 K012 0.900.0272.2 K013 2.7099.035.0/10

Not used Air cleaner clogged sensor Engine coolant level sensor Front axle speed sensor

Resistance between pin 1 and pin 40-106 2: with tank full 177÷197 Ohm with tank half full 58.5÷66 Ohm with tank empty 3.5÷5.5 Ohm

K014 0.900.1420.3 K015 04426492/10

Link to system

40-144 40-144

Link to wiring

40-583

40-583 40-583 40-583

40-200 40-125 40-133 Air conditioning pressure Compressor connector (female 40-196 switch connector): normally open contact - with pressure increasing: contact closed at max 2.4 bar contact open at 28.5 ±1.5 bar - with pressure decreasing: contact closed at 19.5 ±1.5 bar contact open at 1.2 ±0.3 Bar

40-583 40-583 40-583 40-583

Description

Link to system

Link to wiring

40-200

40-583

40-407 40-133 40-125

40-540 40-540 40-583

40-407 40-106

40-583 40-529

40-196 40-200

40-529 40-529

Table 522 Sys- P/N tem

K015 04426492/10

K016 K016 K016 0.900.0504.8

K016 K017 04216354

Characteristics/Notes

Air conditioning pressure Compressor connector (female switch connector): normally open contact - with pressure increasing: contact closed at max 2.4 bar contact open at 28.5 ±1.5 bar - with pressure decreasing: contact closed at 19.5 ±1.5 bar contact open at 1.2 ±0.3 Bar Wiring connector Wiring connector Steering angle sensor Pin 1 = signal Pin 2 = 5V power Pin 3 = ground Voltage on pin 1 with wheels straight 2.5V ± 0.1V Wiring connector Air temperature sensor T (°C)

T (°C)

Rnom (Ω)

Rmin (Ω)

-40

39656

37013

42298

30

1662

1610

-35

30080

28173

31988

35

1389

1348

1430

-30

23026

21639

24414

40

1166

1133

1198

-25

17781

16763

18800

45

983,3

957,8

1009

-20

13846

13092

14600

50

833,2

812,9

853,4

-15

10867

10305

11429

55

709

693

725,1

-10

8594

8172

9015

60

605,9

593,2

618,7

-5

6845

6526

7164

65

520

509,8

530,1

0

Rnom (Ω)

5490

Rmin (Ω)

5248

Rmax (Ω)

Rmax (Ω) 1715

5732

70

447,9

439,8

456

5

4432

4247

4618

75

387,3

380,9

393,8

10

3601

3458

3743

80

336,1

331

341,3

15

2943

2833

3053

85

292,8

288,7

296,8

20

2420

2334

2505

90

255,8

252,6

259

25

2000

1934

2067

04216354

K018 0.014.4826.3

40-92

External air temperature sensor

Fig. 2841

Wiring diagrams Sys- P/N tem

K019 0.009.2194.4/20

K020 K021 0.012.4371.0 K021 0.012.4371.0 K022 0.012.1507.4

K022 0.012.1507.4

K023 04438667 K024 K025 2.7099.982.0

K026 0.011.9428.0 K027 2.7099.033.0/10 K027 2.7099.033.0/10 K028 04416649

K028 04416649

K029 K030 K030

Description

Characteristics/Notes

Front axle suspension po- Pin 1 = ground Pin 2 = signal output sition sensor Pin 3 = 10Vdc power Output 0.2Vdc (sensor released) Output 8.3Vdc (sensor fully depressed) Not used Steering system pressure Normally closed (NC) contact Switching pressure: 5 bar ± 0.7 Steering system pressure Normally closed (NC) contact Switching pressure: 5 bar ± 0.7 Brakes circuit pressure Pin 1 = 5.0Vdc power Pin 2 = ground sensor Pin 3 = analogue signal Output 0.5Vdc (0 bar) Brakes circuit pressure Pin 1 = 5.0Vdc power Pin 2 = ground sensor Pin 3 = analogue signal Output 0.5Vdc (0 bar) Output 4.5Vdc (40 Bar) Rear lifter position sensor Pin 1 = ground Pin 2 = 5V DC power supply Pin 3 = signal output Not used Hitch draft sensor (RH) Pin 1 = ground Pin 2 = analogue signal Pin 3 = 8V power Signal with no implement hitched: 4V ± 0.2 V Compressed air pressure Power 12V DC Resistance at 0 bar 10-13 Ohm sensor Resistance at 6 Bar 119-129 Ohm Oil tank filter clogging sensor Oil tank filter clogging sensor Oil temperature sensor Resistance between pin 1 and pin 2: at 25°C 1000 ± 15 ohms at 100°C 1696 ± 35 ohms at 150°C 2211 ± 80 Ohms Oil temperature sensor Resistance between pin 1 and pin 2: at 25°C 1000 ± 15 ohms at 100°C 1696 ± 35 ohms at 150°C 2211 ± 80 Ohms Front hitch position sensor Front PTO speed sensor Front PTO speed sensor Output 4.5Vdc (40 Bar)

Link to system

Link to wiring

40-141

40-499

40-133

40-576 40-576

40-125

40-576

40-321

40-576

40-480

40-576

40-315

40-576

40-315

40-576 40-576

40-331

40-576

40-133

40-576

40-125

40-576

40-125

40-576

40-133

40-576

40-315 40-474 40-309

40-576 40-576 40-576

40-93

Wiring diagrams Table 523 Sys- P/N tem

K031 0.010.1214.4

K032 0.900.0064.4 K033 04904050

K034 04218185 K034 04218185 K034 04218185 K035 2.7059.007.0/10

K036 04218186 K036 04218186 K036 04218186 K037 04454440/20

K037 04454440/20

K037 04454440/20

Description

Characteristics/Notes

Link to system

PTO speed sensor - (USA Pin 1 = ground 40-474 Pin 2 = analogue signal: Export) 0 Volt with sensor covered by metal 12 Volt with sensor exposed Pin 3 = 12 V power input Trailer braking low pres40-331 sure switch Exhaust gas temperature 40-120 sensor T (°C)

Rs (Ω)

ΔRs (Ω)

UO (V)

-40

169,7

±1,9

0,725

0

200,5

±1,9

0,835

25

219,6

±1,9

0,900

50

238,5

±1,9

0,963

100

275,9

±1,9

1,081

200

349,0

±1,8

1,293

300

419,7

±1,9

1,478

400

488,1

±2,4

1.640

500

554,1

±2,9

1,783

600

617,8

±3,4

1,909

700

679,2

±3,8

2,022

800

738,2

±4,2

2,123

850

766,8

±4,4

2,170

Link to wiring

40-499

40-533 40-518

04904050

Fig. 2842

40-231

40-518

40-297

40-518

40-216

40-518

40-120

40-518

40-297

40-518

40-216

40-518

40-231

40-518

40-286

40-540

40-407

40-540

40-250

40-540

Link to system

Link to wiring

sensor

40-133

40-540

sensor

40-407

40-540

NOX sensor upline from catalytic converter NOX sensor upline from catalytic converter NOX sensor upline from catalytic converter AdBlue level sensor Resistance between pin 1 and pin 2: with tank full 19,030 -19,850 ohm with tank half full 2,098 - 2,225 ohm with tank empty 215 - 265 ohm NOX sensor downline of catalytic converter NOX sensor downline of catalytic converter NOX sensor downline of catalytic converter Steering wheel angle sen- Pin 1: CAN-L signal Pin 2: 9 - 32V power feed sor Pin 3: ground Pin 4: CAN-H signal Steering wheel angle sen- Pin 1: CAN-L signal Pin 2: 9 - 32V power feed sor Pin 3: ground Pin 4: CAN-H signal Steering wheel angle sen- Pin 1: CAN-L signal Pin 2: 9 - 32V power feed sor Pin 3: ground Pin 4: CAN-H signal

Table 524 Sys- P/N tem

K038 K038

40-94

Description

Steering angle (Agrosky) Steering angle (Agrosky)

Characteristics/Notes

Wiring diagrams Sys- P/N tem

Description

K039

Brake hydraulic system pressure sensor - 60 Km/h

K044 K045 04199447

RAIL pressure sensor Crankshaft speed sensor Pin1 = digital signal Pin 2 = ground Camshaft speed sensor Pin1 = digital signal Pin 2 = ground Pin3 = signal shielding Engine coolant temperature sensor Turbine air temperature/ pressure sensor

K046 04214103 K047 04210196 K048 04216645

Characteristics/Notes

T (°C) [°F]

Signal (Ω)

-40 [-40]

44373

0 [32]

5774

25 [77]

2014

40 [104]

1150

80 [176]

315

125 [257]

Link to system

Link to wiring

40-231 40-297 40-216 40-106 40-106

40-570 40-570 40-570 40-590 40-590

40-106

40-590

40-106

40-590

40-106

40-590

40-106 40-106 40-106

40-590 40-590 40-590 40-590

40-200 40-200

40-556 40-556

Link to system

Link to wiring

40-315

40-583

40-141

40-499

40-141 40-141

40-499 40-499

40-474 40-309 40-133 40-125 40-315

40-576 40-531 40-531 40-531 40-531 40-576

40-474 40-309 40-474 40-309 40-474 40-309 40-331

40-531 40-531 40-531 40-531 40-531 40-531 40-533

98

Relative pressure (bar)

Signal (V)

0

~ 1,000

0,5

~ 1,550

1

~ 2,100

max 1,6

~ 2,700 04216645

K049 04213842 K050 04213842 K051 K052 04210196 K055 0.014.1326.0 K056 0.014.1324.0

Fig. 2843

Oil pressure sensor Fuel low pressure sensor Not used Engine oil temperature sensor Sunlight sensor Temperature sensor Resistance between pin 1 and pin 2: 2,200 ± 110 Ohm at 25°C

40.2.16 - L - Electromagnets and solenoid valves Table 525 Sys- P/N tem

L001 04451764 L002 0.900.1132.5 L003 0.900.1132.5 L004 0.900.1132.5 L005 L006 L007 L008 04451764 L009 L010 L011 L012 0.900.0939.9

Description

Rear hitch ‘UP’ control solenoid valve Front axle ‘Down’ control solenoid Front axle “Up” control coil Front axle suspension Load Sensing control coil Not used Rear PTO control solenoid valve Differential lock control solenoid valve Rear hitch DOWN control solenoid valve PTO 1,000 E engagement control solenoid valve PTO 1,000N engagement control solenoid valve PTO 540E engagement control solenoid valve Trailer parking brake control solenoid valve

Characteristics/Notes

40-95

Wiring diagrams Sys- P/N tem

L013 0.018.3290.4 L014 0.900.0813.8 L015 2.4569.021.0 L016 L017

Description

Characteristics/Notes

AdBlue heating solenoid valve Front PTO control solenoid valve AGROSKY control disable solenoid valve Proportional solenoid valve “EPB” solenoid valve

Link to system

Link to wiring

40-120

40-518

40-474 40-309 40-407

40-588 40-588 40-540

40-106

40-590

40-331

40-576

40.2.17 - M - Electrical/electronic devices, flasher units and timers Table 526 Sys- P/N tem

Description

M001 2.8519.133.0/20

Transmission control unit

2.8519.133.0/20

Transmission control unit

2.8519.133.0/20

Transmission control unit

2.8519.133.0/20

Transmission control unit

2.8519.133.0/20

Transmission control unit

M002 02959593

Characteristics/Notes

Engine control unit

Link to system

Link to wiring

40-133 40-125 40-480 40-133 40-321 40-125 40-366 40-125 40-474 40-250 40-309 40-297 40-216 40-133 40-321 40-480 40-231 40-125 40-231 40-480 40-133 40-216 40-297 40-250 40-321 40-216 40-120 40-250 40-144 40-231

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-106 40-116 40-112 40-297 40-250 40-216 40-106 40-112 40-120 40-297 40-231 40-116

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Table 527 Sys- P/N tem

Description

M002 02959593

Engine control unit

02959593

Engine control unit

40-96

Characteristics/Notes

Wiring diagrams Sys- P/N tem

Description

M003 2.8519.134.0/50

HLHP unit

M003 2.8519.134.0/50

HLHP unit

Characteristics/Notes

Link to system

Link to wiring

40-366 40-309 40-196 40-194 40-144 40-231 40-297 40-125 40-133 40-216 40-349 40-250 40-373 40-346 40-200 40-321 40-397 40-379

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-388 40-407 40-141 40-315 40-336 40-321 40-216 40-200 40-309 40-297 40-125 40-315 40-250 40-231 40-349 40-373 40-487 40-388 40-397 40-144 40-480 40-336 40-407 40-346 40-474 40-366 40-133 40-194 40-196 40-141

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-168 40-442

40-571 40-571

Table 528 Sys- P/N tem

Description

M003 2.8519.134.0/50

HLHP unit

M003 2.8519.136.0/40

HLHP unit - USA version

M003 2.8519.136.0/40

HLHP unit - USA version

M003 2.8519.136.0/40

HLHP unit - USA version

Characteristics/Notes

Table 529 Sys- P/N tem

M004 2.8639.007.0/10

Description

Hazard lights flasher unit

Characteristics/Notes

40-97

Wiring diagrams Sys- P/N tem

Description

M005

Internal transmission control unit

M006 2.7099.977.4

Radar

M006 2.7099.976.4

Radar

M008 2.8519.148.0

ISO 11786 control unit

M009 0.019.0636.0

“AGROSKY” Antenna

M009 0.019.0644.0 M009 0.019.0636.0 M009 0.019.0644.0 0.019.0644.0

“AGROSKY” Antenna “AGROSKY” Antenna “AGROSKY” Antenna “AGROSKY” Antenna

40-98

Characteristics/Notes

Link to system

Link to wiring

40-133 40-216 40-297 40-366 40-231 40-125 40-315

40-576 40-576 40-576 40-576 40-576 40-576 40-576

Pin 1 = ground Pin 2 = pulse signal (100 pulses/ metre) Pin 3 = power 12 V With the radar powered on, the voltage at pin 2 should change when a hand is passed in front of the sensor Radar nominal frequency: 24125 MHz ± 75 MHz Pin 1 = ground 40-315 Pin 2 = pulse signal (100 pulses/ metre) Pin 3 = power 12 V With the radar powered on, the voltage at pin 2 should change when a hand is passed in front of the sensor Radar nominal frequency: 24300 MHz ± 75 MHz 40-231 40-216 40-297 40-349 40-388 40-245 40-373 40-407 40-268 40-397 40-397 40-286 40-407 40-277

40-576

40-535 40-535 40-535 40-535 40-565 40-565 40-565 40-558 40-565 40-558 40-558 40-558 40-558 40-558

Wiring diagrams Table 530 Sys- P/N tem

Description

M010

Microphone

M011

ISO 11783 control unit

M012 2.8639.012.0

Turn indicator control unit (USA) Electronically controlled hydraulic power steering (grey connector) Electronically controlled hydraulic power steering (black connector) Turbocharger

2.4569.021.0 2.4569.021.0 M014 04509411

M015 0.019.5438.4/20 M016 M017 0.900.2223.9

Characteristics/Notes

Air conditioning control unit (blue connector) Relay unit Webasto ECU

Link to system

Link to wiring

40-397 40-373 40-407 40-388 40-487 40-379 40-277 40-407 40-379 40-286 40-250 40-388 40-397 40-487 40-268 40-442

40-537 40-559 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-528

40-286 40-250 40-407 40-407

40-540 40-540 40-540 40-540

40-216 40-231 40-297 40-250 40-106 40-200 40-418 40-418 40-418

40-590 40-590 40-590 40-590 40-590 40-556 40-556 40-585 40-580

Link to system

Link to wiring

40-341 40-341

40-583 40-583

40-331 40-297 40-231 40-321 40-112 40-480 40-216 40-194 40-194

40-583 40-583 40-583 40-583 40-583 40-583 40-583 40-549 40-549

40-112 40-112 40-112 40-120 40-120 40-341

40-518 40-511 40-590 40-518 40-518 40-580

40.2.18 - N - Electric motors and actuators Table 531 Sys- P/N tem

N002 04414105 N003 04414105 N004 0.018.6330.4/10

N005 0.015.8702.4/10 N006 0.015.8702.4/10

Description

Windscreen washer pump Rear windscreen washer pump E.P.B. device

N007 0.900.2154.0

Left hand cab suspension Right hand cab suspension Starter motor “+30”

N007 N008 N009 N010

Starter motor AdBlue pump AdBlue dispenser Rear screen wiper motor

0.900.2154.0 04600620 04600619 04413192

Characteristics/Notes

40-99

Wiring diagrams Sys- P/N tem

Description

N011 0.019.6609.4

Windscreen wiper motor

N012

Electronically controlled hydraulic power steering

N013

Pneumatic seat compressor Windscreen washer pump Rear windscreen washer pump Webasto circuit pump

N018 04414105 N019 04414105 N020 0.019.6494.0

Characteristics/Notes

Link to system

Link to wiring

40-341 40-341 40-341 40-341 40-286 40-245 40-277 40-397 40-250 40-268 40-349

40-545 40-551 40-561 40-563 40-537 40-559 40-537 40-537 40-537 40-537 40-571

40-341 40-341

40-579 40-579

40-418

40-585

Link to system

Link to wiring

40-250 40-297 40-231 40-216 40-216 40-297 40-231 40-231 40-216 40-250 40-297 40-216 40-231 40-297 40-250 40-231 40-297 40-216 40-250 40-297 40-216 40-231 40-250 40-297 40-231 40-250 40-216 40-231 40-297

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Link to system

Link to wiring

40-250 40-216 40-194 40-112 40-120

40-571 40-571 40-571 40-571 40-518

40.2.19 - O - Resistors, rheostats, diodes and diode boards Table 532 Sys- P/N tem

O001

Description

Characteristics/Notes

CAN line termination connector CAN line termination connector

O002

CAN line termination connector CAN line termination connector

O003

CAN line termination connector CAN line termination connector

O004

CAN line termination connector CAN line termination connector

Table 533 Sys- P/N tem

O005 O006 0.018.3706.4/10

40-100

Description

CAN line termination connector Diode and resistance board AdBlue pick-up line with resistance

Characteristics/Notes

Wiring diagrams Sys- P/N tem

O007 0.018.3706.4/10 O008 0.018.3787.4/10 O009 O011 O012

Description

Characteristics/Notes

Link to system

Link to wiring

40-120

40-518

40-120

40-518

40-297 40-231 40-216 40-349

40-518 40-518 40-518 40-580

40-286 40-250 40-277 40-268 40-245 40-250 40-286 40-268 40-277 40-245 40-268 40-286 40-277 40-245 40-250 40-250 40-277 40-268

40-537 40-537 40-537 40-537 40-559 40-537 40-537 40-537 40-537 40-559 40-537 40-537 40-537 40-559 40-537 40-537 40-537 40-537

Link to system

Link to wiring

CAN line termination connector CAN line termination connector

40-286

40-537

Not used Wiring connector

40-245 40-277 40-286 40-268 40-277 40-268 40-245 40-286 40-397 40-250 40-388 40-407 40-379 40-487 40-397 40-487 40-250 40-379 40-388 40-407 40-268 40-250 40-277 40-286

40-537 40-559 40-537 40-537 40-561 40-561 40-561 40-561 40-561 40-561 40-561 40-561 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537

AdBlue return pipeline with resistance AdBlue delivery pipeline with resistance CAN line termination connector Rear defrost heater element CAN line termination connector

CAN line termination connector

O013

CAN line termination connector

Table 534 Sys- P/N tem

O013

Description

CAN line termination connector O014

Diode connector

Diode board

O015

CAN line termination connector

Characteristics/Notes

40-101

Wiring diagrams Table 535 Sys- P/N tem

Description

O016

Diode board

O017

Diode board

O018

CAN line termination connector CAN line termination connector LED carrier connector Diode

O019

Characteristics/Notes

Link to system

Link to wiring

40-397 40-407 40-388 40-487 40-379 40-487 40-388 40-379 40-407 40-397 40-286 40-250 40-286 40-250 40-418 40-418

40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-540 40-540 40-540 40-540 40-585 40-585

Link to system

Link to wiring

40-346 40-346 40-349

40-571 40-571 40-571

40-349 40-200 40-196 40-168 40-178 40-156 40-321 40-450 40-422 40-442 40-147 40-431 40-480 40-216 40-231 40-336 40-297 40-297 40-336 40-231 40-216 40-297 40-231 40-216 40-336 40-216

40-571 40-583 40-583 40-507 40-507 40-507 40-509 40-509 40-509 40-509 40-507 40-509 40-509 40-516 40-516 40-516 40-516 40-516 40-516 40-516 40-516 40-516 40-516 40-516 40-516 40-516

Link to system

Link to wiring

40-336 40-297 40-231

40-516 40-516 40-516

40.2.20 - P - Various services Table 536 Sys- P/N tem

P001 0.017.0265.4/10 P002 0.017.0265.4/10 P003 2.6039.020.0

Description

P006 2.6030.011.0

LH front loudspeaker RH front loudspeaker Auxiliary cab power outlet socket (25A) Power outlet socket in cab Air conditioning compressor Trailer socket

P006 2.6039.027.0

Trailer socket

P006 2.6030.011.0 P006 2.6039.027.0

Trailer socket Trailer socket

P007 2.3729.005.0

Utility distributor 1

P008 2.3729.005.0

Utility distributor 2

P009 2.3729.005.0

Utility distributor 3

P010 2.3729.005.0

Utility distributor 4

P004 2.6039.517.0 P005 04437339/10

Characteristics/Notes

Table 537 Sys- P/N tem

P010 2.3729.005.0

40-102

Description

Utility distributor 4

Characteristics/Notes

Wiring diagrams Sys- P/N tem

Description

P011 2.3729.005.0

Utility distributor 5

P012 2.3729.005.0

Utility distributor 6

P013 2.3729.005.0

Utility distributor 7

P014 2.6039.020.0

Auxiliary power outlet socket (30A) Front implement power outlet socket

P015 2.6039.039.0

Characteristics/Notes

P016 0.017.0266.4/10 P017 0.017.0266.4/10 P018 0.015.8626.4

RH rear loudspeaker LH rear loudspeaker LH rear view mirror

P018 0.019.4636.4

LH rear view mirror

P019 0.015.8625.4

RH rear view mirror

Link to system

Link to wiring

40-216 40-231 40-336 40-297 40-231 40-216 40-336 40-297 40-297 40-336 40-216 40-231 40-349

40-516 40-516 40-516 40-516 40-516 40-516 40-516 40-516 40-516 40-516 40-516 40-516 40-576

40-442 40-147 40-168 40-431 40-422 40-156 40-346 40-346 40-349 40-349 40-349 40-349 40-349

40-500 40-500 40-500 40-500 40-500 40-500 40-580 40-580 40-545 40-551 40-561 40-563 40-545

Link to system

Link to wiring

40-349 40-349 40-349 40-349 40-349 40-268 40-286 40-407 40-388 40-487 40-277 40-379 40-397 40-250 40-407 40-379 40-487 40-397 40-388 40-379 40-250 40-388 40-397 40-407 40-268 40-286 40-277 40-487 40-250 40-268

40-551 40-561 40-563 40-535 40-535 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-510 40-510 40-510 40-510 40-510 40-510 40-510 40-510 40-510 40-510 40-510 40-510 40-510 40-510 40-512 40-512

Table 538 Sys- P/N tem

Description

Characteristics/Notes

P019 0.015.8625.4 P019 0.019.4635.4

RH rear view mirror RH rear view mirror

P020 04422324.4/10 04422324.4/10 P021

ISO 11786 socket ISO 11786 socket ISO 11783 socket in cab

P022

Front ISOBUS socket

11783

P023

Front ISOBUS socket

11783

P024

Rear ISOBUS 11783 socket

40-103

Wiring diagrams Table 539 Sys- P/N tem

Description

Characteristics/Notes

P024

Rear ISOBUS 11783 socket

P025

Rear ISOBUS 11783 socket

P026 P027 2.6030.011.0 P028 0.019.6523.0 0.019.6523.0

Radio Trailer socket Electric aerial Webasto unit Webasto unit

Link to system

Link to wiring

40-397 40-388 40-487 40-379 40-286 40-407 40-277 40-407 40-379 40-487 40-388 40-397 40-346 40-321 40-346 40-418 40-418

40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-512 40-580 40-586 40-580 40-585 40-585

Link to system

Link to wiring

40-366 40-216 40-250 40-231 40-297 40-388 40-487 40-397 40-407 40-379 40-379 40-277 40-250 40-397 40-388 40-487 40-286 40-407 40-268 40-418

40-571 40-571 40-571 40-571 40-571 40-559 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-537 40-585

Link to system

Link to wiring

40-112 40-469 40-210 40-210 40-469 40-210 40-469

40-511 40-511 40-511 40-583 40-583 40-514 40-514

40.2.21 - R - Diagnostics Table 540 Sys- P/N tem

Description

Characteristics/Notes

R001 R002

Diagnostic socket CANBUS diagnostic connector

R003

RS 232 connector

R004

ISO11783 socket

R005

Webasto diagnostic connector

diagnostic

40.2.22 - T - Power supply points (+15 o +30) Table 541 Sys- P/N tem

Description

T001 2.9559.047.0

Battery positive terminal

2.9559.047.0

Battery positive terminal

2.9559.047.0

Battery positive terminal

40-104

Characteristics/Notes

Wiring diagrams Sys- P/N tem

T004 2.9559.064.0

Description

Positive terminal of the auxiliary battery

Characteristics/Notes

Link to system

Link to wiring

40-480 40-216 40-231 40-321 40-297 40-331 40-112

40-583 40-583 40-583 40-583 40-583 40-583 40-583

40-105

Wiring diagrams 40.3 - Systems

40.3.1 - S001 - Electrical engine governor

WATER IN FUEL

GND HAND GAS

E2-67

HOLD SWITCH

HAND GAS

HOLD SWITCH

HAND GAS

+30

+30

+30

GND

GND

GND

70

26

69

67

51

30

46

16

1

3

5

2

4

6

Bm013

20

29

84

58

85

86

87

65

64

66

48

49

37 33

30

1

2

A B4

A B3

1

2

D011

36

37

2

3

4

D087

+15

D011

C002

D036 19

35

16 11

10

18

4

5

5

4

3

2

1

1

K010

K017 K005

13

14

H001a

Fig. 2844 - Electric engine governor - System (1/2) l l l l l l l l l l l l l

A004 - Cylinder 1 injector A005 - Cylinder 2 injector A006 - Cylinder 3 injector D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D011 (M) - Wiring connector (Wiring loom 0.020.8658.4) D011 (F) - Wiring connector (Wiring loom 04218107) D012 (M) - Wiring connector (Wiring loom 0.018.9992.4/10) D012 (F) - Wiring connector (Wiring loom 0.020.8658.4) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D036 (M) - Wiring connector (Wiring loom 0.021.0396.4) D036 (F) - Wiring connector (Wiring loom 0.019.2383.4/20)

40-106

ECU

1

2

4 pos

GND

12

SIG.

11

SUPPLY

9

HAND GAS

t

15

HAND GAS

2

HOLD SWITCH

1

HOLD SWITCH

2

+15 ENGINE

1

GND HAND GAS

+30

3A

20

34

1D

7.5A

D031 B008

5

10A

A D6

B010

A A7

D012

B B3

Bb007

A D5

To Can Bus

D009

+15

+30

C003

C003a

GND

WATER IN FUEL

50

GND GAS PEDAL

AMBIENT TEMP. (2)

10

GAS PEDAL

AMBIENT TEMP. (1)

13

SIGNAL GAS PEDAL

TANK INDICATOR

21

30A

FUSE PDU3 (INSTRUM. +30)

5

3A

GND

M002a

+15 INSTRUMENT

M002

12

+15

Bb004

E002

1

2

1

2

1

2

t

M

M014

K003

A004 A005 A006 K052 D0078790

Wiring diagrams

WATER IN FUEL

GND HAND GAS

E2-67

HOLD SWITCH

HAND GAS

HOLD SWITCH

HAND GAS

+30

+30

+30

GND

GND

GND

70

26

69

67

51

30

46

16

1

3

5

2

4

6

Bm013

20

29

84

58

85

86

87

65

64

66

48

49

37 33

30

1

2

A B4

A B3

1

2

D011

36

37

2

3

4

D087

+15

D011

C002

D036 19

35

16 11

10

18

4

5

5

4

3

2

1

1

K017 K005

13

14

H001a

ECU

1

2

4 pos

GND

12

SIG.

11

SUPPLY

9

HAND GAS

K010

15

HAND GAS

2

HOLD SWITCH

1 t

HOLD SWITCH

2

+15 ENGINE

1

GND HAND GAS

+30

3A

20

34

1D

7.5A

D031 B008

5

10A

A D6

B010

A A7

D012

B B3

Bb007

A D5

To Can Bus

D009

+15

+30

C003

C003a

GND

WATER IN FUEL

50

GND GAS PEDAL

AMBIENT TEMP. (2)

10

GAS PEDAL

AMBIENT TEMP. (1)

13

SIGNAL GAS PEDAL

TANK INDICATOR

21

30A

FUSE PDU3 (INSTRUM. +30)

5

3A

GND

M002a

+15 INSTRUMENT

M002

12

+15

Bb004

E002

1

2

1

2

1

2

t

M

M014

K003

A004 A005 A006 K052 D0078790

Fig. 2844 - Electric engine governor - System (1/2) l l l l l l l l l l l l l

D087 (M) - Wiring connector (Wiring loom 04502029) D087 (F) - Wiring connector (Wiring loom 04218107) E002 - Instrument panel H001a - Armrest K003 - Accelerator pedal position sensor K005 - Water in fuel sensor K010 - Fuel level sensor K017 - Air temperature sensor K052 - Engine oil temperature sensor L016 - Proportional solenoid valve M002 - Engine ECU M002a - Engine control unit M014 - Turbocharger

40-107

Wiring diagrams

M002a

23

45

44

43

24

25

46

36

78

17

40

42

41

20

19

31

25

32

3

1

4

2

1

2

1

2

1

2

3

101

75

99

15

21

9

13

14

1

2

3

2

1

102

100

13

74

11

21

73

24

28

29

22

23

2

1

2

3

4

72

35

54

27

17

D011

22

1

26

D088

39

2

1

2

1

A007 A008 A009 L016

K044

K045

K046

1

K047

K048

1

2

3

K049

4

1

2

3

4

K050 D0078340

Fig. 2845 - Electric engine governor - System (2/2) l l l l l l l l l l l l l l l l

A007 - Cylinder 4 injector A008 - Cylinder 5 injector A009 - Cylinder 6 injector D011 (M) - Wiring connector (Wiring loom 0.020.8658.4) D011 (F) - Wiring connector (Wiring loom 04218107) D088 (M) - Wiring connector (Wiring loom 04502029) D088 (F) - Wiring connector (Wiring loom 04218107) K044 - RAIL pressure sensor K045 - Crankshaft speed sensor K046 - Camshaft speed sensor K047 - Engine coolant temperature sensor K048 - Turbine air temperature/pressure sensor K049 - Oil pressure sensor K050 - Fuel low pressure sensor L016 - Proportional solenoid valve M002a - Engine control unit

40-108

Wiring diagrams Table 542 Sys- P/N tem

Description

B010

C002

Fuse (10A) 3A Fuse - Cluster (F1-A/4, +15) 7.5A Fuse - Engine (F1-A/7, +15) 30A Fuse - Engine (F2/13-14, +30) Engine ground

C003

Cab ground

A004 A005 A006 A007 A008 A009 B008

04504666 04504666 04504666 04504666 04504666 04504666

Characteristics/Notes

Position

Wiring loom

40-592 40-592 40-592 40-592 40-592 40-592 40-514

Cylinder 1 injector Cylinder 2 injector Cylinder 3 injector Cylinder 4 injector Cylinder 5 injector Cylinder 6 injector Fuse (3A)

Cab ground

Fig. 2846

40-518 40-571 40-571 40-571 40-583

Fig. 2847

Fig. 2848

40-571

40-571

Fig. 2849

40-109

Wiring diagrams Sys- P/N tem

Description

D009

Wiring connector

D011

Wiring connector

D012

Wiring connector

D012

Wiring connector

D031

Wiring connector

D036

Wiring connector

D087

Wiring connector

D088

Wiring connector

40-110

Characteristics/Notes

Position

Wiring loom

40-571 40-583

Fig. 2850

Fig. 2851

Fig. 2852

Fig. 2853

Fig. 2854

40-571 40-590 40-518

40-571

40-583 40-514

40-529 40-583

40-590 40-592 40-590 40-592

Wiring diagrams Sys- P/N tem

E002

Description

Characteristics/Notes

Position

Wiring loom

40-571

Instrument panel

Fig. 2855

Armrest

40-571

Fig. 2856

Table 543 Sys- P/N tem

K003

K005 K010

K017 04216354 K044 K045 04199447 K046 04214103 K047 04210196 K048 04216645 K049 04213842 K050 04213842 K052 04210196

Description

Characteristics/Notes

Accelerator pedal Sensor N°1 Pin 1 = 5.0Vdc power position sensor Pin 2 = ground Pin 4 = 0.5V - 4.5V analogue signal Sensor N°2 Pin 6 = 5.0Vdc power Pin 5 = ground Pin 3 = 0.5V - 4.5V analogue signal Water in fuel sensor Fuel level sensor Resistance between pin 1 and pin 2: with tank full 177÷197 Ohm with tank half full 58.5÷66 Ohm with tank empty 3.5÷5.5 Ohm Air temperature Drawing 04216354 sensor RAIL pressure sensor Crankshaft speed Pin1 = digital signal Pin 2 = ground Camshaft speed Pin1 = digital signal Pin 2 = ground sensor Pin3 = signal shielding Engine coolant temperature sensor Turbine air tem- Drawing 04216645 perature/pressure sensor Oil pressure sensor Fuel low pressure sensor Engine oil temperature sensor

Position

Wiring loom

40-571

Fig. 2857

40-583 40-583

40-529 40-590 40-590 40-590 40-590 40-590 40-590 40-590 40-590

40-111

Wiring diagrams Sys- P/N tem

L016

M002 02959593

02959593

M014 04509411

Description

Position

Wiring loom

40-590

Proportional solenoid valve Engine control unit

Engine control unit

Turbocharger

40.3.2 - S002 - Starter

40-112

Characteristics/Notes

40-571

Fig. 2858

Fig. 2858

40-571

40-590

Wiring diagrams

6

7

b

T001 +30a

a

+30b

C001 GND

+30

A8

C1

1

+15 WOLP

5

+30 WOLP

50

2

9

13

14

+30

3A

4

15A

75

C003

3

15A

A

A

B

A1

B8

C8

BATTERY

N004

J006

15

+30

+30

B017

30A

D032

B2

2

T004 GND

C004

5

B C1

2

D033

+15 4

30A

B016

Bb002 D009 3

C002

2

J006a

J006b

To AdBlue

B C5

1 83

0

1

Bb014

30

3

30A

6 A3A

6

+15

64

Bf018

58

GND

+50 KEY

6

+50 KEY

GND

4

H002 +30 WOLP

GND

2

D1

GND

5

Bf016

Bm013

2

3

+30

3

1

C003

+30

+30

2

I006

O005

GND

1

+30

95

D011

94

30A

M

+30

M002

3 K3A

N007

M002a

+30

BATTERY AUXILIARY

D0078770

Fig. 2859 - Starter - System l l l l l l l l l l l l l l l l l l l

D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D011 (M) - Wiring connector (Wiring loom 0.020.8658.4) D011 (F) - Wiring connector (Wiring loom 04218107) D032 (M) - Wiring connector (Wiring loom 0.021.0396.4) D032 (F) - Wiring connector (Wiring loom 0.018.9992.4/10) D033 (M) - Wiring connector (Wiring loom 0.021.0396.4) D033 (F) - Wiring connector (Wiring loom 0.018.9992.4/10) H002 - Work light control I006 - Ignition switch J006 - Battery disconnect contactor J006a - Battery disconnect contactor J006b - Battery disconnect contactor M002 - Engine ECU M002a - Engine control unit N004 - E.P.B. device N007 - Starter motor N007 - Starter motor “+30” O005 - Diode and resistance board

Table 544 Sys- P/N tem

B016 B017

Description

Fuse (30A) Fuse (30A) 5A Fuse - EPB (F1A/2, +15)

Characteristics/Notes

Position

Wiring loom

40-518 40-518 40-571 40-113

Wiring diagrams Sys- P/N tem

Description

C002

3A Fuse - Work light display (F1A/14, +15) 15A Fuse - Ignition key (F1-A/16, +30) 15A Fuse - Work light display (F1A/18, +30) 30A Fuse - Engine (F2/13-14, +30) Battery negative terminal Engine ground

C003

Cab ground

C004 D009

Negative terminal of the auxiliary battery Wiring connector

D011

Wiring connector

D032

Wiring connector

C001

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571 40-571 40-498 40-498

Fig. 2860

Fig. 2861

40-583 40-571 40-583

Fig. 2862

Fig. 2863

40-114

40-571

40-571 40-590 40-518 40-583

Wiring diagrams Sys- P/N tem

Description

D033

Wiring connector

H002

Work light switch

I006

Starter switch

Characteristics/Notes

Position

Wiring loom

40-518 40-583

Fig. 2864

Fig. 2865

40-571

40-571

83

15

75

Pos

Pin

50

30

86s

30

15

50

75

83

0 1 2 0.015.0485.4

J006

Battery disconnect contactor Battery disconnect contactor

Battery disconnect contactor

Fig. 2867

Fig. 2866

40-518 40-511

Fig. 2868

40-511

Fig. 2869

40-115

Wiring diagrams Sys- P/N tem

Description

M002 02959593

Engine control unit

02959593

Engine control unit

N004 N007

E.P.B. device Starter motor “+30”

O005

Diode and resistance board Battery positive terminal Positive terminal of the auxiliary battery

T001 T004

40-116

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 2870

Fig. 2870

40-571

40-583 40-518 40-511 40-590 40-571 40-511 40-583

Wiring diagrams 40.3.3 - S003 - Preheating

+30

+30

GND

GND

GND

GND

INSTRUMENT

3

5

2

4

6

58

73

+30

6

88

58

7

8

D031

3A

+30

B008

63

D011

C003

+30

M002a

1

30A

Bm013

M002

250A

B001

C003a

A010

INSTRUMENT

150A FUSE PDU3 (INSTRUM. +30)

5

19

GND

12

INSTRUMENT

21

1

2

a

B020

3A

Bb004

+15

A D5

+30

D009

5

b

J032 E002

D0078760

Fig. 2871 - Preheating - System l l l l l l l l l l l l l

A010 - Preheating device D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D011 (M) - Wiring connector (Wiring loom 0.020.8658.4) D011 (F) - Wiring connector (Wiring loom 04218107) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) E002 - Instrument panel J032 - Preheating relay J032a - Preheating relay J032b - Preheating relay M002 - Engine ECU M002a - Engine control unit

40-117

Wiring diagrams Table 545 Sys- P/N tem

A010 04258670

Description

Characteristics/Notes

B001

Preheating device Power supply: 12V Total resistance at 20°C: 0.061 ohms Fuse (250A)

B008

Fuse (3A)

B020

Pre-heating relay supply fuse (150A) 3A Fuse - Cluster (F1-A/4, +15) 30A Fuse - Engine (F2/13-14, +30) Cab ground

C003

Cab ground

D009

Wiring connector

Position

Wiring loom

40-589 40-514

Fig. 2872

Fig. 2873

40-589 40-571 40-571 40-571

Fig. 2874

Fig. 2875

Fig. 2876

40-118

40-514

40-571

40-571 40-583

Wiring diagrams Sys- P/N tem

Description

D011

Wiring connector

D031

Wiring connector

E002

Instrument panel

J032 04216031

Preheating relay

04216031

Preheating relay

04216031 M002 02959593

Preheating relay Engine control unit

02959593

Engine control unit

Characteristics/Notes

Position

Wiring loom

40-571 40-590 40-583 40-514

Fig. 2877

Fig. 2878

Fig. 2879

Fig. 2880

40-571

40-590

40-589 40-590 40-589 40-571

40-571

Fig. 2880

40-119

Wiring diagrams 40.3.4 - S004 - AdBlue M002

59

48

15

47

62

26

3

4

41

92

37

61

80

GND

89

GND

82

GND

5

GND

19

+30

57

+30

70

14

1

3

5

2

4

6

58

C003

30A

Bm013

+30

3A

Bb004

+15

10

+30

M002a

D012

J010

B3

B4

1

3

A5

A4

A3

C2

C1

A1

C7

2

A2

B1

1

2

t

B2

B7

B6

2

1

D8

A7

A8

A6

B8

B5

87a

C3

87

86

85 30

87a

87

86

C002

D6

t

K033

N009

3

2

11

12

8

10

5

9

6

87a

87

86

85

30

5

6

7

J006a

4

J006b 3

b

a

4

2

3

I025

87a

87

86

85 30

J006

Fig. 2881 - AdBlue - System l l l l l l l l l l

10A

30A

1

J007

l

D012 (M) - Wiring connector (Wiring loom 0.018.9992.4/10) D012 (F) - Wiring connector (Wiring loom 0.020.8658.4) I025 - Battery disconnect switch J006 - Battery disconnect contactor J006a - Battery disconnect contactor J006b - Battery disconnect contactor J007 - AdBlue pump control relay J008 - AdBlue pickup line heater power feed relay J009 - AdBlue return line heater power feed relay J010 - AdBlue delivery line heater power feed relay J011 - AdBlue system power feed relay K033 - Exhaust gas temperature sensor

40-120

C002

C002

To Start

2

l

J009

C002

B014

N008

B011

+30

4

15A

B009

C002

K035

30

85

86 87

J011

87a

2

1

2

1

2

1

2

1

L013 O007 O008 O006

85

30

J008 D0068550

Wiring diagrams M002

59

48

15

47

62

26

3

4

41

92

37

61

80

GND

89

GND

82

GND

5

GND

19

1

3

5

2

4

6

58

C003

30A

Bm013

+30

3A

Bb004

+15

57

+30

70

14

+30

10

+30

M002a

D012

J010

B3

B4

1

3

A5

A4

A3

C2

C1

A1

C7

2

A2

B1

1

2

t

B2

B7

B6

2

1

D8

A7

A8

A6

B8

B5

87a

C3

87

86

85 30

87a

87

86

C002

D6

t

K033

N009

3

2

11

12

8

10

5

9

6

87a

87

86

85

30

10A

30A

J009

4

5

6

7

J006a

3

J006b

To Start

b

a

4

2

3

I025

C002

C002

C002 2

B014

N008

B011

+30

4

15A

B009

C002

K035

1

87a

87

86

85 30

30

J007

85

86 87

J011

87a

2

1

2

1

2

1

2

1

L013 O007 O008 O006

85

30

J008 D0068550

J006

Fig. 2881 - AdBlue - System l l l l l l l l l

K035 - AdBlue level sensor L013 - AdBlue heating solenoid valve M002 - Engine ECU M002a - Engine control unit N008 - AdBlue pump N009 - AdBlue dispenser O006 - AdBlue pick-up line with resistance O007 - AdBlue return pipeline with resistance O008 - AdBlue delivery pipeline with resistance

Table 546 Sys- P/N tem

B009

Description

Fuse (15A)

Characteristics/Notes

Position

Wiring loom

40-518 40-121

Wiring diagrams Sys- P/N tem

B011 B014

Description

C002

Fuse (10A) Fuse (30A) 3A Fuse - Cluster (F1-A/4, +15) 30A Fuse - Engine (F2/13-14, +30) Engine ground

C003

Cab ground

D012

Wiring connector

D012

Wiring connector

I025

Battery disconnect switch

Characteristics/Notes

Position

Wiring loom

40-518 40-518 40-571 40-571 40-518

Fig. 2882

Fig. 2883

Fig. 2884

Fig. 2885

4

1

2

3

Pos

Pin

1

2

3

40-571

40-518

40-571

40-518

4

0 1 2.7659.373.0

J006

40-122

Battery disconnect contactor

Fig. 2886

40-518

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

J008 J009 J010 J011 K033 04904050

K035

AD Blue pump control relay AdBlue suction line heater power supply relay AdBlue return line heater power supply relay AdBlue delivery line heater power supply relay AdBlue system power supply relay Exhaust gas temperature sensor

Wiring loom

40-511

Battery disconnect contactor

Fig. 2887

Battery disconnect contactor

J007

Position

Fig. 2888

40-511

40-518 40-518 40-518 40-518 40-518

T (°C)

Rs (Ω)

ΔRs (Ω)

UO (V)

-40

169,7

±1,9

0,725

0

200,5

±1,9

0,835

25

219,6

±1,9

0,900

50

238,5

±1,9

0,963

100

275,9

±1,9

1,081

200

349,0

±1,8

1,293

300

419,7

±1,9

1,478

400

488,1

±2,4

1.640

500

554,1

±2,9

1,783

600

617,8

±3,4

1,909

700

679,2

±3,8

2,022

800

738,2

±4,2

2,123

850

766,8

±4,4

2,170

40-518

04904050

Fig. 2889

AdBlue level sen- Resistance between pin 1 and pin sor 2: with tank full 19,030 -19,850 ohm with tank half full 2,098 - 2,225 ohm with tank empty 215 - 265 ohm

40-518

40-123

Wiring diagrams Sys- P/N tem

Description

L013

AdBlue heating solenoid valve

M002 02959593

Engine control unit

02959593

Engine control unit

N008 04600620 N009 04600619 O006

AdBlue pump AdBlue dispenser AdBlue pick-up line with resistance

O007

AdBlue return pipeline with resistance

Characteristics/Notes

Position

Wiring loom

40-518

Fig. 2890

Fig. 2891

Fig. 2891

Fig. 2892

Fig. 2893

40-124

40-571

40-571

40-518 40-518 40-518

40-518

l

l

l

pos

K001

2

1

2

L007 A C6

P

1

K021

3

freq

M001 A D5 B B8 B A2

2

1

K014 B A5

A C7

2

P

0

1

K027

1

4

3

2

I007

1

1

2

K004 A A6 B D5 A B8

3

1

2

K016

D009

D008

20A

GND

+30 ECU

GND

+15 INSTRUMENT

FUSE PDU3 (INSTRUM.+30)

HYDRAULIC SENSOR EV DF

FRONT AXLE SPEED SENSOR

STEERING PRESS SWITCH

FRONT AXLE SPEED

GND

GND

GND

+30

+30

+30

+15 HLHP

ASM SIGNAL

NO SW

NC SW

+5 HLHP

SEAT SENSOR SIGNAL

SENSOR GND HLHP

SENSOR GND HLHP

SENSOR GND HLHP

OIL TEMP.SENSOR

+5V HLHP

M005

D009

D009

Bm003

A D5

D008

+30

C003

D031

TRANSMISSION

AdBlue delivery pipeline with resistance

GND

A C4

D008

3A 7.5A

Bb005

GND SGR GROUP

7 6 12 3 10 14 13 5 12 21 17 74 76 43 18 2 4 6 1 3 5 8 33 63 64 71 39 31 53 9 10 72

E002

Position

Supply

1

D009

+15

+15

A B5

D008

C002

C003a

+30 SGR

Characteristics/Notes

Signal

3 5A

Bf003

TRANSM.PEDAL SW DIG. CLUTCH

13

M001b

SUPPLY

2

Bb004

+30

TRANSM.PEDAL SW DIG. CLUTCH

Description

SIG.

1 5A

Bb015

D008

+15 TRANSMISSION SGR

O008

GND

D041

+15

+30 15A

Bf001

D008

Sys- P/N tem

SUPPLY

15

SIG.

To fig. 2/2

D008

5A

Bb017

A B6

GND

TRANSM.PEDAL SW DIG. CLUTCH

+15

Wiring diagrams Wiring loom

40-518

Fig. 2894

40.3.5 - S005 - Transmission

M003

A D3

5

3

t

2

1

V

K028

D0068560

Fig. 2895 - Transmission - System (1/2)

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4)

40-125

Wiring diagrams M005

M003

+30 SGR

GND SGR GROUP

TRANSMISSION

GND

+30 ECU

GND

+15 INSTRUMENT

FUSE PDU3 (INSTRUM.+30)

HYDRAULIC SENSOR

EV DF

FRONT AXLE SPEED SENSOR

STEERING PRESS SWITCH

FRONT AXLE SPEED

GND

GND

GND

+30

+30

+30

+15 HLHP

ASM SIGNAL

NO SW

NC SW

+5 HLHP

SEAT SENSOR SIGNAL

SENSOR GND HLHP

SENSOR GND HLHP

SENSOR GND HLHP

OIL TEMP.SENSOR

+5V HLHP

6

12

3

10

14

13

5

12

21

17

74

76

43

18

2

4

6

1

3

5

8

33

63

64

71

39

31

53

9

10

72

A D3

D008

+30

C003

D031

C003a

B A5

D008

A C4

A C6

B B8

B A2

2

1

A C7

D009

D008

D008

D009

D008

3A

7.5A

+15

C002

+15

Bb005

5

Bb004

+30 5A

+15

Bb015

+30

Bm003

D009

5A

Bf003

D008 15A

Bf001

+15

5A

A D5

A B5

Bb017

A B6

D009

TRANSM.PEDAL SW DIG. CLUTCH

7

20A

TRANSM.PEDAL SW DIG. CLUTCH

13

D008

+15 TRANSMISSION SGR

E002

M001b

A A6

B D5

A B8

3

1

2

3

P

freq

L007

K021

K014

Fig. 2895 - Transmission - System (1/2) l l l l l l l l l l l l l l l l

D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D041 (M) - Wiring connector (Wiring loom 0.019.2474.4/10) D041 (F) - Wiring connector (Wiring loom 0.020.8664.4) E002 - Instrument panel I007 - Safety switch K001 - Clutch pedal depressed proximity sensor K004 - Operator present sensor K014 - Front axle speed sensor K016 - Steering angle sensor K021 - Steering circuit pressure switch K027 - Oil tank filter clogging sensor K028 - Oil temperature sensor L007 - Differential lock control solenoid valve M001 - Transmission control unit M001b - Transmission control unit

40-126

4

1 0

3

2

1

1

2

1

P

3

2

1

t V

K001

M001

l

2

GND

1

Supply

2

Signal

1

SUPPLY

2

SIG.

3

1

GND

pos

SUPPLY

2 SIG.

1 GND

TRANSM.PEDAL SW DIG. CLUTCH

15

D041

To fig. 2/2

A D5

K027

I007

K004

K016

K028

D0068560

l

l

l pos

K001 2

1 2

L007

M001 A C6

A D5

1

P

K021 3

freq

B B8 B A2

2 1

K014 A C7

2 0

1

K027 1

4 3

P

2

I007 1 1 2

K004

A A6 B D5 A B8

3 1 2

GND

A C4

D009

D008

D008

+15

+15 3A 7.5A

Bb005

+30

C003

D031

D009

B A5

K016

D009

D008

20A

Bm003

A D5

Supply

1

D009

D008

C002

C003a

5A

Bf003

TRANSM.PEDAL SW DIG. CLUTCH

TRANSM.PEDAL SW DIG. CLUTCH

+30 SGR

GND SGR GROUP

TRANSMISSION

GND

+30 ECU

GND

+15 INSTRUMENT

FUSE PDU3 (INSTRUM.+30)

HYDRAULIC SENSOR EV DF

FRONT AXLE SPEED SENSOR

STEERING PRESS SWITCH

FRONT AXLE SPEED

GND

GND

GND

+30

+30

+30

+15 HLHP

ASM SIGNAL

NO SW

NC SW

+5 HLHP

SEAT SENSOR SIGNAL

SENSOR GND HLHP

SENSOR GND HLHP

SENSOR GND HLHP

OIL TEMP.SENSOR

+5V HLHP

M005

Signal

3

Bb004

+30

A B5

SUPPLY

2 5A

Bb015

D008

+15 TRANSMISSION SGR

7 6 12 3 10 14 13 5 12 21 17 74 76 43 18 2 4 6 1 3 5 8 33 63 64 71 39 31 53 9 10 72

E002

SIG.

D041

+15

+30 15A

Bf001

D008 13

M001b

GND

1

SUPPLY

15

SIG.

To fig. 2/2

D008

5A

Bb017

A B6

GND

TRANSM.PEDAL SW DIG. CLUTCH

+15

Wiring diagrams M003

A D3

5

3

t

2 1

V

K028

D0068560

Fig. 2895 - Transmission - System (1/2)

M003 - HLHP control unit M003 - HLHP unit - USA version M005 - Internal transmission control unit

40-127

Wiring diagrams H003a

H003

K003

K002 pos

NEUTRAL

REVERSE

GND COM TTV SMATIC+TRAM

TUMB WHEEL +5

10

3

1

11 +5V TRANSMITION

FRONT

12

GND COM MOTOR HLHP

13

+5V MOTOR HLHP

18

SIGNAL PEDAL GAS HLHP

10

7

8

4

6

2

4

2

M001a

M001

To fig. 1/2

D001

22

GND COM TUB WHEEL

8

1

ANGLE CLUCT SIGNAL

11

SIG.

3,9 Ω

5

5

GND COM

3,9 Ω

20

3

2

SMART WHEEL SIGNAL

3,9 Ω

19

pos

6

1

SIG.

21

5

GND

18

6

SUPPLY

1

GND

2

SIG.

4

1 0 2

3

SUPPLY

SUPPLY

pos

M001c D0068570

Fig. 2896 - Transmission - System (2/2) l l l l l l l l l l

D001 (M) - Wiring connector (Wiring loom 0.020.8658.4) D001 (F) - Wiring connector (Wiring loom 0.014.0007.4/20) H003 - Shuttle control lever H003a - Shuttle control lever I007 - Safety switch K002 - Clutch pedal position sensor K003 - Accelerator pedal position sensor M001 - Transmission control unit M001a - Transmission control unit M001c - Transmission control unit

Table 547 Sys- P/N tem

40-128

Description

3A Fuse - Cluster (F1-A/4, +15)

Characteristics/Notes

Position

Wiring loom

40-571

Wiring diagrams Sys- P/N tem

Description

C002

7.5A Fuse - HLHP control unit (F1-A/5, +15) 5A Fuse - Transmission (F1-A/15, +15) 5A Fuse - SGR Transmission (F1A/17, +15) 7.5A Fuse - SGR Transmission (F1A/1, +30) 5A Fuse - Transmission control unit (F1-B/3, +30) 20A Fuse - HLHP control unit (F2/3-6, +30) Engine ground

C003

Cab ground

Cab ground

D001

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571 40-571 40-571 40-571 40-576

Fig. 2897

Fig. 2898

Fig. 2899

40-571

40-571

40-496 40-571

Fig. 2900

40-129

Wiring diagrams Sys- P/N tem

Description

D008

Wiring connector

D009

Wiring connector

D031

Wiring connector

D041

Wiring connector

E002

Instrument panel

H003

Shuttle control lever Shuttle control lever

40-130

Characteristics/Notes

Position

Wiring loom

40-571 40-576

Fig. 2901

Fig. 2902

Fig. 2903

Fig. 2904

Fig. 2905

40-571 40-583

40-583 40-514

40-531 40-576

40-571

40-496 40-496

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

I007

Safety switch

K001

Clutch pedal pressed proximity sensor

K002

Clutch pedal posi- Pin 1 = power (Nominal 5.0V) Pin 2 = ground tion sensor Pin 4 = analogue signal

Position

Wiring loom

40-571

Fig. 2906

Fig. 2907

40-571

40-571

Table 548 Sys- P/N tem

K003

K004

K014 K016

Description

Characteristics/Notes

Accelerator pedal Sensor N°1 Pin 1 = 5.0Vdc power position sensor Pin 2 = ground Pin 4 = 0.5V - 4.5V analogue signal Sensor N°2 Pin 6 = 5.0Vdc power Pin 5 = ground Pin 3 = 0.5V - 4.5V analogue signal Operator present sensor

Front axle speed sensor Steering angle sen- Pin 1 = signal Pin 2 = 5V power sor Pin 3 = ground Voltage on pin 1 with wheels straight 2.5V ± 0.1V

Position

Wiring loom

40-571

Fig. 2909

40-571

Fig. 2910

40-583 40-583

40-131

Wiring diagrams Sys- P/N tem

K021

K027 K028 04416649

L007

M001

Description

Characteristics/Notes

Position

Wiring loom

40-576

Steering

system Normally closed (NC) contact Switching pressure: 5 bar ± 0.7 Oil tank filter clogging sensor Oil temperature Resistance between pin 1 and pin sensor 2: at 25°C 1000 ± 15 ohms at 100°C 1696 ± 35 ohms at 150°C 2211 ± 80 Ohms Differential lock control solenoid valve

Transmission control unit

Transmission control unit

Transmission control unit

Transmission control unit

40-576 40-576

40-531

Fig. 2911

Fig. 2912

Fig. 2912

Fig. 2912

Fig. 2912

40-132

40-571

40-571

40-571

40-571

Wiring diagrams Sys- P/N tem

Description

M003

HLHP unit

M003

HLHP unit - USA version

M005

Internal transmission control unit

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 2913

Fig. 2913

40-571

40-576

40-133

Wiring diagrams 40.3.6 - S005A - Transmission - Version with performance steering M005

M003

+30 SGR

GND SGR GROUP

TRANSMISSION

GND

+30 ECU

GND

+15 INSTRUMENT

FUSE PDU3 (INSTRUM.+30)

HYDRAULIC SENSOR

EV DF

FRONT AXLE SPEED SENSOR

STEERING PRESS SWITCH

FRONT AXLE SPEED

GND

GND

GND

+15 HLHP

+30

+30

+30

ASM SIGNAL

NO SW

NC SW

+5 HLHP

SEAT SENSOR SIGNAL

SENSOR GND HLHP

SENSOR GND HLHP

SENSOR GND HLHP

OIL TEMP.SENSOR

+5V HLHP

6

12

3

10

14

13

5

12

21

17

74

76

43

18

2

4

6

8

1

3

5

33

63

64

71

39

31

53

9

10

72

A D3

D008 B A5

+30

C003

D031

C003a

B D5

D008 A C6

B B8

B A2

1

A C7

2

3

A B8

K016

D008

D008

D009

A A6

A C4

D008

D009

7.5A

3A

+15

C002

+15

Bb005

5

Bb004

+30 5A

+15

Bb015

+30

Bm003

D009

5A

Bf003

D008 15A

Bf001

+15

5A

A D5

A B5

Bb017

A B6

D009

TRANSM.PEDAL SW DIG. CLUTCH

7

20A

TRANSM.PEDAL SW DIG. CLUTCH

13

D008

+15 TRANSMISSION SGR

E002

M001b

2

1

2

3

4

1 0

3

K001

L007

K021

K014

K027

I007

Fig. 2914 - Transmission - Version with performance steering - System (1/2) l l l l l l l l l l l l l l l

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D041 (M) - Wiring connector (Wiring loom 0.019.2474.4/10) D041 (F) - Wiring connector (Wiring loom 0.020.8664.4) E002 - Instrument panel I007 - Safety switch K001 - Clutch pedal depressed proximity sensor K004 - Operator present sensor K014 - Front axle speed sensor K016 - Wiring connector K021 - Steering circuit pressure switch K027 - Oil tank filter clogging sensor

40-134

1

6

4

5

1

V

M001

l

2

1

P

2

3 GND

2

Supply

1

Signal

2 freq

GND

3

Supply

1 P

Signal

2

SUPPLY

1

To ISO 11783

SIG.

3

2

GND

pos

SUPPLY

2 SIG.

1 GND

TRANSM.PEDAL SW DIG. CLUTCH

15

K028

K004

D041

To fig. 2/2

A D5

1

1

t

V

K038

D0078750

l

l

l

l

l

l

l

l pos

K001 L007 1

P

K021 3

freq

2 1

K014 A C7

2 0

1

K027 1

1

4 3

P

M001 2

I007 1 2

6

3 1

4 5

2

1

V GND

2 B A2 B D5

Supply

1 B B8

K016

A A6

Signal

2 A C6

GND

A C4

D008

+15

D009

D008

+15

3A 7.5A

Bb005

+30

C003

D031

D009

2

D009

D008

20A

Bm003

A D5

Supply

1

D009

D008

C002

Bb004

5A

Bf003

TRANSM.PEDAL SW DIG. CLUTCH

TRANSM.PEDAL SW DIG. CLUTCH

+30 SGR

GND SGR GROUP

TRANSMISSION

GND

+30 ECU

GND

+15 INSTRUMENT

FUSE PDU3 (INSTRUM.+30)

HYDRAULIC SENSOR EV DF

FRONT AXLE SPEED SENSOR

STEERING PRESS SWITCH

FRONT AXLE SPEED

GND

GND

GND

+15 HLHP

+30

+30

+30

ASM SIGNAL

NO SW

NC SW

+5 HLHP

SEAT SENSOR SIGNAL

SENSOR GND HLHP

SENSOR GND HLHP

SENSOR GND HLHP

OIL TEMP.SENSOR

+5V HLHP

M005

Signal

3

C003a

+30

A B5

SUPPLY

2 5A

Bb015

D008

+15 TRANSMISSION SGR

7 6 12 3 10 14 13 5 12 21 17 74 76 43 18 2 4 6 8 1 3 5 33 63 64 71 39 31 53 9 10 72

E002

SIG.

D041

+15

+30 15A

Bf001

D008 13

M001b

GND

1

SUPPLY

15

SIG.

To fig. 2/2

D008

5A

Bb017

A B6

GND

TRANSM.PEDAL SW DIG. CLUTCH

+15

Wiring diagrams M003

B A5 A D3

5

A B8

3 2

A D5

K004

1

t

K028

To ISO 11783

3

K038 V

D0078750

Fig. 2914 - Transmission - Version with performance steering - System (1/2)

K028 - Oil temperature sensor K038 - Steering angle sensor (Agrosky) L007 - Differential lock control solenoid valve M001 - Transmission control unit M001b - Transmission control unit M003 - HLHP control unit M003 - HLHP unit - USA version M005 - Internal transmission control unit

40-135

Wiring diagrams H003a

H003

K003

K002 pos

NEUTRAL

REVERSE

GND COM TTV SMATIC+TRAM

TUMB WHEEL +5

10

3

1

11 +5V TRANSMITION

FRONT

12

GND COM MOTOR HLHP

13

+5V MOTOR HLHP

18

SIGNAL PEDAL GAS HLHP

10

7

8

4

6

2

4

2

M001a

M001

To fig. 1/2

D001

22

GND COM TUB WHEEL

8

1

ANGLE CLUCT SIGNAL

11

SIG.

3,9 Ω

5

5

GND COM

3,9 Ω

20

3

2

SMART WHEEL SIGNAL

3,9 Ω

19

pos

6

1

SIG.

21

5

GND

18

6

SUPPLY

1

GND

2

SIG.

4

1 0 2

3

SUPPLY

SUPPLY

pos

M001c D0068570

Fig. 2915 - Transmission - Version with performance steering - System (2/2) l l l l l l l l l

D001 (M) - Wiring connector (Wiring loom 0.020.8658.4) D001 (F) - Wiring connector (Wiring loom 0.014.0007.4/20) H003 - Shuttle control lever H003a - Shuttle control lever K002 - Clutch pedal position sensor K003 - Accelerator pedal position sensor M001 - Transmission control unit M001a - Transmission control unit M001c - Transmission control unit

Table 549 Sys- P/N tem

40-136

Description

3A Fuse - Cluster (F1-A/4, +15)

Characteristics/Notes

Position

Wiring loom

40-571

Wiring diagrams Sys- P/N tem

Description

C002

7.5A Fuse - HLHP control unit (F1-A/5, +15) 5A Fuse - Transmission (F1-A/15, +15) 5A Fuse - SGR Transmission (F1A/17, +15) 7.5A Fuse - SGR Transmission (F1A/1, +30) 5A Fuse - Transmission control unit (F1-B/3, +30) 20A Fuse - HLHP control unit (F2/3-6, +30) Engine ground

C003

Cab ground

Cab ground

D001

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571 40-571 40-571 40-571 40-576

Fig. 2916

Fig. 2917

Fig. 2918

40-571

40-571

40-496 40-571

Fig. 2919

40-137

Wiring diagrams Sys- P/N tem

Description

D008

Wiring connector

D009

Wiring connector

D031

Wiring connector

D041

Wiring connector

E002

Instrument panel

H003

Shuttle control lever Shuttle control lever

40-138

Characteristics/Notes

Position

Wiring loom

40-571 40-576

Fig. 2920

Fig. 2921

Fig. 2922

Fig. 2923

Fig. 2924

40-571 40-583

40-583 40-514

40-531 40-576

40-571

40-496 40-496

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

I007

Safety switch

K001

Clutch pedal pressed proximity sensor

K002

Clutch pedal posi- Pin 1 = power (Nominal 5.0V) Pin 2 = ground tion sensor Pin 4 = analogue signal

Position

Wiring loom

40-571

Fig. 2925

Fig. 2926

40-571

40-571

Table 550 Sys- P/N tem

K003

K004

K014 K016 K021 K027

Description

Characteristics/Notes

Accelerator pedal Sensor N°1 Pin 1 = 5.0Vdc power position sensor Pin 2 = ground Pin 4 = 0.5V - 4.5V analogue signal Sensor N°2 Pin 6 = 5.0Vdc power Pin 5 = ground Pin 3 = 0.5V - 4.5V analogue signal Operator present sensor

Front axle speed sensor Wiring connector Steering system Normally closed (NC) contact Switching pressure: 5 bar ± 0.7 Oil tank filter clogging sensor

Position

Wiring loom

40-571

Fig. 2928

40-571

Fig. 2929

40-583 40-540 40-576 40-576 40-139

Wiring diagrams Sys- P/N tem

K028 04416649

K038 L007

M001

Description

Characteristics/Notes

Position

Wiring loom

40-576

Oil temperature Resistance between pin 1 and pin sensor 2: at 25°C 1000 ± 15 ohms at 100°C 1696 ± 35 ohms at 150°C 2211 ± 80 Ohms Steering angle sensor (Agrosky) Differential lock control solenoid valve

Transmission control unit

Transmission control unit

Transmission control unit

Transmission control unit

40-540 40-531

Fig. 2930

Fig. 2931

Fig. 2931

Fig. 2931

Fig. 2931

40-140

40-571

40-571

40-571

40-571

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

M003

HLHP unit

M003

HLHP unit - USA version

M005

Internal transmission control unit

Position

Wiring loom

40-571

Fig. 2932

Fig. 2932

40-571

40-576

40.3.7 - S006 - Front axle suspension

7

2

4

5

6

1

2

1

2

1

2

1

Bb005

2

3

5

1

L003 L004 L002

SIG. pos

SUPPLY

GND

D037

+15

C002

7.5A

3

D009

2

+30

1

+30

3

4

20A

A B8

6

+30

A C3

+30

B A5

8

Bm003

A C4

9

GND

A C6

31

C003

A C5

53

GND

34

GND

70

HLHP

FRONT AXLE POS.SENS.

75

SENSOR GND HLHP

+5V HLHP

82

SENSOR GND HLHP

EV LS F.A.

EV DOWN F.A.

83

SENSOR GND HLHP

EV UP F.A.

M003

K019

D0068580

Fig. 2933 - Front axle suspension - System l l l

D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D037 (M) - Wiring connector (Wiring loom 0.021.0396.4) 40-141

Wiring diagrams

7

2

4

5

6

1

2

1

2

1

2

1

Bb005

3

5

1

L003 L004 L002

SIG. pos

SUPPLY

GND

D037

+15

C002

2

7.5A

3

D009

2

+30

1

+30

3

4

20A

A B8

6

+30

A C3

+30

B A5

8

Bm003

A C4

9

GND

A C6

31

C003

A C5

53

GND

34

GND

70

HLHP

FRONT AXLE POS.SENS.

75

SENSOR GND HLHP

+5V HLHP

82

SENSOR GND HLHP

EV LS F.A.

EV DOWN F.A.

83

SENSOR GND HLHP

EV UP F.A.

M003

K019

D0068580

Fig. 2933 - Front axle suspension - System l l l l l l l

D037 (F) - Wiring connector (Wiring loom 0.015.3974.4/10) K019 - Front axle suspension position sensor L002 - Front axle ‘Down’ control coil L003 - Front axle ‘Up’ control coil L004 - Front axle suspension Load Sensing control coil M003 - HLHP control unit M003 - HLHP unit - USA version

Table 551 Sys- P/N tem

C002

Description

Characteristics/Notes

Position

Wiring loom

40-571

7.5A Fuse - HLHP control unit (F1-A/5, +15) 20A Fuse - HLHP control unit (F2/3-6, +30) Engine ground

40-571 40-583

Fig. 2934

40-142

Wiring diagrams Sys- P/N tem

Description

C003

Cab ground

D009

Wiring connector

D037

Wiring connector

K019

Front axle suspen- Pin 1 = ground sion position sen- Pin 2 = signal output Pin 3 = 10Vdc power sor Output 0.2Vdc (sensor released) Output 8.3Vdc (sensor fully depressed) Front axle ‘Down’ control coil Front axle “Up” control coil Front axle suspension Load Sensing control coil HLHP unit

L002 L003 L004 M003

M003

HLHP unit - USA version

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 2935

Fig. 2936

40-571 40-583

40-499 40-583 40-499

40-499 40-499 40-499 40-571

Fig. 2937

40-571

Fig. 2937

40-143

Wiring diagrams 40.3.8 - S007 - Instrument panel

2

1

GND

GND

+30

+30

+30

5

1

30A

Bm013

C003

C002

3A

1 0

1

P

Level

Signal

2

GND

D+

SUPPLY

+30

B008

+30

5

A001a

D0068590

K012

K010

K013

M002

Fig. 2938 - Instrument panel - System l l l l l l l l l l l l l l l

A001a - Alternator “D+” D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) E002 - Instrument panel H001 - Armrest K010 - Fuel level sensor K012 - Air filter clogging sensor K013 - Engine coolant level sensor M002 - Engine ECU M003 - HLHP control unit M003 - HLHP unit - USA version

40-144

20A

GND

3

Bm003

HLHP

2

C003

3A

Bb004

4

7.5A

1

SENSOR GND HLHP

3

6

Bb005

5

SENSOR GND HLHP

2

+5V HLHP

4

8

+30

1

31

+15

B B3

53

+30

A C2

+5V HLHP

6

+30

SENSOR GND HLHP

58

+30

+30 ARMREST

36

C003a

B B4

+15

B B3

72

15A

57

+30

A B6

18

D031

A D5

+30 ARMREST

62

D009

D008 A C5

Bf005

81

GND

12

+15 CUSTER

3

GND

26

GND

HENTER

25

GND

ESCAPE

2

GND

DECREMENT

+15 INSTRUMENT

23

16

10

GND

INCREMENT

24

15

DECREMENT

ESCAPE

9

14

INCREMENT

ENTER

5

13

9

ENGINE PRESSURE

ENGINE PRESSURE

13

12

8

COLLANT LEVEL

GND

8

11

7

COLLANT LEVEL

TANK INDICATOR

21

M003

COLLANT LEVEL

AIR FILTER

7

C003a

FUSE PDU3

H001

D+

E002

Wiring diagrams Table 552 Sys- P/N tem

Description

B008

C002

Fuse (3A) 3A Fuse - Cluster (F1-A/4, +15) 7.5A Fuse - HLHP control unit (F1-A/5, +15) 15A Fuse - Armrest (F1-B/5, +30) 20A Fuse - HLHP control unit (F2/3-6, +30) 30A Fuse - Engine (F2/13-14, +30) Engine ground

C003

Cab ground

Characteristics/Notes

Position

Wiring loom

40-576

Alternator “D+”

Cab ground

Fig. 2939

40-514 40-571 40-571 40-571 40-571 40-571 40-583

Fig. 2940

Fig. 2941

40-571

40-571

Fig. 2942

40-145

Wiring diagrams Sys- P/N tem

Description

D008

Wiring connector

D009

Wiring connector

D031

Wiring connector

E002

Instrument panel

H001

Armrest

K010

Fuel level sensor

K012

Air cleaner clogged sensor Engine coolant level sensor

K013

40-146

Characteristics/Notes

Position

Wiring loom

40-571 40-576

Fig. 2943

Fig. 2944

Fig. 2945

Fig. 2946

Resistance between pin 1 and pin 2: with tank full 177÷197 Ohm with tank half full 58.5÷66 Ohm with tank empty 3.5÷5.5 Ohm

Fig. 2947

40-571 40-583

40-583 40-514

40-571

40-571

40-583

40-583 40-583

Wiring diagrams Sys- P/N tem

Description

M002 02959593

Engine control unit

M003

HLHP unit

M003

HLHP unit - USA version

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 2948

Fig. 2949

40-571

40-571

Fig. 2949

40-147

Wiring diagrams 40.3.9 - S008 - Lights – Version without front hitch Jd006

Jh003

87 86 85

30

87a

87 86 85

30

D009

87a

B A1

Jh001

F024

LOW BEAM HIGH BEAM CONTROL

Jh004

To fig. 2/2

F026

Jh006

C003a

A D1

Jh005 87 86 85

87a

30

87 86 85

87a

30

D001

15A

Bf014

7.5A

Bf013

7.5A

Bf011

Bf010

4

10 11

+30

15A

Bf009

C003a

To fig. 2/2

D052 2

30

A D8

5A

A D7

5

D001

1

87 86 85

87a

FL/AL LH 0

D009

D023

1

Bf007

To ISO 11783

1

+30

D026

To ISO 11783

To fig. 2/2

D013

1

2

3

85 30

D052

86

15A

2

87

C003a

87a

13

14

23

5

6

12

16

21

H002

D044

D003

P006

3

C002

D008

C003a

C002

To ISO 11783

D009 D034

D009

3

11

FUSE PDU3 (INSTRUM.+30)

5

2

FULL BEAM LIGHT

7

1

+15 INSTRUMENT

I009

3

3A

Bb004

C003a

+15

D031

3A

B008

3A

Bb014

5A

Bf018 1

GND

2

POSITION

10

+58

9

3

+15 WOLP

I008

6

2 7

+30 WOLP

5

D013

+30

+15

+30

D006 To fig. 2/2

C003 3

B B3

A A2

5

GND

2

A A3

A D5

FULL BEAM LIGHT

8

5

+30 WOLP

7

2

1

C003a

5A

Bf012

+30 5A

Bf011

3

+15

9

C003a

10

D001

D013

+30

+30

5

3

2

F005

1

3

6

58L

31

P015

E002 D0078300

Fig. 2950 - Lights – Version without front hitch - System (1/2) l l l l l l l l l

D001 (M) - Wiring connector (Wiring loom 0.020.8658.4) D001 (F) - Wiring connector (Wiring loom 0.014.0007.4/20) D003 (M) - Wiring connector (Wiring loom 0.019.2379.4/20) D003 (F) - Wiring connector (Wiring loom 0.020.8658.4) D006 (M) - Wiring connector (Wiring loom 0.019.2379.4/20) D006 (F) - Wiring connector (Wiring loom 0.020.8658.4) D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4)

40-148

Wiring diagrams l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l

D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D013 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D013 (F) - Wiring connector (Wiring loom 0.020.8658.4) D023 (M) - Wiring connector (Wiring loom 0.020.8658.4) D023 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D026 (M) - Wiring connector (Wiring loom 0.020.8658.4) D026 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D034 (M) - Wiring connector (Wiring loom 0.017.8425.4/10) D034 (F) - Wiring connector (Wiring loom 0.021.0396.4) D044 (M) - Wiring connector (Wiring loom 0.015.5429.4/20) D044 (F) - Wiring connector (Wiring loom 0.020.8664.4) D052 (M) - Wiring connector (Wiring loom 0.019.2378.4/40) D052 (F) - Wiring connector (Wiring loom 0.012.2018.4/20) E002 - Instrument panel F005 - Left hand sidelight F024 - Left hand rear sidelight F026 - License plate light H002 - Work light control I008 - Road lights switch I009 - Top lights switch Jd006 - Same bonnet relay (R4/6) Jh001 - Road lights/Top lights relay (R3/1) Jh003 - Road lights/Top lights relay (R3/3) Jh004 - High beam relay (R3/4) Jh005 - Sidelights relay (R3/5) Jh006 - Low beam relay (R3/6) P006 - Trailer socket P015 - Front implement power outlet socket

40-149

Wiring diagrams

F020

2

5

1

3

17

C003a

C003a

12

15

1

2

A D8

To fig. 1/2

D009 A D1

A D7

D036

D006

B A1

C002

C002

D009

A B7

To fig. 1/2

To fig. 1/2

D009

+15

To fig. 1/2

15A

12

Bb003

1

D026

D001

HORN CONTROL

16

1

2

1

E004

2

F009

13

1

F008

1

2

F007

1

2

F010

2

3

3

2

1

F003

D0078740

Fig. 2951 - Lights – Version without front hitch - System (2/2) l l l l l l l l l l l l l l l

D001 (M) - Wiring connector (Wiring loom 0.020.8658.4) D001 (F) - Wiring connector (Wiring loom 0.014.0007.4/20) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D026 (M) - Wiring connector (Wiring loom 0.020.8658.4) D026 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D036 (M) - Wiring connector (Wiring loom 0.021.0396.4) D036 (F) - Wiring connector (Wiring loom 0.019.2383.4/20) E004 - Horn F003 - Right hand sidelight F007 - Right hand high beam headlight F008 - Right hand low beam headlight F009 - Left hand low beam headlight F010 - Left hand high beam headlight F020 - RH rear sidelight

40-150

Wiring diagrams Table 553 Sys- P/N tem

B008

Bf011

Bf011

C002

Description

Characteristics/Notes

Position

Wiring loom

40-514 40-571

Fuse (3A) 15A Fuse - Windscreen wiper (F1A/3, +15) 3A Fuse - Cluster (F1-A/4, +15) 3A Fuse - Work light display (F1A/14, +15) 15A Fuse - Lights relay protection (F1-B/7, +30) 15A Fuse - Lights relay protection (F1-B/9, +30) 7.5A Fuse - Left hand sidelights (F1B/10, +30) 5A Fuse - Road lights/Top lights relay protection (F1B/11, +30) 5A Fuse - Road lights/Top lights relay protection (F1B/11, +30) 5A Fuse - Lights (F1-B/12, +15) 7.5A Fuse - Right hand sidelights (F1B/13, +30) 15A Fuse - Sidelights relay protection (F1-B/14, +30) 15A Fuse - Work light display (F1A/18, +30) Engine ground

40-571 40-571 40-571 40-571 40-571 40-571

40-571

40-571 40-571 40-571 40-571 40-583

Fig. 2952

40-151

Wiring diagrams Sys- P/N tem

C003

Description

Characteristics/Notes

Position

Wiring loom

40-571

Cab ground

Cab ground

D001

Wiring connector

D003

Wiring connector

D003

Wiring connector

D006

Wiring connector

Fig. 2953

Fig. 2954

Fig. 2955

Fig. 2956

Fig. 2957

Fig. 2958

40-152

40-571

40-496 40-571

40-571

40-524

40-571

Wiring diagrams Sys- P/N tem

Description

D006

Wiring connector

D008

Wiring connector

D009

Wiring connector

D013

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-526

Fig. 2959

Fig. 2960

Fig. 2961

Fig. 2962

D023

Wiring connector

Fig. 2963

40-571 40-576

40-571 40-583

40-571

40-537

40-571 40-520

Fig. 2964

40-153

Wiring diagrams Sys- P/N tem

D026

Description

Characteristics/Notes

Position

Wiring loom

40-571 40-522

Wiring connector

Fig. 2965

Table 554 Sys- P/N tem

Description

D031

Wiring connector

D034

Wiring connector

D036

Wiring connector

D044

Wiring connector

D052

Wiring connector

E002

Instrument panel

E004 01169304

Horn

40-154

Characteristics/Notes

Position

Wiring loom

40-583 40-514

Fig. 2966

Fig. 2967

Fig. 2968

Fig. 2969

40-583 40-507

40-529 40-583

40-500 40-576 40-496 40-520 40-571

40-529

Wiring diagrams Sys- P/N tem

Description

F003

RH sidelight

F005

LH sidelight

F007

F026 04414115 H002

RH high beam headlight RH low beam headlight LH low beam headlight LH high beam headlight Right hand rear sidelight Left hand rear sidelight License plate light Work light switch

I008

Road lights switch

F008 F009 F010 F020 F024

Characteristics/Notes

Position

Wiring loom

40-526

Fig. 2970

Fig. 2971

40-524

40-529 40-529 40-529 40-529 40-522 40-520 40-496 40-571

Fig. 2972

40-571

0 1 2

Pos

Pin

1

2

3

4

5

6

7

4

5

6

9

8

1

2

3

10

7

8

9

10

0 1 2 2.7659.376.0

Fig. 2974

Fig. 2973

40-155

Wiring diagrams Sys- P/N tem

I009

Description

Characteristics/Notes

Position

Wiring loom

40-571

Top lights switch 0 1

Pos

Pin

1

2

3

4

5

7

4

5

6

9

8

1

2

3

10

6

7

8

0 1

2.7659.377.0

P006 P015

40-156

Same bonnet relay (R4/6) Road lights/Top lights relay (R3/1) Road lights/Top lights relay (R3/3) High beam relay (R3/4) Sidelights relay (R3/5) Low beam relay (R3/6) Trailer socket Front implement power outlet socket

Fig. 2975

Fig. 2976

40-571 40-571 40-571 40-571 40-571 40-571 40-507 40-500

Wiring diagrams 40.3.10 - S009 - Lights – Version with front hitch Jd006

Jh003

87 86 85

30

87 86 85

87a

30

D009

87a

B A1

Jh006

Jh001

F024

LOW BEAM HIGH BEAM CONTROL

Jh004

To fig. 2/2

F026

C003a

A D1

Jh005 87 86 85

30

87a

87 86 85

30

D006

D003

D003

4

4

D001

D001

+30

D013

+30 3

13

14

23

5

6

12

16

21

P006

C002

D008 To fig. 2/2

D044

D003 3

11

C003a

C002

To ISO 11783

D009 D034

B008

D009

5

2

H002

2

7

1

FULL BEAM LIGHT

I009

1

FUSE PDU3 (INSTRUM.+30)

2

+15 INSTRUMENT

8

GND

7

POSITION

10

+58

9

B B3

A A2

3

+15 WOLP

I008

6

A A3

7

+30 WOLP

5

3A

Bb004

C003a

+15

D031

3A

Bb014

5A

Bf018

To fig. 2/2

C003a

C003 3

2

5

GND

2

1

A D5

FULL BEAM LIGHT

8

5

+30 WOLP

7

3A

+30

+15

+30

D006 3

C003a

D013

D001

+15 5A

Bf012

5A

Bf011

+30

9

15A

Bf014

Bf011

4

+30

15A

Bf009

To fig. 2/2

C003a

10 11

To ISO 11783

5

10

30

1

To fig. 2/2

D052

To fig. 2/2

+30

2

87 86 85

7.5A

D009

D006

D052

C003a

A D7

Bf007

15A

A D8

1

1

To ISO 11783

To fig. 2/2

2

D026

D013 1

5

1

87a

FL/AL LH 0

7.5A

87a

Bf013

1

Bf010

2

3

85 30

D023

86

5A

87

87a

3

3

2

F005

1

3

6

58L

31

P015

E002 D0078310

Fig. 2977 - S009 - Lights – Version with front hitch - System (1/2) l l l l l l l l l l

D001 (M) - Wiring connector (Wiring loom 0.020.8658.4) D001 (F) - Wiring connector (Wiring loom 0.014.0007.4/20) D003 (M) - Wiring connector (Wiring loom 0.019.2379.4/20) D003 (F) - Wiring connector (Wiring loom 0.020.8658.4) D006 (M) - Wiring connector (Wiring loom 0.019.2379.4/20) D006 (F) - Wiring connector (Wiring loom 0.020.8658.4) D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) 40-157

Wiring diagrams Jd006

Jh003

87 86 85

30

87 86 85

87a

30

D009

87a

B A1

Jh001

F024

LOW BEAM HIGH BEAM CONTROL

Jh004

To fig. 2/2

F026

Jh006

C003a

A D1

Jh005 87 86 85

30

87a

87 86 85

30

4

4

D001

D001 3

13

14

23

5

6

12

16

21

P006

D044

To fig. 2/2

C002

D008

C003a

C002

D003 3

11

3

3

2

F005

1

3

6

58L

31

P015

E002 D0078310

Fig. 2977 - S009 - Lights – Version with front hitch - System (1/2) l l l l l l l l l l l l

D013 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D013 (F) - Wiring connector (Wiring loom 0.020.8658.4) D023 (M) - Wiring connector (Wiring loom 0.020.8658.4) D023 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D026 (M) - Wiring connector (Wiring loom 0.020.8658.4) D026 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D034 (M) - Wiring connector (Wiring loom 0.017.8425.4/10) D034 (F) - Wiring connector (Wiring loom 0.021.0396.4) D044 (M) - Wiring connector (Wiring loom 0.015.5429.4/20) D044 (F) - Wiring connector (Wiring loom 0.020.8664.4)

40-158

15A

Bf014

D013 To ISO 11783

D009 D034

B008

D009

5

2

H002

2

7

1

FULL BEAM LIGHT

I009

1

FUSE PDU3 (INSTRUM.+30)

2

+15 INSTRUMENT

8

GND

7

POSITION

10

+58

9

B B3

A A2

3

+15 WOLP

I008

6

A A3

7

+30 WOLP

5

3A

Bb004

C003a

+15

D031

3A

Bb014

5A

Bf018

To fig. 2/2

C003 3

2

5

GND

2

1

A D5

FULL BEAM LIGHT

8

5

+30 WOLP

7

3A

+30

+15

+30

D006 3

C003a

+15 5A

Bf012

5A

Bf011

+30

9

C003a

D013

D001

+30

+30

+30

Bf011

4

7.5A

15A

Bf009

To fig. 2/2

C003a

10 11

To ISO 11783

5

10

30

1

To fig. 2/2

D052

To fig. 2/2

+30

2

87 86 85

87a

FL/AL LH 0

D006

D003

D003

D009

D006

D052

C003a

A D7

Bf007

15A

A D8

1

1

To ISO 11783

To fig. 2/2

2

D026

D013 1

5

1

7.5A

87a

Bf013

1

Bf010

2

3

85 30

D023

86

5A

87

87a

Wiring diagrams Jd006

Jh003

87 86 85

30

87 86 85

87a

30

D009

87a

B A1

Jh001

F024

LOW BEAM HIGH BEAM CONTROL

Jh004

To fig. 2/2

F026

Jh006

C003a

A D1

Jh005 87 86 85

30

87a

87 86 85

30

4

4

D001

D001 3

15A

Bf014

D013

13

14

23

5

6

12

16

21

P006

C002

D008 To fig. 2/2

D044

D003 3

11

C003a

C002

To ISO 11783

D009 D034

B008

D009

5

2

H002

2

7

1

FULL BEAM LIGHT

I009

1

FUSE PDU3 (INSTRUM.+30)

2

+15 INSTRUMENT

8

GND

7

POSITION

10

+58

9

B B3

A A2

3

+15 WOLP

I008

6

A A3

7

+30 WOLP

5

3A

Bb004

C003a

+15

D031

3A

Bb014

5A

Bf018

To fig. 2/2

C003 3

2

5

GND

2

1

A D5

FULL BEAM LIGHT

8

5

+30 WOLP

7

3A

+30

+15

+30

D006 3

C003a

+15 5A

Bf012

5A

Bf011

+30

9

C003a

D013

D001

+30

+30

+30

Bf011

4

7.5A

15A

Bf009

To fig. 2/2

C003a

10 11

To ISO 11783

5

10

30

1

To fig. 2/2

D052

To fig. 2/2

+30

2

87 86 85

87a

FL/AL LH 0

D006

D003

D003

D009

D006

D052

C003a

A D7

Bf007

15A

A D8

1

1

To ISO 11783

To fig. 2/2

2

D026

D013 1

5

1

7.5A

87a

Bf013

1

Bf010

2

3

85 30

D023

86

5A

87

87a

3

3

2

F005

1

3

6

58L

31

P015

E002 D0078310

Fig. 2977 - S009 - Lights – Version with front hitch - System (1/2) l l l l l l l l l l l l

D052 (M) - Wiring connector (Wiring loom 0.019.2378.4/40) D052 (F) - Wiring connector (Wiring loom 0.012.2018.4/20) E002 - Instrument panel F005 - Left hand sidelight F024 - Left hand rear sidelight F026 - License plate light H002 - Work light control I008 - Road lights switch I009 - Top lights switch Jd006 - Same bonnet relay (R4/6) Jh001 - Road lights/Top lights relay (R3/1) Jh003 - Road lights/Top lights relay (R3/3) 40-159

Wiring diagrams Jd006

Jh003

87 86 85

30

87 86 85

87a

30

D009

87a

B A1

Jh001

F024

LOW BEAM HIGH BEAM CONTROL

Jh004

To fig. 2/2

F026

Jh006

C003a

A D1

Jh005 87 86 85

30

87a

87 86 85

30

4

4

D001

D001 3

I009

13

14

23

5

6

12

16

21

P006

D044

To fig. 2/2

C002

D008

C003a

C002

D003 3

11

3

3

2

F005

1

3

6

58L

31

P015

E002 D0078310

Fig. 2977 - S009 - Lights – Version with front hitch - System (1/2) l l l l l

Jh004 - High beam relay (R3/4) Jh005 - Sidelights relay (R3/5) Jh006 - Low beam relay (R3/6) P006 - Trailer socket P015 - Front implement power outlet socket

40-160

15A

Bf014

D013 To ISO 11783

D009 D034

B008

D009

5

2

H002

2

7

1

FULL BEAM LIGHT

1

FUSE PDU3 (INSTRUM.+30)

2

+15 INSTRUMENT

8

GND

7

POSITION

10

+58

9

B B3

A A2

3

+15 WOLP

I008

6

A A3

7

+30 WOLP

5

3A

Bb004

C003a

+15

D031

3A

Bb014

5A

Bf018

To fig. 2/2

C003 3

2

5

GND

2

1

A D5

FULL BEAM LIGHT

8

5

+30 WOLP

7

3A

+30

+15

+30

D006 3

C003a

+15 5A

Bf012

5A

Bf011

+30

9

C003a

D013

D001

+30

+30

+30

Bf011

4

7.5A

15A

Bf009

To fig. 2/2

C003a

10 11

To ISO 11783

5

10

30

1

To fig. 2/2

D052

To fig. 2/2

+30

2

87 86 85

87a

FL/AL LH 0

D006

D003

D003

D009

D006

D052

C003a

A D7

Bf007

15A

A D8

1

1

To ISO 11783

To fig. 2/2

2

D026

D013 1

5

1

7.5A

87a

Bf013

1

Bf010

2

3

85 30

D023

86

5A

87

87a

Wiring diagrams

F043

1

2

3

4

1

4

2

3

2

1

4

4

3

To fig. 1/2

To fig. 1/2

D001

1

2

C003a

15

A D7

1

2

1

E004

2

F009

13

1

F008

1

2

F007

1

2

F010

D026

D036 16

To fig. 1/2

12

A D8

To fig. 1/2

D009 A D1

D006

B A1

C002

C002

D009

A B7

To fig. 1/2

To fig. 1/2

D009

+15

C003a

15A

12 17

Bb003

1

D006

D003

HORN CONTROL

F044

2

3

3

2

F003

1

3

1

5

2

1

F020

D0069030

Fig. 2978 - S009 - Lights – Version with front hitch - System (2/2) l l l l l l l l l l l l l l l l l

D001 (M) - Wiring connector (Wiring loom 0.020.8658.4) D001 (F) - Wiring connector (Wiring loom 0.014.0007.4/20) D003 (M) - Wiring connector (Wiring loom 0.019.2379.4/20) D003 (F) - Wiring connector (Wiring loom 0.020.8658.4) D006 (M) - Wiring connector (Wiring loom 0.019.2379.4/20) D006 (F) - Wiring connector (Wiring loom 0.020.8658.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D026 (M) - Wiring connector (Wiring loom 0.020.8658.4) D026 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D036 (M) - Wiring connector (Wiring loom 0.021.0396.4) D036 (F) - Wiring connector (Wiring loom 0.019.2383.4/20) E004 - Horn F003 - Right hand sidelight F007 - Right hand high beam headlight F008 - Right hand low beam headlight F009 - Left hand low beam headlight 40-161

Wiring diagrams

F043

1

2

3

4

1

4

2

3

2

1

4

4

3

To fig. 1/2

To fig. 1/2

D001

1

2

C003a

15

A D7

1

2

1

E004

2

F009

13

1

F008

1

2

F007

1

2

F010

D026

D036 16

To fig. 1/2

12

A D8

To fig. 1/2

D009 A D1

D006

B A1

C002

C002

D009

A B7

To fig. 1/2

To fig. 1/2

D009

+15

C003a

15A

12 17

Bb003

1

D006

D003

HORN CONTROL

F044

2

3

3

2

F003

1

3

1

5

2

1

F020

D0069030

Fig. 2978 - S009 - Lights – Version with front hitch - System (2/2) l l l l

F010 - Left hand high beam headlight F020 - RH rear sidelight F043 - LH repeater light F044 - RH repeater light

40-162

Wiring diagrams Table 555 Sys- P/N tem

B008

Bf011

C002

Description

Characteristics/Notes

Position

Wiring loom

40-514

Fuse (3A)

15A Fuse - Windscreen wiper (F1A/3, +15) 3A Fuse - Cluster (F1-A/4, +15) 3A Fuse - Work light display (F1A/14, +15) 15A Fuse - Lights relay protection (F1-B/7, +30) 15A Fuse - Lights relay protection (F1-B/9, +30) 7.5A Fuse - Left hand sidelights (F1B/10, +30) 5A Fuse - Road lights/Top lights relay protection (F1B/11, +30) 5A Fuse - Lights (F1-B/12, +15) 7.5A Fuse - Right hand sidelights (F1B/13, +30) 15A Fuse - Sidelights relay protection (F1-B/14, +30) 15A Fuse - Work light display (F1A/18, +30) Engine ground

Fig. 2979

40-571 40-571 40-571 40-571 40-571 40-571 40-571

40-571 40-571 40-571 40-571 40-583 40-576

Fig. 2980

40-163

Wiring diagrams Sys- P/N tem

C003

Description

Characteristics/Notes

Position

Wiring loom

40-571

Cab ground

Cab ground

D001

Wiring connector

D003

Wiring connector

Fig. 2981

Fig. 2982

Fig. 2983

Fig. 2984

Fig. 2985

40-164

40-571

40-496 40-571

40-571

40-524

Wiring diagrams Sys- P/N tem

D006

Description

Characteristics/Notes

Position

Wiring loom

40-571

Wiring connector

Fig. 2986

D008

Wiring connector

D009

Wiring connector

D013

Wiring connector

Fig. 2987

Fig. 2988

Fig. 2989

40-526

40-571 40-576

40-571 40-583

40-571 40-537

Fig. 2990

40-165

Wiring diagrams Table 556 Sys- P/N tem

Description

D023

Wiring connector

D026

Wiring connector

D031

Wiring connector

D034

Wiring connector

D036

Wiring connector

D044

Wiring connector

D052

Wiring connector

40-166

Characteristics/Notes

Position

Wiring loom

40-571 40-520

Fig. 2991

Fig. 2992

Fig. 2993

Fig. 2994

Fig. 2995

40-571 40-522

40-583 40-514

40-583 40-507

40-529 40-583

40-500 40-576 40-496 40-520

Wiring diagrams Sys- P/N tem

Description

E002

Instrument panel

E004 01169304 F003

Horn RH sidelight

F005

LH sidelight

F007

RH high beam headlight RH low beam headlight LH low beam headlight LH high beam headlight Right hand rear sidelight Left hand rear sidelight License plate light Left hand repeater headlight

F008 F009 F010 F020 F024 F026 04414115 F043

F044 H002

Right hand repeater headlight Work light switch

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 2996

Fig. 2997

Fig. 2998

40-529 40-526

40-524

40-529 40-529 40-529 40-529 40-522 40-520 40-496 40-524

Fig. 2999

40-526 40-571

40-167

Wiring diagrams Sys- P/N tem

I008

Description

Characteristics/Notes

Position

Wiring loom

40-571

Road lights switch 0 1 2

Pos

Pin

1

2

3

4

5

6

7

4

5

6

9

8

1

2

3

10

7

9

8

10

0 1 2

Fig. 3001

2.7659.376.0

I009

Fig. 3000

Top lights switch

40-571

0 1

Pos

Pin

1

2

3

4

5

7

4

5

6

9

8

1

2

3

10

6

7

8

0 1

Fig. 3003

2.7659.377.0

Fig. 3002

Table 557 Sys- P/N tem

P006 P015

40-168

Description

Same bonnet relay (R4/6) Road lights/Top lights relay (R3/1) Road lights/Top lights relay (R3/3) High beam relay (R3/4) Sidelights relay (R3/5) Low beam relay (R3/6) Trailer socket Front implement power outlet socket

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571 40-571 40-571 40-571 40-507 40-500

Wiring diagrams 40.3.11 - S010 - Turn indicators DIRECTION LIGHT CONTR OL DIRECTION LEFT

TRAILER 2

TRAILER1

49A

49A

49A

49A

DIR. COM

49

DIRECTION LAMP LEFT

DIRECTION LAMP LEFT

DIRECTION LAMP RIGHT

DIRECTION LAMP RIGHT

4

3

1

2

11

10

6

5

9

2

7

8

3

12

D001

+15 INSTRUMENT

12

3

1

16

17

18

+15

2

D068

C003a

DIRECTION RIGHT

5

E001

0FF 0N 0N 0FF

3A

GND

21

Bb004

FUSE PDU3

E002

2

3

4

5

7

6

9

8

10

11

12

13

14

5

7

15

19

20

4

2

Bm007

15A

Bb008 L

4

1

3

1

2

1

2

M004

3 TRAILER 1

49

D003

3

C003a

C003a

D034

D031 R

1

1

5 49a

6 L

7 R

2 30B(-)

1 +15

3 +30

4 49(+)

I001

2

1

1

2

1

2

2

1

+30

31

4

3A

B008

5

6

TRAILER 2

12

49A

4

GND

1

To iso 11783

12

C003a

D013 4

D006

1

D007

A A4

C002

A A5

D004

A D5

4

D023

D026

D009 5

4

C003a

C003a

C002 D044 6

+30

B B4

+15

B D2

20A

D022

D008

1

P015

P006

F018

F022

F006

F004

D0078730

Fig. 3004 - Turn indicators - System l l l l l l l l l l

D001 (M) - Wiring connector (Wiring loom 0.020.8658.4) D001 (F) - Wiring connector (Wiring loom 0.014.0007.4/20) D003 (M) - Wiring connector (Wiring loom 0.019.2379.4/20) D003 (F) - Wiring connector (Wiring loom 0.020.8658.4) D004 (M) - Wiring connector (Wiring loom 0.019.2379.4/20) D004 (F) - Wiring connector (Wiring loom 0.020.8658.4) D006 (M) - Wiring connector (Wiring loom 0.019.2379.4/20) D006 (F) - Wiring connector (Wiring loom 0.020.8658.4) D007 (M) - Wiring connector (Wiring loom 0.019.2379.4/20) D007 (F) - Wiring connector (Wiring loom 0.020.8658.4) 40-169

Wiring diagrams DIRECTION LIGHT CONTR OL DIRECTION LEFT

TRAILER 2

TRAILER1

49A

49A

49A

49A

DIR. COM

49

DIRECTION LAMP LEFT

DIRECTION LAMP LEFT

DIRECTION LAMP RIGHT

DIRECTION LAMP RIGHT

4

3

1

2

11

10

6

5

9

2

7

8

3

12

D001

+15 INSTRUMENT

12

3

1

16

17

18

+15

2

D068

C003a

DIRECTION RIGHT

5

E001

0FF 0N 0N 0FF

3A

GND

21

Bb004

FUSE PDU3

E002

2

3

4

5

7

6

9

8

10

11

12

13

14

5

7

15

19

20

4

2

P015

1

1

2

L

4

1

3

1

2

1

2

1

2

2

1

P006

F018

F022

F006

F004

D0078730

Fig. 3004 - Turn indicators - System l l l l l l l l l l l l

Bm007

15A

Bb008 2

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D013 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D013 (F) - Wiring connector (Wiring loom 0.020.8658.4) D022 (M) - Configuration connector (Wiring loom 0.020.8658.4) D023 (M) - Wiring connector (Wiring loom 0.020.8658.4) D023 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D026 (M) - Wiring connector (Wiring loom 0.020.8658.4) D026 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4)

40-170

3 TRAILER 1

C003a

49

D003

3

D006

C003a

D034

D031 R

1

1

M004

+30

31

4

3A

B008

5

6

TRAILER 2

12

49A

4

GND

1

To iso 11783

12

C003a

D013 4

D007

1

4

D004

A A4

C002

4

A A5

D023

D026

D009 5

A D5

C003a

C003a

C002 D044 6

+30

B B4

+15

B D2

20A

D022

D008

1

5 49a

6 L

7 R

2 30B(-)

1 +15

I001

3 +30

4 49(+)

Wiring diagrams DIRECTION LIGHT CONTR OL DIRECTION LEFT

TRAILER 2

TRAILER1

49A

49A

49A

49A

DIR. COM

49

DIRECTION LAMP LEFT

DIRECTION LAMP LEFT

DIRECTION LAMP RIGHT

DIRECTION LAMP RIGHT

4

3

1

2

11

10

6

5

9

2

7

8

3

12

D001

+15 INSTRUMENT

12

3

1

16

17

18

+15

2

D068

C003a

DIRECTION RIGHT

5

E001

0FF 0N 0N 0FF

3A

GND

21

Bb004

FUSE PDU3

E002

2

3

4

5

7

6

9

8

10

11

12

13

14

5

7

15

19

20

4

2

Bm007

15A

Bb008 L

4

1

3

1

2

1

2

TRAILER 1

C003a

49

D003

3

M004

3

5 49a

6 L

7 R

2 30B(-)

1 +15

3 +30

4 49(+)

I001

D006

C003a

D034

D031 R

1

1

2

1

1

2

1

2

2

1

+30

31

4

3A

B008

5

6

TRAILER 2

12

49A

4

GND

1

To iso 11783

12

C003a

D013 4

D007

1

4

D004

A A4

C002

4

A A5

D023

D026

D009 5

A D5

C003a

C003a

C002 D044 6

+30

B B4

+15

B D2

20A

D022

D008

1

P015

P006

F018

F022

F006

F004

D0078730

Fig. 3004 - Turn indicators - System l l l l l l l l l l l l

D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D034 (M) - Wiring connector (Wiring loom 0.017.8425.4/10) D034 (F) - Wiring connector (Wiring loom 0.021.0396.4) D044 (M) - Wiring connector (Wiring loom 0.015.5429.4/20) D044 (F) - Wiring connector (Wiring loom 0.020.8664.4) D068 (F) - Configuration connector (Wiring loom 0.020.8658.4) E001 - Instrument panel E002 - Instrument panel F004 - RH turn indicator F006 - LH turn indicator F018 - RH rear turn indicator F022 - LH rear turn indicator 40-171

Wiring diagrams DIRECTION LIGHT CONTR OL DIRECTION LEFT

TRAILER 2

TRAILER1

49A

49A

49A

49A

DIR. COM

49

DIRECTION LAMP LEFT

DIRECTION LAMP LEFT

DIRECTION LAMP RIGHT

DIRECTION LAMP RIGHT

4

3

1

2

11

10

6

5

9

2

7

8

3

12

D001

+15 INSTRUMENT

12

3

1

16

17

18

+15

2

D068

C003a

DIRECTION RIGHT

5

E001

0FF 0N 0N 0FF

3A

GND

21

Bb004

FUSE PDU3

E002

2

3

4

5

7

6

9

8

10

11

12

13

14

5

7

15

19

20

4

2

P015

1

1

2

L

4

1

3

1

2

1

2

1

2

2

1

P006

F018

F022

F006

Fig. 3004 - Turn indicators - System l l l l

Bm007

15A

Bb008 2

I001 - Hazard warning lights switch M004 - Hazard warning lights control unit P006 - Trailer socket P015 - Front implement power outlet socket

40-172

F004

D0078730

3 TRAILER 1

C003a

49

D003

3

D006

C003a

D034

D031 R

1

1

M004

+30

31

4

3A

B008

5

6

TRAILER 2

12

49A

4

GND

1

To iso 11783

12

C003a

D013 4

D007

1

4

D004

A A4

C002

4

A A5

D023

D026

D009 5

A D5

C003a

C003a

C002 D044 6

+30

B B4

+15

B D2

20A

D022

D008

1

5 49a

6 L

7 R

2 30B(-)

1 +15

I001

3 +30

4 49(+)

Wiring diagrams Table 558 Sys- P/N tem

Description

B008

Fuse (3A)

C002

3A Fuse - Cluster (F1-A/4, +15) 15A Fuse - EU/USA emergency lights (F1-A/8, +15) 20A Fuse - EU/USA emergency lights (F2/7-10, +30) Engine ground

Cab ground

D001

Wiring connector

D003

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-514

Fig. 3005

40-571 40-571 40-571 40-583 40-576

Fig. 3006

Fig. 3007

Fig. 3008

40-571

40-496 40-571

40-571

Fig. 3009

40-173

Wiring diagrams Sys- P/N tem

Description

D003

Wiring connector

D004

Wiring connector

D004

Wiring connector

D006

Wiring connector

D006

Wiring connector

D007

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-524

Fig. 3010

Fig. 3011

Fig. 3012

Fig. 3013

Fig. 3014

Fig. 3015

40-174

40-571

40-524

40-571

40-526

40-571

Wiring diagrams Sys- P/N tem

Description

D007

Wiring connector

D008

Wiring connector

D009

Wiring connector

D013

Wiring connector

D013

Wiring connector

D022

Configuration connector

Characteristics/Notes

Position

Wiring loom

40-526

Fig. 3016

Fig. 3017

Fig. 3018

Fig. 3019

Fig. 3020

40-571 40-576

40-571 40-583

40-571

40-537

40-571

40-175

Wiring diagrams Sys- P/N tem

Description

D023

Wiring connector

D026

Wiring connector

D031

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-520

Fig. 3021

Fig. 3022

40-571 40-522

40-583 40-514

Fig. 3023

Table 559 Sys- P/N tem

Description

D034

Wiring connector

D044

Wiring connector

D068

Configuration connector Instrument panel

E001

Characteristics/Notes

Position

Wiring loom

40-583 40-507

Fig. 3024

40-571

Fig. 3025

40-176

40-500 40-576 40-571

Wiring diagrams Sys- P/N tem

Description

E002

Instrument panel

F004

RH turn indicator

F006

LH turn indicator

F018

Right hand rear turn indicator Left hand rear turn indicator Hazard warning lights switch

F022 I001

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 3026

Fig. 3027

Fig. 3028

40-526

40-524

40-522 40-520

1

40-571

0 30

49

L

Pin

15 1

30 3

49 4

49a 5

1

R

6

Pos

2

15

49a

5

b 30

3 4

7

L 6

R 7

0 1 2.7659.110.0

M004

Hazard lights flasher unit

P006 P015

Trailer socket Front implement power outlet socket

Fig. 3030

Fig. 3029

40-571

Fig. 3031

40-507 40-500

40-177

Wiring diagrams 40.3.12 - S011 - Work lights Jg002

P006

2

3

2

87a

87 86

15A

J002

30

87

To fig. 2/2

+30

1

2

1

2

1

2

1

2

1

2

1

2

1

F031

F029

F030

F032

F034

F035

2

F036

9

1

2

1

2

1

2

F033

F025

l l l l l l l l l

D004 (M) - Wiring connector (Wiring loom 0.019.2379.4/20) D004 (F) - Wiring connector (Wiring loom 0.020.8658.4) D007 (M) - Wiring connector (Wiring loom 0.019.2379.4/20) D007 (F) - Wiring connector (Wiring loom 0.020.8658.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D023 (M) - Wiring connector (Wiring loom 0.020.8658.4) D023 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D024 (M) - Wiring connector (yellow) (Wiring loom 0.020.8862.4)

40-178

+30 +58

D009 B D4

A D2

1

2

7

5

14

8

13

6

17

18

H002

Fig. 3032 - Work lights - System (1/2)

7.5A

Bf010

+15 D009

8

19

23

21

+58

7

AUX TRAILER

6

FRONT ROOF

5

FRONT LOW

9

LEFT CORNER LIGHT RELAY

8

+30 WOLP

4

LIFT SERVICE LIGHT

3

+15 WOLP

4

RIGHT CORNER LIGHT RELAY

3

REAR ROOF

2

GND

1

3A

Bb014

2

+30 WOLP

2

2

To fig. 2/2

C003

1

D049

D058

D059

D058

D056

D055

D056 1

4

To fig. 2/2

4

6

D031

D004 D007

D031

10A

+30 15A

Bf018

C003a

C003a

D046

C005

C005

C005

C005

9

1

2

5

1

Bf017

15A

Be004

15A

Be001 D024

C005

C005

4

C005

15

10

C005

11

13

D031

+30

+30 15A

Ba006

+30

C003 15A

D025

Ba005

To fig. 2/2

C003

20A

87a

To fig. 2/2

30

4

30

15A

86 85

86 85

B004

87

87

Bm008

87a

40A

2 87a

8

30

D031

D031

15A

Jg001

86 85

B003

85

+30

87

85 86

3

Jd001

86

To fig. 2/2

30

3

30

20A

Je001

86 85

Bc002

30

87

87a

B006

+30

C003a

B D1

D026

86 85

87

D023

87

87a

J003 Jg003

D009

C002

Je002

30

85

Bf020

D034

3

D0078400

Wiring diagrams Jg002

P006

2

3

2

87a

87 86

15A

J002

30

87

To fig. 2/2

+30

1

2

1

2

1

2

1

2

1

2

1

2

1

F031

F029

F030

F032

F034

F035

2

F036

9

1

2

1

2

1

2

F033

F025

+30 +58

D009

7.5A

Bf010

+15 D009

8

B D4

A D2

1

2

7

5

14

8

13

6

17

18

H002

19

23 +58

7

21 AUX TRAILER

6

FRONT ROOF

5

FRONT LOW

9

LEFT CORNER LIGHT RELAY

8

+30 WOLP

4

LIFT SERVICE LIGHT

3

+15 WOLP

4

RIGHT CORNER LIGHT RELAY

3

REAR ROOF

2

GND

1

3A

Bb014

2

+30 WOLP

2

2

To fig. 2/2

C003

1

D049

D058

D059

D058

D056

D055

D056 1

4

To fig. 2/2

4

6

D031

D004 D007

D031

10A

+30 15A

Bf018

C003a

C003a

D046

C005

C005

C005

C005

9

1

2

5

1

Bf017

15A

Be004

15A

Be001 D024 4

C005

C005

C005

13

15

10

C005

11

D031

+30

+30 15A

Ba006

+30

C003 15A

D025

Ba005

To fig. 2/2

C003

20A

87a

To fig. 2/2

8

30

4

30

15A

86 85

86 85

B004

87

87

Bm008

87a

40A

2 87a

30

D031

D031

15A

Jg001

86 85

B003

85

+30

87

85 86

3

Jd001

86

To fig. 2/2

30

3

30

20A

Je001

86 85

Bc002

30

87

87a

B006

+30

C003a

B D1

D026

86 85

87

D023

87

87a

J003 Jg003

D009

C002

Je002

30

85

Bf020

D034

3

D0078400

Fig. 3032 - Work lights - System (1/2) l l l l l l l l l l l

D024 (F) - Wiring connector (yellow) (Wiring loom 0.020.8658.4) D025 (M) - Wiring connector (brown) (Wiring loom 0.020.8862.4) D025 (F) - Wiring connector (brown) (Wiring loom 0.020.8658.4) D026 (M) - Wiring connector (Wiring loom 0.020.8658.4) D026 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D034 (M) - Wiring connector (Wiring loom 0.017.8425.4/10) D034 (F) - Wiring connector (Wiring loom 0.021.0396.4) D046 (M) - Wiring connector (Wiring loom 0.020.8658.4) D046 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) 40-179

Wiring diagrams Jg002

P006

2

3

2

87a

87 86

15A

J002

30

87

To fig. 2/2

+30

1

2

1

2

1

2

1

2

1

2

1

2

1

F031

F029

F030

F032

F034

F035

2

F036

9

1

2

1

2

1

2

F033

F025

l l l l l l l l l l l

D049 (M) - Wiring connector (Wiring loom 0.019.4559.4/10) D049 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D055 (M) - Wiring connector (Wiring loom 0.019.4689.4/20) D055 (M) - Wiring connector (Wiring loom 0.019.4914.4/20) D055 (F) - Wiring connector (Wiring loom 0.020.8862.4) D055 (F) - Wiring connector (Wiring loom 0.020.8862.4) D056 (M) - Wiring connector (Wiring loom 0.019.4689.4/20) D056 (M) - Wiring connector (Wiring loom 0.019.4914.4/20) D056 (F) - Wiring connector (Wiring loom 0.020.8862.4) D056 (F) - Wiring connector (Wiring loom 0.020.8862.4) D058 (M) - Wiring connector (Wiring loom 0.019.4688.4/10)

40-180

+30 +58

D009 B D4

A D2

1

2

7

5

14

8

13

6

17

18

H002

Fig. 3032 - Work lights - System (1/2)

7.5A

Bf010

+15 D009

8

19

23

21

+58

7

AUX TRAILER

6

FRONT ROOF

5

FRONT LOW

9

LEFT CORNER LIGHT RELAY

8

+30 WOLP

4

LIFT SERVICE LIGHT

3

+15 WOLP

4

RIGHT CORNER LIGHT RELAY

3

REAR ROOF

2

GND

1

3A

Bb014

2

+30 WOLP

2

2

To fig. 2/2

C003

1

D049

D058

D059

D058

D056

D055

D056 1

4

To fig. 2/2

4

6

D031

D004 D007

D031

10A

+30 15A

Bf018

C003a

C003a D046

C005

C005

C005

C005

9

1

2

5

1

Bf017

15A

Be004

15A

Be001 D024 4

C005

C005

C005

13

15

10

C005

11

D031

+30

+30 15A

Ba006

+30

C003 15A

D025

Ba005

To fig. 2/2

C003

20A

87a

To fig. 2/2

8

30

4

30

15A

86 85

86 85

B004

87

87

Bm008

87a

40A

2 87a

30

D031

D031

15A

Jg001

86 85

B003

85

+30

87

85 86

3

Jd001

86

To fig. 2/2

30

3

30

20A

Je001

86 85

Bc002

30

87

87a

B006

+30

C003a

B D1

D026

86 85

87

D023

87

87a

J003 Jg003

D009

C002

Je002

30

85

Bf020

D034

3

D0078400

Wiring diagrams Jg002

P006

2

3

2

87a

87 86

15A

J002

30

87

To fig. 2/2

+30

1

2

1

2

1

2

1

2

1

2

1

2

1

F031

F029

F030

F032

F034

F035

2

F036

9

1

2

1

2

1

2

F033

F025

+30 +58

D009

7.5A

Bf010

+15 D009

8

B D4

A D2

1

2

7

5

14

8

13

6

17

18

H002

19

23 +58

7

21 AUX TRAILER

6

FRONT ROOF

5

FRONT LOW

9

LEFT CORNER LIGHT RELAY

8

+30 WOLP

4

LIFT SERVICE LIGHT

3

+15 WOLP

4

RIGHT CORNER LIGHT RELAY

3

REAR ROOF

2

GND

1

3A

Bb014

2

+30 WOLP

2

2

To fig. 2/2

C003

1

D049

D058

D059

D058

D056

D055

D056 1

4

To fig. 2/2

4

6

D031

D004 D007

D031

10A

+30 15A

Bf018

C003a

C003a D046

C005

C005

C005

C005

9

1

2

5

1

Bf017

15A

Be004

15A

Be001 D024 4

C005

C005

C005

13

15

10

C005

11

D031

+30

+30 15A

Ba006

+30

C003 15A

D025

Ba005

To fig. 2/2

C003

20A

87a

To fig. 2/2

8

30

4

30

15A

86 85

86 85

B004

87

87

Bm008

87a

40A

2 87a

30

D031

D031

15A

Jg001

86 85

B003

85

+30

87

85 86

3

Jd001

86

To fig. 2/2

30

3

30

20A

Je001

86 85

Bc002

30

87

87a

B006

+30

C003a

B D1

D026

86 85

87

D023

87

87a

J003 Jg003

D009

C002

Je002

30

85

Bf020

D034

3

D0078400

Fig. 3032 - Work lights - System (1/2) l l l l l l l l l l l

D058 (M) - Wiring connector (Wiring loom 0.019.4913.4/10) D058 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D058 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D058 (F) - Wiring connector (Wiring loom 0.020.8862.4) D058 (F) - Wiring connector (Wiring loom 0.020.8862.4) D058 (F) - Wiring connector (Wiring loom 0.020.8862.4) D058 (F) - Wiring connector (Wiring loom 0.020.8862.4) D059 (M) - Wiring connector (Wiring loom 0.019.4688.4/10) D059 (M) - Wiring connector (Wiring loom 0.019.4913.4/10) D059 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D059 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) 40-181

Wiring diagrams Jg002

P006

2

3

2

87a

87 86

15A

J002

30

87

To fig. 2/2

+30

1

2

1

2

1

2

1

2

1

2

1

2

1

F031

F029

F030

F032

F034

F035

2

F036

9

1

2

1

2

1

2

F033

F025

l l l l l l l l l l l

D059 (F) - Wiring connector (Wiring loom 0.020.8862.4) D059 (F) - Wiring connector (Wiring loom 0.020.8862.4) D059 (F) - Wiring connector (Wiring loom 0.020.8862.4) D059 (F) - Wiring connector (Wiring loom 0.020.8862.4) F025 - Rear service light F029 - Right hand inner rear work light (on cab roof) F030 - Right hand outer rear work light (on cab roof) F031 - Left hand inner rear work light (on cab roof) F032 - Left hand outer rear work light (on cab roof) F033 - Left hand outer front work light (on cab roof) F033 - Left hand inner front work light (on cab roof)

40-182

+30 +58

D009 B D4

A D2

1

2

7

5

14

8

13

6

17

18

H002

Fig. 3032 - Work lights - System (1/2)

7.5A

Bf010

+15 D009

8

19

23

21

+58

7

AUX TRAILER

6

FRONT ROOF

5

FRONT LOW

9

LEFT CORNER LIGHT RELAY

8

+30 WOLP

4

LIFT SERVICE LIGHT

3

+15 WOLP

4

RIGHT CORNER LIGHT RELAY

3

REAR ROOF

2

GND

1

3A

Bb014

2

+30 WOLP

2

2

To fig. 2/2

C003

1

D049

D058

D059

D058

D056

D055

D056 1

4

To fig. 2/2

4

6

D031

D004 D007

D031

10A

+30 15A

Bf018

C003a

C003a D046

C005

C005

C005

C005

9

1

2

5

1

Bf017

15A

Be004

15A

Be001 D024 4

C005

C005

C005

13

15

10

C005

11

D031

+30

+30 15A

Ba006

+30

C003 15A

D025

Ba005

To fig. 2/2

C003

20A

87a

To fig. 2/2

8

30

4

30

15A

86 85

86 85

B004

87

87

Bm008

87a

40A

2 87a

30

D031

D031

15A

Jg001

86 85

B003

85

+30

87

85 86

3

Jd001

86

To fig. 2/2

30

3

30

20A

Je001

86 85

Bc002

30

87

87a

B006

+30

C003a

B D1

D026

86 85

87

D023

87

87a

J003 Jg003

D009

C002

Je002

30

85

Bf020

D034

3

D0078400

Wiring diagrams Jg002

P006

2

3

2

87a

87 86

15A

J002

30

87

To fig. 2/2

+30

1

2

1

2

1

2

1

2

1

2

1

2

1

F031

F029

F030

F032

F034

F035

2

F036

9

1

2

1

2

1

2

F033

F025

+30 +58

D009

7.5A

Bf010

+15 D009

8

B D4

A D2

1

2

7

5

14

8

13

6

17

18

H002

19

23 +58

7

21 AUX TRAILER

6

FRONT ROOF

5

FRONT LOW

9

LEFT CORNER LIGHT RELAY

8

+30 WOLP

4

LIFT SERVICE LIGHT

3

+15 WOLP

4

RIGHT CORNER LIGHT RELAY

3

REAR ROOF

2

GND

1

3A

Bb014

2

+30 WOLP

2

2

To fig. 2/2

C003

1

D049

D058

D059

D058

D056

D055

D056 1

4

To fig. 2/2

4

6

D031

D004 D007

D031

10A

+30 15A

Bf018

C003a

C003a D046

C005

C005

C005

C005

9

1

2

5

1

Bf017

15A

Be004

15A

Be001 D024 4

C005

C005

C005

13

15

10

C005

11

D031

+30

+30 15A

Ba006

+30

C003 15A

D025

Ba005

To fig. 2/2

C003

20A

87a

To fig. 2/2

8

30

4

30

15A

86 85

86 85

B004

87

87

Bm008

87a

40A

2 87a

30

D031

D031

15A

Jg001

86 85

B003

85

+30

87

85 86

3

Jd001

86

To fig. 2/2

30

3

30

20A

Je001

86 85

Bc002

30

87

87a

B006

+30

C003a

B D1

D026

86 85

87

D023

87

87a

J003 Jg003

D009

C002

Je002

30

85

Bf020

D034

3

D0078400

Fig. 3032 - Work lights - System (1/2) l l l l l l l l l l l

F034 - Left hand outer front work light (on cab roof) F034 - Left hand inner front work light (on cab roof) F035 - Right hand outer front work light (on cab roof) F036 - Left hand outer front work light (on cab roof) F036 - Right hand inner front work light (on cab roof) F039 - Low left hand rear work light F040 - Low right hand rear work light H002 - Work light control J002 - Left hand work light relay (on engine cowl) J003 - Right hand work light relay (on engine cowl) Jd001 - Hitch service light relay (R4/1) 40-183

Wiring diagrams Jg002

P006

2

3

2

87a

87 86

15A

J002

30

87

To fig. 2/2

+30

1

2

1

2

1

2

1

2

1

2

1

2

1

F031

F029

F030

F032

F034

F035

2

F036

9

1

2

1

2

1

2

F033

F025

l l l l l l

Je001 - Relay for front work lights on cab roof (R6/1) Je002 - Relay for rear work lights on cab roof (R6/2) Jg001 - Relay for low front work lights (R1-A/1) Jg002 - Relay for trailer electrical power outlet sockets (R1-A/2) Jg003 - Relay for low rear work lights (R1-A/3) P006 - Trailer socket

40-184

+30 +58

D009 B D4

A D2

1

2

7

5

14

8

13

6

17

18

H002

Fig. 3032 - Work lights - System (1/2)

7.5A

Bf010

+15 D009

8

19

23

21

+58

7

AUX TRAILER

6

FRONT ROOF

5

FRONT LOW

9

LEFT CORNER LIGHT RELAY

8

+30 WOLP

4

LIFT SERVICE LIGHT

3

+15 WOLP

4

RIGHT CORNER LIGHT RELAY

3

REAR ROOF

2

GND

1

3A

Bb014

2

+30 WOLP

2

2

To fig. 2/2

C003

1

D049

D058

D059

D058

D056

D055

D056 1

4

To fig. 2/2

4

6

D031

D004 D007

D031

10A

+30 15A

Bf018

C003a

C003a D046

C005

C005

C005

C005

9

1

2

5

1

Bf017

15A

Be004

15A

Be001 D024 4

C005

C005

C005

13

15

10

C005

11

D031

+30

+30 15A

Ba006

+30

C003 15A

D025

Ba005

To fig. 2/2

C003

20A

87a

To fig. 2/2

8

30

4

30

15A

86 85

86 85

B004

87

87

Bm008

87a

40A

2 87a

30

D031

D031

15A

Jg001

86 85

B003

85

+30

87

85 86

3

Jd001

86

To fig. 2/2

30

3

30

20A

Je001

86 85

Bc002

30

87

87a

B006

+30

C003a

B D1

D026

86 85

87

D023

87

87a

J003 Jg003

D009

C002

Je002

30

85

Bf020

D034

3

D0078400

3

1

2

F012

9

8

5

6

7

4

1

2

1

2

1

2

F015

F014

F011

1

2

F028

1

2

1

2

F040

4

1

2

1

2

F039

1

2

F027

4

C003a 3

D028

3

D007

D004 3

To fig. 1/2

C003a To fig. 1/2

C003a 1

D030

D036 17

To fig. 1/2

D026 3

D047

1

1

9

To fig. 1/2

C003a

D031

D023

C002

To fig. 1/2

C002

To fig. 1/2

8

D051

2

D031

C002

To fig. 1/2

D031

C002

D031

To fig. 1/2

Wiring diagrams

3

1

1

3

2

1

1

2

F037

F038 D0078200

Fig. 3033 - Work lights - System (2/2) l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l

D004 (M) - Wiring connector (Wiring loom 0.019.2379.4/20) D004 (F) - Wiring connector (Wiring loom 0.020.8658.4) D007 (M) - Wiring connector (Wiring loom 0.019.2379.4/20) D007 (F) - Wiring connector (Wiring loom 0.020.8658.4) D023 (M) - Wiring connector (Wiring loom 0.020.8658.4) D023 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D026 (M) - Wiring connector (Wiring loom 0.020.8658.4) D026 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D028 (M) - Wiring connector (Wiring loom 0.017.0496.4/10) D028 (M) - Wiring connector (Wiring loom 0.016.0650.4/10) D028 (F) - Wiring connector (Wiring loom 0.019.2379.4/20) D028 (F) - Wiring connector (Wiring loom 0.019.2379.4/20) D030 (M) - Wiring connector (Wiring loom 0.017.0496.4/10) D030 (M) - Wiring connector (Wiring loom 0.016.0650.4/10) D030 (F) - Wiring connector (Wiring loom 0.019.2379.4/20) D030 (F) - Wiring connector (Wiring loom 0.019.2379.4/20) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D036 (M) - Wiring connector (Wiring loom 0.021.0396.4) D036 (F) - Wiring connector (Wiring loom 0.019.2383.4/20) D047 (M) - Wiring connector (Wiring loom 0.017.0497.4/20) D047 (M) - Wiring connector (Wiring loom 0.016.0642.4/20) D047 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D047 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D051 (M) - Wiring connector (Wiring loom 0.017.0497.4/20) D051 (M) - Wiring connector (Wiring loom 0.016.0642.4/20) D051 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D051 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) F011 - RH front work light - on cowl F012 - Right hand front centre work light - on engine cowl F014 - Left hand front centre work light - on engine cowl F015 - LH front work light - on cowl 40-185

3

1

2

F012

9

8

5

6

7

4

1

2

1

2

1

2

F015

F014

F011

1

2

F028

1

2

1

2

F040

4

1

2

1

2

F039

1

2

F027

4

C003a 3

D028

3

D007

D004 3

To fig. 1/2

C003a To fig. 1/2

C003a 1

D030

D036 17

To fig. 1/2

D026 3

D047

1

1

9

To fig. 1/2

C003a

D031

D023

C002

To fig. 1/2

C002

To fig. 1/2

8

D051

2

D031

C002

To fig. 1/2

D031

C002

D031

To fig. 1/2

Wiring diagrams

3

1

1

3

2

1

1

2

F037

F038 D0078200

Fig. 3033 - Work lights - System (2/2) l l l l l l

F027 - Low right hand rear work light F028 - Low left hand rear work light F037 - LH front work light (on arm) F038 - RH front work light (on arm) F039 - Low left hand rear work light F040 - Low right hand rear work light

Table 560 Sys- P/N tem

B003 B004 B006

40-186

Description

Fuse (40A) Fuse (15A) Fuse (15A) 15A Fuse - Rear work light fuse (F3/5) 15A Fuse - Rear work light fuse (F3/6) 3A Fuse - Work light display (F1A/14, +15) 20A Fuse - Low rear work light relay protection (F4/2-5, +30) 15A Fuse - Front work lights (R6/1-5) 15A Fuse - Front work lights (R6/4-8)

Characteristics/Notes

Position

Wiring loom

40-514 40-514 40-514 40-571 40-571 40-571 40-571

40-571 40-571

Wiring diagrams Sys- P/N tem

Description

C002

7.5A Fuse - Left hand sidelights (F1B/10, +30) 10A Fuse - Hitch relay protection (F1B/17, +30) 15A Fuse - Work light display (F1A/18, +30) 15A Fuse - Trailer lights relay protection (F1-B/20, +30) 20A Fuse - Front work lights relay protection (F2/8-11) Engine ground

C003

Cab ground

Cab ground

C005 D004

Cab ground (roof) Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571 40-571 40-571 40-583

Fig. 3034

Fig. 3035

Fig. 3036

40-571

40-571

40-580 40-571

Fig. 3037

40-187

Wiring diagrams Sys- P/N tem

Description

D004

Wiring connector

D007

Wiring connector

D007

Wiring connector

D009

Wiring connector

D023

Wiring connector

D024

Wiring connector (yellow)

Characteristics/Notes

Position

Wiring loom

40-524

Fig. 3038

Fig. 3039

Fig. 3040

Fig. 3041

Fig. 3042

Fig. 3043

40-188

40-571

40-526

40-571 40-583

40-571 40-520

40-571 40-580

Wiring diagrams Sys- P/N tem

D025

Description

Characteristics/Notes

Position

Wiring loom

40-571 40-580

Wiring connector (brown)

Fig. 3044

Table 561 Sys- P/N tem

Description

D026

Wiring connector

D028

Wiring connector

D028

Wiring connector

D030

Wiring connector

D030

Wiring connector

D031

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-522

Fig. 3045

Fig. 3046

Fig. 3047

40-505 40-503 40-526

40-504 40-502 40-524

40-583 40-514

Fig. 3048

40-189

Wiring diagrams Sys- P/N tem

Description

D034

Wiring connector

D036

Wiring connector

D046

Wiring connector

D047

Wiring connector

D049

Wiring connector

D051

Wiring connector

40-190

Characteristics/Notes

Position

Wiring loom

40-583 40-507

Fig. 3049

Fig. 3050

Fig. 3051

40-529 40-583

40-571 40-522

40-506 40-502 40-522 40-544 40-522 40-506 40-501 40-520

Wiring diagrams Table 562 Sys- P/N tem

Description

D055

Wiring connector

D056

Wiring connector

D058

Wiring connector

D059

Wiring connector

F011

Rh front work light on cowl RH centre front work light - on engine cowl LH centre front work light - on engine cowl Lh front work light on cowl Rear service light RH lower rear work light LH lower rear work light

F012 F014 F015 F025 F027 F028

Characteristics/Notes

Position

Wiring loom

40-546 40-554 40-580 40-547 40-552 40-580 40-545 40-551 40-580 40-561 40-563 40-545 40-551 40-580 40-561 40-563 40-529 40-529 40-529 40-529 40-544 40-506 40-506

Table 563 Sys- P/N tem

F029 F029 F030 F030 F031 F031 F032

Description

Right hand inner rear work light (on cab roof) Right hand inner rear work light (on cab roof) Right hand outer rear work light (on cab roof) Right hand outer rear work light (on cab roof) Left hand inner rear work light (on cab roof) Left hand inner rear work light (on cab roof) Left hand outer rear work light (on cab roof)

Characteristics/Notes

Position

Wiring loom

40-546 40-554 40-546 40-554 40-547 40-552 40-547

40-191

Wiring diagrams Sys- P/N tem

F032 F033 F033 F033 F033 F034 F034 F034 F034 F035 F035 F035 F035 F036 F036 F036 F036 F037 F037

40-192

Description

Left hand outer rear work light (on cab roof) Left hand outer front work light (on cab roof) Left hand outer front work light (on cab roof) Left hand inner front work light (on cab roof) Left hand inner front work light (on cab roof) Left hand inner front work light (on cab roof) Left hand inner front work light (on cab roof) Left hand outer front work light (on cab roof) Left hand outer front work light (on cab roof) Right hand outer front work light (on cab roof) Right hand outer front work light (on cab roof) Right hand outer front work light (on cab roof) Right hand outer front work light (on cab roof) Left hand outer front work light (on cab roof) Right hand inner front work light (on cab roof) Right hand inner front work light (on cab roof) Right hand inner front work light (on cab roof) Lh front work light (on arm) Lh front work light (on arm)

Characteristics/Notes

Position

Wiring loom

40-552 40-545 40-551 40-561 40-563 40-545 40-551 40-561 40-563 40-545 40-551 40-561 40-563 40-545 40-551 40-561 40-563 40-504 40-502

Wiring diagrams Sys- P/N tem

F037 F038 F038 F038 F039

Description

Characteristics/Notes

Position

Wiring loom

40-504

Lh front work light (on arm) Rh front work light (on arm) Rh front work light (on arm) Rh front work light (on arm) LH lower rear work light

40-505 40-503 40-505 40-502

Table 564 Sys- P/N tem

F040

H002

Description

Position

Wiring loom

40-501

RH lower rear work light Work light switch

J002

Left hand work light relay (on engine cowl)

J003

Right hand work light relay (on engine cowl) Hitch service light relay (R4/1) Relay for front work lights on cab roof (R6/1) Relay for rear work lights on cab roof (R6/2) Relay for low front work lights (R1-A/1) Relay for trailer electrical power outlet sockets (R1A/2) Relay for low rear work lights (R1-A/3) Trailer socket

P006

Characteristics/Notes

40-571

Fig. 3052

Fig. 3053

40-514

40-514 40-571 40-571 40-571 40-571 40-571

40-571 40-507

40-193

Wiring diagrams 40.3.13 - S012 - Semi-active cab suspension

53

A A7

B C5

B C6

B C4

B C7

B C2

B C3

A A6

2

6

7

5

8

3

4

1

4

5

1

5

3

6

2

1

6

GND SEMSOR

DUMPER GIGHT +

LINEAR SENSOR RIGHT

DUMPER RIGHT -

GND SEMSOR

GND SEMSOR

DUMPER LEFT -

9

8

6

4

2

3

5

1

20A

+30

Bm003

C003

7.5A

+15

7.5A

2 R3

I012

O005

N006

5

3

2 GND SEMSOR

1

LINEAR SENSOR LEFT

9

DUMPER LEFT +

10

5

3

R1

1

R2

2

2

8

1

7

4

C003a

Bf010

+58

D038

Bb005

D008

31

+30

22

+30

SENSOR GND HLHP

23

+30

LINEAR SENSOR LEFT

94

GND

DUMPER RIGHT -

LINEAR SENSOR RIGHT

78

GND

DUMPER LEFT +

79

GND

DUMPER RIGHT +

93

HLHP

DUMPER LEFT -

71

SENSOR GND HLHP

+5V HLHP

24

SENSOR GND HLHP

SEMI ACTIVE CABIN

M003

N005

D0068610

Fig. 3054 - Semi-active cab suspension - System l l l l l l l l l l

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D038 (M) - Wiring connector (Wiring loom 0.019.4711.4/10) D038 (F) - Wiring connector (Wiring loom 0.020.8664.4) I012 - Semi-active cab control switch M003 - HLHP control unit M003 - HLHP unit - USA version N005 - Left hand cab suspension N006 - Right hand cab suspension O005 - Diode and resistance board

Table 565 Sys- P/N tem

40-194

Description

7.5A Fuse - HLHP control unit (F1-A/5, +15) 7.5A Fuse - Left hand sidelights (F1B/10, +30) 20A Fuse - HLHP control unit (F2/3-6, +30)

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571

Wiring diagrams Sys- P/N tem

C003

Description

Characteristics/Notes

Position

Wiring loom

40-571

Cab ground

Cab ground

D008

Wiring connector

D038

Wiring connector

I012

Semi-active cab control switch

M003

HLHP unit

Fig. 3055

Fig. 3056

Fig. 3057

Fig. 3058

40-571

40-571 40-576

40-549 40-576 40-571

40-571

Fig. 3059

40-195

Wiring diagrams Sys- P/N tem

Description

M003

HLHP unit - USA version

N005

Left hand cab suspension Right hand cab suspension Diode and resistance board

N006 O005

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 3059

40-549 40-549 40-571

40.3.14 - S013 - Manual air conditioner

7

13

+30

+30

4

GND

+30

GND

5

3

2

1

+30

20A

GND

Bm003

C003

+15 HLH

7.5A

7.5A

+15

C003a

Bb005

+58

6

9

11

8

B C1

D009

D016 B A8

B B8

2

1

3

5

4

8

B C6

9

B D7

B C7

B D8

A B1

21

18

1

2

1

1

2 0 t

K018

1

P

K015

P005

6

8

D036

5

To fig. 2/2

4

Bf010

+30 3

To Webasto

2

7.5A

Bf002

7.5A

Ba003 +30

D008 1

To fig. 2/2

10

62

30A

Bc013

7.5A

Ba009

+15

+30 40A

To Webasto

C003a

Bc017 D073

D074 1

AC ENGAGEMENT

M003

D0078690

Fig. 3060 - Manual A/C system - System (1/2) 40-196

Wiring diagrams l l l l l l l l l l l l l l l

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D016 (M) - Wiring connector (Wiring loom 0.019.5311.4/10) D016 (F) - Wiring connector (Wiring loom 0.020.8658.4) D036 (M) - Wiring connector (Wiring loom 0.021.0396.4) D036 (F) - Wiring connector (Wiring loom 0.019.2383.4/20) D073 (F) - Wiring connector (Wiring loom 0.020.8658.4) D074 (F) - Wiring connector (Wiring loom 0.020.8658.4) K015 - Air conditioning pressure switch K018 - External air temperature sensor M003 - HLHP control unit M003 - HLHP unit - USA version P005 - Air conditioning system compressor

D074

D073

D016 D0078700

Fig. 3061 - Manual A/C system - System (2/2) l l l l

D016 (M) - Wiring connector (Wiring loom 0.019.5311.4/10) D016 (F) - Wiring connector (Wiring loom 0.020.8658.4) D073 (F) - Wiring connector (Wiring loom 0.020.8658.4) D074 (F) - Wiring connector (Wiring loom 0.020.8658.4)

40-197

Wiring diagrams Table 566 Sys- P/N tem

C003

Description

Position

Wiring loom

40-571

7.5A Fuse - Air conditioning compressor fuse (F3/3) 7.5A Fuse - Air conditioning fuse (F3/9, +15) 7.5A Fuse - HLHP control unit (F1-A/5, +15) 30A fuse - Heating unit (F4/13-14, +30) 40A Fuse - Heating system (F4/17-18, +30) 7.5A Fuse - Air conditioning system fuse (F1/2, +30) 7.5A Fuse - Left hand sidelights (F1B/10, +30) 20A Fuse - HLHP control unit (F2/3-6, +30) Cab ground

Cab ground

D008

Characteristics/Notes

Wiring connector

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Fig. 3062

Fig. 3063

Fig. 3064

40-198

40-571

40-571 40-576

Wiring diagrams Sys- P/N tem

Description

D009

Wiring connector

D016

Wiring connector

D036

Wiring connector

D073

Wiring connector

D074 K015

Wiring connector Air conditioning Compressor connector (female pressure switch connector): normally open contact - with pressure increasing: contact closed at max 2.4 bar contact open at 28.5 ±1.5 bar - with pressure decreasing: contact closed at 19.5 ±1.5 bar contact open at 1.2 ±0.3 Bar External air temperature sensor

K018

Characteristics/Notes

Position

Wiring loom

40-571 40-583

Fig. 3065

Fig. 3066

Fig. 3067

Fig. 3068

40-556 40-571

40-529 40-583

40-571

40-571 40-583

40-529

40-199

Wiring diagrams Sys- P/N tem

Description

M003

HLHP unit

M003

HLHP unit - USA version

P005

Air conditioning compressor

40-200

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 3069

Fig. 3069

40-571

40-583

Wiring diagrams 40.3.15 - S014 - Automatic air conditioning

6

7

13

+30

+30

4

GND

+30

GND

5

3

2

1

+30

20A

GND

Bm003

C003

+15 HLH

7.5A

7.5A

+15

C003a

Bb005

+58

6

9

11

8

B C1

D009

D016 B A8

B B8

2

1

3

5

4

8

B C6

9

B D7

B C7

B D8

A B1

1

1

To fig. 2/3

21

18

1

2

2 0 t

K018 D0078660

1

P

K015

P005

5

8

D036

4

Bf010

+30 3

To Webasto

2

7.5A

Bf002

7.5A

Ba003 +30

D008 1

To fig. 3/3

10

62

30A

Bc013

7.5A

Ba009

+15

+30 40A

To Webasto

Bc017

C003a

D073

D074 1

AC ENGAGEMENT

M003

Fig. 3070 - Automatic A/C system - System (1/3) l l l l l l l l l l l l l l l

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D016 (M) - Wiring connector (Wiring loom 0.019.5311.4/10) D016 (F) - Wiring connector (Wiring loom 0.020.8658.4) D036 (M) - Wiring connector (Wiring loom 0.021.0396.4) D036 (F) - Wiring connector (Wiring loom 0.019.2383.4/20) D073 (F) - Wiring connector (Wiring loom 0.020.8658.4) D074 (F) - Wiring connector (Wiring loom 0.020.8658.4) K018 - External air temperature sensor M003 - HLHP control unit M003 - HLHP unit - USA version M015 - A/C control unit (blue connector) P005 - Air conditioning system compressor

40-201

Wiring diagrams

3

2

1

2

1

9

7

24

25

21

10

ATTUATOR

ATTUATOR

SENSOR SOLAR

SENSOR SOLAR

To fig. 1/3

2

1

3

5

4

8

9

+30KEY

GND

17

16

26 SW BINARY

18

+15KEY

15

+58 POSITION

6 EXTERNAL SENSOR TEMPERATURE

Blue

22 EXTERNAL SENSOR TEMPERATURE

To fig. 3/3

D016

4

ATTUATOR

K055

ATTUATOR

K056

8

23

25

2

1

21

16

18

9

22

10

14

17

15

5

24

Yellow

M015 D0078670

Fig. 3071 - Automatic A/C system - System (2/3) l l l l l l l l l l l l l l l l l l

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D016 (M) - Wiring connector (Wiring loom 0.019.5311.4/10) D016 (F) - Wiring connector (Wiring loom 0.020.8658.4) D036 (M) - Wiring connector (Wiring loom 0.021.0396.4) D036 (F) - Wiring connector (Wiring loom 0.019.2383.4/20) D073 (F) - Wiring connector (Wiring loom 0.020.8658.4) D074 (F) - Wiring connector (Wiring loom 0.020.8658.4) K014 - Front axle speed sensor K018 - External air temperature sensor K055 - Sunlight sensor K056 - Temperature sensor M003 - HLHP control unit M003 - HLHP unit - USA version M015 - A/C control unit (blue connector) P005 - Air conditioning system compressor

40-202

Wiring diagrams

D074

D073

D0078680

Fig. 3072 - Automatic A/C system - System (3/3) l l l l l l l l l l l l l l l l l l l

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D016 (M) - Wiring connector (Wiring loom 0.019.5311.4/10) D016 (F) - Wiring connector (Wiring loom 0.020.8658.4) D036 (M) - Wiring connector (Wiring loom 0.021.0396.4) D036 (F) - Wiring connector (Wiring loom 0.019.2383.4/20) D073 (F) - Wiring connector (Wiring loom 0.020.8658.4) D074 (F) - Wiring connector (Wiring loom 0.020.8658.4) K014 - Front axle speed sensor K015 - Air conditioning pressure switch K018 - External air temperature sensor K055 - Sunlight sensor K056 - Temperature sensor M003 - HLHP control unit M003 - HLHP unit - USA version M015 - A/C control unit (blue connector) P005 - Air conditioning system compressor

Table 567 Sys- P/N tem

Description

7.5A Fuse - Air conditioning compressor fuse (F3/3) 7.5A Fuse - Air conditioning fuse (F3/9, +15)

Characteristics/Notes

Position

Wiring loom

40-571 40-571

40-203

Wiring diagrams Sys- P/N tem

C003

Description

Characteristics/Notes

Position

Wiring loom

40-571

7.5A Fuse - HLHP control unit (F1-A/5, +15) 30A fuse - Heating unit (F4/13-14, +30) 40A Fuse - Heating system (F4/17-18, +30) 7.5A Fuse - Air conditioning system fuse (F1/2, +30) 7.5A Fuse - Left hand sidelights (F1B/10, +30) 20A Fuse - HLHP control unit (F2/3-6, +30) Cab ground

Cab ground

D008

Wiring connector

D009

Wiring connector

40-571 40-571 40-571 40-571 40-571 40-571

Fig. 3073

Fig. 3074

Fig. 3075

Fig. 3076

40-204

40-571

40-571 40-576

40-571 40-583

Wiring diagrams Sys- P/N tem

Description

D016

Wiring connector

D036

Wiring connector

D073

Wiring connector

D074 K014

Wiring connector Front axle speed sensor Air conditioning Compressor connector (female pressure switch connector): normally open contact - with pressure increasing: contact closed at max 2.4 bar contact open at 28.5 ±1.5 bar - with pressure decreasing: contact closed at 19.5 ±1.5 bar contact open at 1.2 ±0.3 Bar External air temperature sensor Sunlight sensor

K015

K018 K055

Characteristics/Notes

Position

Wiring loom

40-556 40-571

Fig. 3077

Fig. 3078

Fig. 3079

40-529 40-583

40-571

40-571 40-583 40-583

40-529 40-556

Fig. 3080

40-205

Wiring diagrams Sys- P/N tem

Description

K056

Temperature sen- Resistance between pin 1 and pin sor 2: 2,200 ± 110 Ohm at 25°C

M003

HLHP unit

M003

HLHP unit - USA version

M015

Air conditioning control unit (blue connector) Air conditioning compressor

P005

40-206

Characteristics/Notes

Position

Wiring loom

40-556

Fig. 3081

Fig. 3082

Fig. 3083

40-571

40-571

40-556 40-583

Wiring diagrams 40.3.16 - S015 - +15 Positives Jn001

Ja001

I006 0 30

87a

87 86 85

40A

+30

40A

Bf016

Bm017

30

1 2 83

15

P

15

75

50

78

50

+30

3A

Bm015

Bb020

30

15A

30

+30

87 86 85

C003

87a

5A 3A 7.5A 10A 15A 5A 7.5A 5A

3A 5A 5A 5A

7.5A

Ba010

Bb004 Bb005 Bb006 Bb007

To Electronic engine governor

Bb008 Bb009 Bb010 Bf012 Ba007 Ba008

Ba009 Be002

8C

C002

15A

Bb019 Bc003

B015

3A

Bb018

20A

15A

Bb016

D012

7.5A

15A

Bb015

B010

7.5A

Bb003

Bb013

10A

3A 7.5A

20A

Bb011 Bb012

B013

5A 15A

7.5A

Bb002

Bb014

15A

10A

Bb001

Bb017

87a

87 86 85

30

J012 D0078720

Fig. 3084 - S015 - +15 Positives - System l l l l l l

D012 (M) - Wiring connector (Wiring loom 0.018.9992.4/10) D012 (F) - Wiring connector (Wiring loom 0.020.8658.4) I006 - Ignition switch J012 - Nox sensor power relay Ja001 - Ignition key relay (F3/1) Jn001 - Ignition key relay (R7/1)

40-207

Wiring diagrams Table 568 Sys- P/N tem

B010 B013 B015

40-208

Description

Fuse (10A) Fuse (15A) Fuse (20A) 5A fuse - Tierra fuse (F3/7, +15) 5A fuse - Fuse (F3/8, +15) 7.5A Fuse - Air conditioning fuse (F3/9, +15) 15A Fuse - U.S.A. trailer lights fuse (F3/10, +15) 10A Fuse - ISO 11786 (F1-A/1, +15) 5A Fuse - EPB (F1A/2, +15) 15A Fuse - Windscreen wiper (F1A/3, +15) 3A Fuse - Cluster (F1-A/4, +15) 7.5A Fuse - HLHP control unit (F1-A/5, +15) 7.5A Fuse - Pneumatic seat (F1-A/6, +15) 7.5A Fuse - Engine (F1-A/7, +15) 15A Fuse - EU/USA emergency lights (F1-A/8, +15) 3A Fuse - iMonitor + MMI (F1-A/9, +15) 3A Fuse - ISOBUS 11783 (F1-A/10, +15) 7.5A Fuse - Rear view mirrors (F1A/11, +15) 10A Fuse - Rear windscreen wiper (F1-A/12, +15) 15A Fuse - Brake lights (F1-A/13, +15) 3A Fuse - Work light display (F1A/14, +15) 5A Fuse - Transmission (F1-A/15, +15)

Characteristics/Notes

Position

Wiring loom

40-518 40-518 40-518 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

Position

Wiring loom

40-571

7.5A Fuse - Radar/ PTO/distributors (F1-A/16, +15) 5A Fuse - SGR Transmission (F1A/17, +15) 5A Fuse - Radio (F1-A/18, +15) 7.5A Fuse - External electric power outlet sockets (F1A/19, +15) 3A Fuse - Ignition key (F1-A/20, +15) 20A Fuse - Seat/ brakes (F4/3-6, +15) 15A fuse - ABS trailer socket (R6/26, +15)

40-571 40-571 40-571

40-571 40-571 40-571

Table 569 Sys- P/N tem

Description

C002

15A Fuse - Ignition key (F1-A/16, +30) 40A Fuse - Ignition key relay protection (F2/15-16) 40A Fuse - Ignition key relay protection (F2/17-18) Engine ground

D012

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571 40-518

Fig. 3085

40-518

Fig. 3086

40-209

Wiring diagrams Sys- P/N tem

Description

D012

Wiring connector

I006

Starter switch

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 3087

40-571

83

15

75

Pos

Pin

50

30

86s

30

15

50

75

83

0 1 2 0.015.0485.4

J012

40-210

Nox sensor power supply relay Ignition key relay (F3/1) Ignition key relay (R7/1)

Fig. 3088

Fig. 3089

40-518 40-571 40-571

Wiring diagrams

250A

20A 40A

B016

30A

30A 3A

87a

Bm002

Bm001 20A

86 87

B021

87a

B008

Je001

Je002

7

B015

+30a

T001b

T001

a

T001a

b

+30b GND

+30

C001

C002

6

J006a

5

J006b 4

86 87

20A

30A

B014

A001 3

85

B

To AdBlue

2

30

B003

D032

B+

B002

C003

B001

20A

Bm003

85

To working lights

20A

Bm007

20A

Bm008

20A

Bm013

Bm015

Bm009

20A

30A

40A

Bm017

40A

15A

Ba002

Bc001

Ba001

3A

20A

20A

Bc008

Bc002

20A

Bf001

Bc017

40A

30

D002

7.5A

Bf002

Bf003

5A

7.5A

Bf004

15A

Bf005

Bf006

5A

15A

Bf008

Bf009

Bf007

15A

15A

15A

Bf014

Bf011

5A

15A

Bf015

3A

Bf017

Bf016

15A

10A

Bf018

Bf019

5A

15A

Bf020

5A

15A

Bc013 30A

Ba004

40.3.17 - S016 - +30 Positives

BATTERY

D0078320

J006

Fig. 3090 - +30 Positives - System l l l l l l l l l l

A001 - Alternator “B+” D002 (M) - Wiring connector (Wiring loom 0.020.8658.4) D002 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D032 (M) - Wiring connector (Wiring loom 0.021.0396.4) D032 (F) - Wiring connector (Wiring loom 0.018.9992.4/10) J006 - Battery disconnect contactor J006a - Battery disconnect contactor J006b - Battery disconnect contactor Je001 - Relay for front work lights on cab roof (R6/1) Je002 - Relay for rear work lights on cab roof (R6/2)

40-211

Wiring diagrams Table 570 Sys- P/N tem

Description

A001

Alternator “B+”

B001

Fuse (250A)

B002 B003 B008

Fuse (200A) Fuse (40A) Fuse (3A)

B014 B015 B016 B021

Fuse (30A) Fuse (20A) Fuse (30A) Fuse (30A) 15A Fuse - Lights fuse and power outlet socket (F3/1, +30) 3A Fuse - Work Display Fuse (F3/2, +30) 5A fuse - Tierra fuse (F3/4, +30) 20A fuse - Webasto (heater) (F4/1-4, +30) 20A Fuse - Low rear work light relay protection (F4/2-5, +30) 20A Fuse - Rear defrost (F4/8-11) 30A fuse - Heating unit (F4/13-14, +30)

40-212

Characteristics/Notes

Position

Wiring loom

40-589 40-512 40-514

Fig. 3091

Fig. 3092

Fig. 3093

40-514

40-514 40-514 40-514

40-518 40-518 40-518 40-514 40-571

40-571 40-571 40-571 40-571

40-571 40-571

Wiring diagrams Sys- P/N tem

Bf011

Description

40A Fuse - Heating system (F4/17-18, +30) 7.5A Fuse - SGR Transmission (F1A/1, +30) 7.5A Fuse - Air conditioning system fuse (F1/2, +30) 5A Fuse - Transmission control unit (F1-B/3, +30) 15A Fuse - Turn indicator relay protection (F1-B/4, +30) 15A Fuse - Armrest (F1-B/5, +30) 5A Fuse - Radio (F1-B/6, +30) 15A Fuse - Lights relay protection (F1-B/7, +30) 15A Fuse - iMonitor (F1-B/8, +30) 15A Fuse - Lights relay protection (F1-B/9, +30) 5A Fuse - Road lights/Top lights relay protection (F1B/11, +30) 15A Fuse - Sidelights relay protection (F1-B/14, +30) 3A Fuse - Cab lights (F1-B/15, +30)

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571 40-571 40-571

40-571 40-571 40-571 40-571 40-571 40-571

40-571 40-571

40-213

Wiring diagrams Table 571 Sys- P/N tem

C001 C002

Description

Characteristics/Notes

Position

Wiring loom

40-571

15A Fuse - Ignition key (F1-A/16, +30) 10A Fuse - Hitch relay protection (F1B/17, +30) 15A Fuse - Work light display (F1A/18, +30) 5A fuse - Webasto (thermo call) (F1B/19, +30) 15A Fuse - Trailer lights relay protection (F1-B/20, +30) 20A Fuse - Tractor electric power outlet sockets (F2/1-4, +30) 20A Fuse - Cab electric power outlet sockets (F2/2-5, +30) 20A Fuse - HLHP control unit (F2/3-6, +30) 20A Fuse - EU/USA emergency lights (F2/7-10, +30) 20A Fuse - Front work lights relay protection (F2/8-11) 20A Fuse - Steering (F2/9-12, +30) 30A Fuse - Engine (F2/13-14, +30) 40A Fuse - Ignition key relay protection (F2/15-16) 40A Fuse - Ignition key relay protection (F2/17-18) Battery negative terminal Engine ground

40-571 40-571 40-571 40-571 40-571

40-571

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-498 40-498

Fig. 3094

40-214

Wiring diagrams Sys- P/N tem

Description

C003

Cab ground

D002

Wiring connector

D032

Wiring connector

J006

Battery disconnect contactor Battery disconnect contactor

Battery disconnect contactor

Relay for front work lights on cab roof (R6/1) Relay for rear work lights on cab roof (R6/2)

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 3095

Fig. 3096

Fig. 3097

40-571 40-514

40-518 40-583

40-518 40-511

Fig. 3098

Fig. 3099

40-511

40-571 40-571

40-215

Wiring diagrams Sys- P/N tem

T001

Description

Position

Wiring loom

40-511

Battery positive terminal

Battery positive terminal Battery positive terminal

40-216

Characteristics/Notes

Fig. 3100

40-583 40-514

Wiring diagrams 40.3.18 - S017 - CAN BUS Line - Standard version

28

2

24

12

14

2

13

1

+15

+15

7.5A

C003

20A

+30

3

Supply +12V (+30)

27

Supply +12V (+30)

CAN-H AUX

8

15A

CAN-L AUX

2

Bf018

+15 HLHP

4

+30

GND

6

GND

GND

1

Supply +12V (+15)

GND

3

3A

+30

5

CAN-L AUX

+30

49

Bb014

+30

50

H002 CAN-H AUX

CAN-L VEHIC

30

Bb005

CAN-H VEHIC

32

Bm003

CAN-L DISTR

3

CAN-H DISTR

2

O004

C003

M003

O003

To fig. 2/3

B A3

8

3

5

4

C003a

5A

Ba004

Ba007

R002 CAN-L ENG.

CAN-H ENG.

GND

GND

GND

GND

+30

+30

+30

J

86

85

83

82

58

6

2

4

3

5

1

C003

5

4

D016

+30

3

To manual heating

C003a

+15

7

10A

Bb001

6

10

4

3

1

2

B2

C2

B8

C8

Ba002

3A

Bb004

CAN L

To fig. 2/3

+30

9

3A

8

C003a

7

+15

12

GND

11

+15

13

CAN H

D021

D014 14

To Webasto

CAN-H VEHIC.

K

C003a

CAN-L VEHIC.

C

+30

CAN-H DISTR.

D

7.5A

CAN-L DISTR.

L

Bf002

CAN-H VEHIC.

M

30A

CAN-L VEHIC.

E

Bm013

CAN-H ENG.

M002

CAN-L ENG.

F N

1

+15

7.50A

+15 CAN-L AUTOG.

P

9

CAN-H AUTOG.

5A

Bb016

Bb002 CAN-H ISO

+15 CAN-L AUX

B

CAN-L ISO

CAN-H AUX

A

10

+30

B A4

5A

A D5

D078

A C7

D009

B C1

CAN RES

CAN-H VEHIC.

9

10

20

19

5

4

2

1

+30

CAN RES

3

+30 WOOD

+15 I INSTUMENT

3

GND

FUSE PDU3

E002

2

GND

14

CAN-H AUX

15

CAN-L AUX

11

CAN-L VEHIC.

12

CAN-H VEHIC.

21

+15 CLUSTER

5 GND

M008

O002

E003

2

1

3

H001a

4

D0078530

Fig. 3101 - CAN BUS Line - Standard version - System (1/3) l l l l l l l l l

D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D014 (M) - Wiring connector (Wiring loom 0.019.9826.4/30) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D016 (M) - Wiring connector (Wiring loom 0.019.5311.4/10) D016 (F) - Wiring connector (Wiring loom 0.020.8658.4) D021 (M) - Wiring connector (Wiring loom 0.019.2571.4/10) D021 (F) - Wiring connector (Wiring loom 0.020.8658.4) D078 (F) - Wiring connector (Wiring loom 0.020.8658.4) 40-217

Wiring diagrams l l l l l l l l l l l l l l l

E002 - Instrument panel E003 - Work display H001a - Armrest H002 - Work light control M002 - Engine ECU M003 - HLHP control unit M003 - HLHP unit - USA version M008 - ISO 11786 control unit O002 - CAN line termination connector O002a - CAN line termination connector O003 - CAN line termination connector O003a - CAN line termination connector O004 - CAN line termination connector O004a - CAN line termination connector R002 - CANBUS diagnostic connector

40-218

Wiring diagrams P012

7

8

9

12

B016

C3

C2

A8

C8

CAN-H

CAN-L

11

P013

D035

D032

C1

GND

C004 T004

6

-31

5

A

A

B8

A1 30A

B008

D031 4

C002

3

GND

2

CAN H 2

1

CAN L 2

10

B

4

+15 EPB

4 GND

3 CAN-H

2 CAN-L

SUPPLY

1

SUPPLY

5 3

30A

2

+30

1

B017

4

D033

3

3A

2

1

GND

CAN-H

4

CAN-L

3

SUPPLY

2

1

GND

CAN-H

4

CAN-L

3

SUPPLY

2

1

GND

CAN-H

4

CAN-L

3

SUPPLY

2

1

GND

CAN-H

4

CAN-L

3

SUPPLY

CAN-H

2

GND

CAN-L

SUPPLY

1

+30

P010

P007

30A

P011

+30

P008

D009

N004

13

14

6

17

18

8

6

5

CAN L TRANSMISSION

+30 ECU

2

CAN H TRANSMISSION

CAN L VEICHLE

CAN H VEICHLE

3

10

17

18

G

H

U U V

3A

Bb004

+15

C003a

+15 5A

Bb017

Bf001

7.5A

+30

5A

+15

Bb015

5A

4

1

16

17

3

9

5

10

15

16

1

2

4

A B3

A B2

A B5

A B6

3

1

2

12

13 +15 TRASMISSION

8

+30 SGR

7

CAN L

12

CAN H

11

D062

C002

13

GND

D014

D008

To fig. 1/3

+30

Bf003

C003a

+30 15A

Bf008

+30 20A

+15 3A

Bm009

Bb009

C003a

K039

14

R002

1

GND

2

CAN-H

M001c

1

3

CAN-L

4

4

SUPPLY

2

CAN L TRANSMISSION

M001b

To fig. 1/3

3

GND

B A3

+15 CLUSTER

B A4

+15 TRANSMISSION

A D5

CAN H TRANSMISSION

B C1

D090

A C7

GND

C002

C002

P009

3

9

10

CAN L ISOBUS

2

1

22

21 CAN H VEICHLE

CAN H ISOBUS

3

CAN L VEICHLE

CAN L AUX

4

+30 MONITOR

9

+15 MONITOR

8

GND

24

GND

23 CAN H AUX

M005

E005a

D0078120

Fig. 3102 - CAN BUS Line - Standard version - System (2/3) l l l l l l l l l l

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D014 (M) - Wiring connector (Wiring loom 0.019.9826.4/30) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D032 (M) - Wiring connector (Wiring loom 0.021.0396.4) D032 (F) - Wiring connector (Wiring loom 0.018.9992.4/10) 40-219

Wiring diagrams l l l l l l l l l l l l l l l l l l l l

D033 (M) - Wiring connector (Wiring loom 0.021.0396.4) D033 (F) - Wiring connector (Wiring loom 0.018.9992.4/10) D035 (M) - Wiring connector (Wiring loom 0.018.9990.4/10) D035 (F) - Wiring connector (Wiring loom 0.021.0396.4) D062 (M) - Wiring connector (Wiring loom 0.019.9826.4/30) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) D090 (M) - Wiring connector (Wiring loom 0.020.5056.4) D090 (F) - Wiring connector (Wiring loom 0.021.0396.4) E005a - I-Monitor K039 - Brake hydraulic system pressure sensor-60 Km/h M001b - Transmission control unit M001c - Transmission control unit M005 - Internal transmission control unit N004 - E.P.B. device P007 - Utility distributor N° 1 P008 - Utility distributor N° 2 P009 - Utility distributor N° 3 P010 - Utility distributor N° 4 P011 - Utility distributor N° 5 P012 - Utility distributor N° 6 P013 - Utility distributor N° 7 R002 - CANBUS diagnostic connector M002a

O001

3

16

10

18

4

5

5

4

3

2

1

98

77

6C

5C

15A

C002

B013

+15

+15

10A

1D

B010

11

D012

D011

C003

2

CAN-H2 CAN-H ENG

l

CAN-L2 CAN-H ENG

l

M014

O009

Fig. 3103 - CAN BUS Line - Standard version - System (3/3) l l l l l l

D011 (M) - Wiring connector (Wiring loom 0.020.8658.4) D011 (F) - Wiring connector (Wiring loom 04218107) D012 (M) - Wiring connector (Wiring loom 0.018.9992.4/10) D012 (F) - Wiring connector (Wiring loom 0.020.8658.4) K034 - NOX sensor ahead of catalytic converter K036 - NOX sensor after catalytic converter

40-220

K034

2

3 GND

1

K036

4 SUPPLY

M

4

CAN-L

3

CAN-H

2

GND

CAN-H

1

SUPPLY

3

CAN-L

2 ECU

D0068760

Wiring diagrams

16

10

18

4

5

5

4

3

2

1

CAN-H2 CAN-H ENG

3

98

77

6C

5C

15A

C002

B013

+15

+15

10A

1D

B010

11

D012

D011

C003

2

CAN-L2 CAN-H ENG

M002a

O001

O009

K034

2

3 GND

1

K036

4 SUPPLY

M

M014

4

CAN-L

3

CAN-H

2

GND

CAN-H

1

SUPPLY

3

CAN-L

2 ECU

D0068760

Fig. 3103 - CAN BUS Line - Standard version - System (3/3) l l l l

M002a - Engine control unit M014 - Turbocharger O001 - CAN line termination connector O001a - CAN line termination connector

Table 572 Sys- P/N tem

Description

B008

Fuse (3A)

B010 B013 B016 B017

Fuse (10A) Fuse (15A) Fuse (30A) Fuse (30A) 3A Fuse - Work Display Fuse (F3/2, +30) 5A fuse - Tierra fuse (F3/4, +30)

Characteristics/Notes

Position

Wiring loom

40-514

Fig. 3104

40-518 40-518 40-518 40-518 40-571 40-571

40-221

Wiring diagrams Sys- P/N tem

40-222

Description

5A fuse - Tierra fuse (F3/7, +15) 10A Fuse - ISO 11786 (F1-A/1, +15) 5A Fuse - EPB (F1A/2, +15) 3A Fuse - Cluster (F1-A/4, +15) 7.5A Fuse - HLHP control unit (F1-A/5, +15) 3A Fuse - iMonitor + MMI (F1-A/9, +15) 3A Fuse - Work light display (F1A/14, +15) 5A Fuse - Transmission (F1-A/15, +15) 7.5A Fuse - Radar/ PTO/distributors (F1-A/16, +15) 5A Fuse - SGR Transmission (F1A/17, +15) 7.5A Fuse - SGR Transmission (F1A/1, +30) 7.5A Fuse - Air conditioning system fuse (F1/2, +30) 5A Fuse - Transmission control unit (F1-B/3, +30) 15A Fuse - iMonitor (F1-B/8, +30) 15A Fuse - Work light display (F1A/18, +30) 20A Fuse - HLHP control unit (F2/3-6, +30) 20A Fuse - Steering (F2/9-12, +30) 30A Fuse - Engine (F2/13-14, +30)

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Wiring diagrams Sys- P/N tem

Description

C002

Engine ground

C003

Cab ground

Cab ground

C004

Negative terminal of the auxiliary battery

Characteristics/Notes

Position

Wiring loom

40-518 40-583

Fig. 3105

Fig. 3106

Fig. 3107

40-571

40-571

40-583

40-223

Wiring diagrams Table 573 Sys- P/N tem

Description

D008

Wiring connector

D009

Wiring connector

D011

Wiring connector

D012

Wiring connector

D012

Wiring connector

D014

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-576

Fig. 3108

Fig. 3109

Fig. 3110

Fig. 3111

Fig. 3112

40-224

40-571 40-583

40-571 40-590 40-518

40-571

40-559

Wiring diagrams Sys- P/N tem

Description

D014

Wiring connector

D016

Wiring connector

D021

Wiring connector

D031

Wiring connector

D032

Wiring connector

D033

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 3113

Fig. 3114

Fig. 3115

Fig. 3116

Fig. 3117

40-556 40-571

40-535 40-571

40-583 40-514

40-518 40-583

40-518 40-583

Fig. 3118

40-225

Wiring diagrams Sys- P/N tem

Description

D035

Wiring connector

D062

Wiring connector

D062

Wiring connector

D078

Wiring connector

D090

Wiring connector

E002

Instrument panel

Characteristics/Notes

Position

Wiring loom

40-516 40-583

Fig. 3119

Fig. 3120

Fig. 3121

Fig. 3122

Fig. 3123

40-226

40-559

40-542

40-571

40-583 40-570 40-571

Wiring diagrams Sys- P/N tem

E003

Description

Position

Wiring loom

40-571

Work Display

I-Monitor

Armrest

H002

Characteristics/Notes

Work light switch

Fig. 3124

Fig. 3125

Fig. 3126

40-542

40-571

40-571

Fig. 3127

40-227

Wiring diagrams Table 574 Sys- P/N tem

K034 04218185 K036 04218186 K039

Description

Position

Wiring loom

40-518

NOX sensor upline from catalytic converter NOX sensor downline of catalytic converter Brake hydraulic system pressure sensor - 60 Km/h Transmission control unit

Transmission control unit

M002 02959593

Engine control unit

02959593

Engine control unit

M003

Characteristics/Notes

HLHP unit

40-518 40-570 40-571

Fig. 3128

Fig. 3128

Fig. 3129

Fig. 3129

Fig. 3130

40-228

40-571

40-571

40-571

40-571

Wiring diagrams Sys- P/N tem

Description

M003

HLHP unit - USA version

M005

Internal transmission control unit ISO 11786 control unit

M008

M014 04509411 N004 O001

O002

Turbocharger E.P.B. device CAN line termination connector CAN line termination connector CAN line termination connector

CAN line termination connector

O003

CAN line termination connector

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 3130

40-576 40-535

Fig. 3131

40-590 40-583 40-571 40-571 40-571

Fig. 3132

Fig. 3132

40-571

40-571

Fig. 3133

40-229

Wiring diagrams Sys- P/N tem

Description

O004

CAN line termination connector

P007 P008 P009 P010 P011 P012 P013 R002

T004

40-230

Position

Wiring loom

40-571

CAN line termination connector

CAN line termination connector

O009

Characteristics/Notes

CAN line termination connector Utility distributor 1 Utility distributor 2 Utility distributor 3 Utility distributor 4 Utility distributor 5 Utility distributor 6 Utility distributor 7 CANBUS diagnostic connector

Positive terminal of the auxiliary battery

Fig. 3133

Fig. 3134

Fig. 3134

40-571

40-571

40-518 40-516 40-516 40-516 40-516 40-516 40-516 40-516 40-571

Fig. 3135

40-583

Wiring diagrams 40.3.19 - S017A - Standard CAN BUS line - Version with automatic A/C system

28

2

24

12

14

2

13

1

+15

+15

7.5A

C003

20A

+30

3

Supply +12V (+30)

27

Supply +12V (+30)

CAN-H AUX

8

15A

CAN-L AUX

2

Bf018

+15 HLHP

4

+30

GND

6

GND

GND

1

Supply +12V (+15)

GND

3

3A

+30

5

CAN-L AUX

+30

49

Bb014

+30

50

H002 CAN-H AUX

CAN-L VEHIC

30

Bb005

CAN-H VEHIC

32

Bm003

CAN-L DISTR

3

CAN-H DISTR

2

O004

C003

M003

O003

To fig. 2/3

B A3

8

3

5

4

C003a

5A

Ba004

Ba007

R002

GND

+30

+30

+30

58

6

2

4

3

5

1

7

3

5

4

14

1

15

18

17

D016

+30

C003 C003a

+15 10A

Bb001

6

4

3

1

2

B2

C2

B8

C8

Ba002

3A

Bb004

CAN L

To fig. 2/3

+30

10

3A

9

C003a

8

+15

7

GND

12

+15

11

CAN H

13

Blue

M015

D021

D014 14

To Webasto

GND

82

+15KEY

GND

83

C003a

GND

85

GND

CAN-H ENG.

86

+30

CAN-L ENG.

J

7.5A

CAN-H VEHIC.

K

Bf002

CAN-L VEHIC.

C

+30KEY

CAN-H DISTR.

D

LINEA CAN-L AUX

CAN-L DISTR.

L

LINEA CAN-H AUX

CAN-H VEHIC.

M

30A

CAN-L VEHIC.

E

Bm013

CAN-H ENG.

M002

CAN-L ENG.

F N

1

+15

7.50A

+15 CAN-L AUTOG.

P

9

CAN-H AUTOG.

5A

Bb016

Bb002 CAN-H ISO

+15 CAN-L AUX

B

CAN-L ISO

CAN-H AUX

A

10

+30

B A4

5A

A D5

D078

A C7

D009

B C1

O002

CAN RES

CAN-H VEHIC.

9

10

20

19

5

4

2

1

+30

CAN RES

3

+30 WOOD

+15 I INSTUMENT

3

GND

FUSE PDU3

E002

2

GND

14

CAN-H AUX

15

CAN-L AUX

11

CAN-L VEHIC.

12

CAN-H VEHIC.

21

+15 CLUSTER

5 GND

M008

E003

2

1

3

H001a

4

D0078530

Fig. 3136 - S017A - Standard CAN BUS line - Version with automatic A/C system - System (1/3) l l l l l l l l l

D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D014 (M) - Wiring connector (Wiring loom 0.019.9826.4/30) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D016 (M) - Wiring connector (Wiring loom 0.019.5311.4/10) D016 (F) - Wiring connector (Wiring loom 0.020.8658.4) D021 (M) - Wiring connector (Wiring loom 0.019.2571.4/10) D021 (F) - Wiring connector (Wiring loom 0.020.8658.4) D078 (F) - Wiring connector (Wiring loom 0.020.8658.4) 40-231

Wiring diagrams l l l l l l l l l l l l l l l

E002 - Instrument panel E003 - Work display H001a - Armrest H002 - Work light control M002 - Engine ECU M003 - HLHP control unit M003 - HLHP unit - USA version M008 - ISO 11786 control unit O002 - CAN line termination connector O002a - CAN line termination connector O003 - CAN line termination connector O003a - CAN line termination connector O004 - CAN line termination connector O004a - CAN line termination connector R002 - CANBUS diagnostic connector

40-232

Wiring diagrams P012

8

9

12

B016

30A

D032

B008 C3

C2

A8

C8

CAN-L

CAN-H

GND

C1

11

P013

A

A

B8

A1 30A

7

C004 T004

6

-31

5

C002

4

GND

3

CAN H 2

2

D035

1

CAN L 2

10

B

4

+15 EPB

4 GND

3 CAN-H

2 CAN-L

SUPPLY

1

SUPPLY

5 3

+30

2

B017

1

D033

4

3A

3

GND

2

D031

1

CAN-H

4

CAN-L

3

SUPPLY

2

1

GND

CAN-H

4

CAN-L

3

SUPPLY

2

1

GND

CAN-H

4

CAN-L

3

SUPPLY

2

1

GND

CAN-H

4

CAN-L

3

SUPPLY

CAN-H

2

GND

CAN-L

SUPPLY

1

+30

P010

P007

30A

P011

+30

P008

D009

N004

13

14

6

17

18

8

6

5

CAN L TRANSMISSION

+30 ECU

2

CAN H TRANSMISSION

CAN L VEICHLE

CAN H VEICHLE

3

10

17

18

G

H

U U V

3A

Bb004

+15

C003a

+15 5A

Bb017

Bf001

7.5A

+30

5A

+15

Bb015

5A

4

1

16

17

3

9

5

10

15

16

1

2

4

A B3

A B2

A B5

A B6

3

1

2

12

13 +15 TRASMISSION

8

+30 SGR

7

CAN L

12

CAN H

11

D062

C002

13

GND

D014

D008

To fig. 1/3

+30

Bf003

C003a

+30 15A

Bf008

+30 20A

+15 3A

Bm009

Bb009

C003a

K039

14

R002

1

GND

2

CAN-H

M001c

1

3

CAN-L

4

4

SUPPLY

2

CAN L TRANSMISSION

M001b

To fig. 1/3

3

GND

B A3

+15 CLUSTER

B A4

+15 TRANSMISSION

A D5

CAN H TRANSMISSION

B C1

D090

A C7

GND

C002

C002

P009

3

9

10

CAN L ISOBUS

2

1

22

21 CAN H VEICHLE

CAN H ISOBUS

3

CAN L VEICHLE

CAN L AUX

4

+30 MONITOR

9

+15 MONITOR

8

GND

24

GND

23 CAN H AUX

M005

E005a

D0078120

Fig. 3137 - S017A - Standard CAN BUS line - Version with automatic A/C system - System (2/3) l l l l l l l l l l

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D014 (M) - Wiring connector (Wiring loom 0.019.9826.4/30) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D032 (M) - Wiring connector (Wiring loom 0.021.0396.4) D032 (F) - Wiring connector (Wiring loom 0.018.9992.4/10) 40-233

Wiring diagrams l l l l l l l l l l l l l l l l l l l l

D033 (M) - Wiring connector (Wiring loom 0.021.0396.4) D033 (F) - Wiring connector (Wiring loom 0.018.9992.4/10) D035 (M) - Wiring connector (Wiring loom 0.018.9990.4/10) D035 (F) - Wiring connector (Wiring loom 0.021.0396.4) D062 (M) - Wiring connector (Wiring loom 0.019.9826.4/30) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) D090 (M) - Wiring connector (Wiring loom 0.020.5056.4) D090 (F) - Wiring connector (Wiring loom 0.021.0396.4) E005a - I-Monitor K039 - Brake hydraulic system pressure sensor-60 Km/h M001b - Transmission control unit M001c - Transmission control unit M005 - Internal transmission control unit N004 - E.P.B. device P007 - Utility distributor N° 1 P008 - Utility distributor N° 2 P009 - Utility distributor N° 3 P010 - Utility distributor N° 4 P011 - Utility distributor N° 5 P012 - Utility distributor N° 6 P013 - Utility distributor N° 7 R002 - CANBUS diagnostic connector M002a

O001

3

16

10

18

4

5

5

4

3

2

1

98

77

6C

5C

15A

C002

B013

+15

+15

10A

1D

B010

11

D012

D011

C003

2

CAN-H2 CAN-H ENG

l

CAN-L2 CAN-H ENG

l

M014

O009

K034

2

3 GND

1

K036

4 SUPPLY

M

4

CAN-L

3

CAN-H

2

GND

CAN-H

1

SUPPLY

3

CAN-L

2 ECU

D0068760

Fig. 3138 - S017A - Standard CAN BUS line - Version with automatic A/C system - System (3/3) l l l l l l

D011 (M) - Wiring connector (Wiring loom 0.020.8658.4) D011 (F) - Wiring connector (Wiring loom 04218107) D012 (M) - Wiring connector (Wiring loom 0.018.9992.4/10) D012 (F) - Wiring connector (Wiring loom 0.020.8658.4) K034 - NOX sensor ahead of catalytic converter K036 - NOX sensor after catalytic converter

40-234

Wiring diagrams

16

10

18

4

5

5

4

3

2

1

CAN-H2 CAN-H ENG

3

98

77

6C

5C

15A

C002

B013

+15

+15

10A

1D

B010

11

D012

D011

C003

2

CAN-L2 CAN-H ENG

M002a

O001

O009

K034

2

3 GND

1

K036

4 SUPPLY

M

M014

4

CAN-L

3

CAN-H

2

GND

CAN-H

1

SUPPLY

3

CAN-L

2 ECU

D0068760

Fig. 3138 - S017A - Standard CAN BUS line - Version with automatic A/C system - System (3/3) l l l l

M002a - Engine control unit M014 - Turbocharger O001 - CAN line termination connector O001a - CAN line termination connector

Table 575 Sys- P/N tem

Description

B008

Fuse (3A)

B010 B013 B016 B017

Fuse (10A) Fuse (15A) Fuse (30A) Fuse (30A) 3A Fuse - Work Display Fuse (F3/2, +30) 5A fuse - Tierra fuse (F3/4, +30)

Characteristics/Notes

Position

Wiring loom

40-514

Fig. 3139

40-518 40-518 40-518 40-518 40-571 40-571

40-235

Wiring diagrams Sys- P/N tem

40-236

Description

5A fuse - Tierra fuse (F3/7, +15) 10A Fuse - ISO 11786 (F1-A/1, +15) 5A Fuse - EPB (F1A/2, +15) 3A Fuse - Cluster (F1-A/4, +15) 7.5A Fuse - HLHP control unit (F1-A/5, +15) 3A Fuse - iMonitor + MMI (F1-A/9, +15) 3A Fuse - Work light display (F1A/14, +15) 5A Fuse - Transmission (F1-A/15, +15) 7.5A Fuse - Radar/ PTO/distributors (F1-A/16, +15) 5A Fuse - SGR Transmission (F1A/17, +15) 7.5A Fuse - SGR Transmission (F1A/1, +30) 7.5A Fuse - Air conditioning system fuse (F1/2, +30) 5A Fuse - Transmission control unit (F1-B/3, +30) 15A Fuse - iMonitor (F1-B/8, +30) 15A Fuse - Work light display (F1A/18, +30) 20A Fuse - HLHP control unit (F2/3-6, +30) 20A Fuse - Steering (F2/9-12, +30) 30A Fuse - Engine (F2/13-14, +30)

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

Wiring diagrams Sys- P/N tem

Description

C002

Engine ground

C003

Cab ground

Cab ground

C004

Negative terminal of the auxiliary battery

Characteristics/Notes

Position

Wiring loom

40-518 40-583

Fig. 3140

Fig. 3141

Fig. 3142

40-571

40-571

40-583

40-237

Wiring diagrams Table 576 Sys- P/N tem

Description

D008

Wiring connector

D009

Wiring connector

D011

Wiring connector

D012

Wiring connector

D012

Wiring connector

D014

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-576

Fig. 3143

Fig. 3144

Fig. 3145

Fig. 3146

Fig. 3147

40-238

40-571 40-583

40-571 40-590 40-518

40-571

40-559

Wiring diagrams Sys- P/N tem

Description

D014

Wiring connector

D016

Wiring connector

D021

Wiring connector

D031

Wiring connector

D032

Wiring connector

D033

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 3148

Fig. 3149

Fig. 3150

Fig. 3151

Fig. 3152

40-556 40-571

40-535 40-571

40-583 40-514

40-518 40-583

40-518 40-583

Fig. 3153

40-239

Wiring diagrams Sys- P/N tem

Description

D035

Wiring connector

D062

Wiring connector

D078

Wiring connector

D090

Wiring connector

E002

Instrument panel

E003

Work Display

Characteristics/Notes

Position

Wiring loom

40-516 40-583

Fig. 3154

Fig. 3155

Fig. 3156

Fig. 3157

Fig. 3158

40-240

40-559 40-542

40-571

40-583 40-570 40-571

40-571

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

Position

Wiring loom

40-542

I-Monitor

Fig. 3159

Table 577 Sys- P/N tem

Description

H002

Work light switch

K034 04218185

NOX sensor upline from catalytic converter NOX sensor downline of catalytic converter Brake hydraulic system pressure sensor - 60 Km/h Transmission control unit

K036 04218186 K039

Characteristics/Notes

Position

Wiring loom

40-571

Armrest

Fig. 3160

Fig. 3161

40-571

40-518 40-518 40-570 40-571

Fig. 3162

40-241

Wiring diagrams Sys- P/N tem

Description

M002 02959593

Engine control unit

02959593

Engine control unit

Position

Wiring loom

40-571

Transmission control unit

M003

HLHP unit

M003

HLHP unit - USA version

M005

Internal transmission control unit

40-242

Characteristics/Notes

Fig. 3162

Fig. 3163

Fig. 3163

Fig. 3164

Fig. 3164

40-571

40-571

40-571

40-571

40-576

Wiring diagrams Sys- P/N tem

Description

M008

ISO 11786 control unit

M014 04509411 N004 O001

Turbocharger E.P.B. device CAN line termination connector CAN line termination connector CAN line termination connector

O002

CAN line termination connector

O003

CAN line termination connector

CAN line termination connector

Characteristics/Notes

Position

Wiring loom

40-535

Fig. 3165

40-590 40-583 40-571 40-571 40-571

Fig. 3166

Fig. 3166

Fig. 3167

40-571

40-571

40-571

Fig. 3167

40-243

Wiring diagrams Sys- P/N tem

O004

Description

P007 P008 P009 P010 P011 P012 P013 R002

T004

40-244

Position

Wiring loom

40-571

CAN line termination connector

CAN line termination connector

O009

Characteristics/Notes

CAN line termination connector Utility distributor 1 Utility distributor 2 Utility distributor 3 Utility distributor 4 Utility distributor 5 Utility distributor 6 Utility distributor 7 CANBUS diagnostic connector

Positive terminal of the auxiliary battery

Fig. 3168

Fig. 3168

40-571

40-518 40-516 40-516 40-516 40-516 40-516 40-516 40-516 40-571

Fig. 3169

40-583

Wiring diagrams

+30

D014

3A

4

15A

CAN-l

3

3

Bf008

CAN-H

2

Bb009

H007

120 ohm

C003a

To Can Bus Standard

O013c

+15

40.3.20 - S017B - Visual guidance Can Bus line - Version without ISO11783

17

9

18

14

13

8

7

5

15

16

1

2

3

6

D060

10

7

3

4

1

2

17

5

6

3

4

9

10

8

23

24

4

3

2

1

CAN-L AUX

GND

GND

+15 MONITOR

+30 MONITOR

4

8

9

21

22

CAN-L

CAN-H ISOBUS

CAN-L ISOBUS

CAN-H VEHICLE

CAN-L VEHICLE

M009

E005a

4

5

O013b

3 CAN-H

O013

D062

16

CAN-H AUX

D071

6

N012

2

3

120 ohm

O012

D0078550

Fig. 3170 - Visual guidance Can Bus line - Version without ISO11783 - System l l l l l l l l l l

D014 (M) - Wiring connector (Wiring loom 0.019.9826.4/30) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D060 (F) - Wiring connector (Wiring loom 0.019.9826.4/30) D060 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D060 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D060 (F) - Wiring connector (Wiring loom 0.019.9826.4/30) D062 (M) - Wiring connector (Wiring loom 0.019.9826.4/30) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) D071 (M) - Wiring connector (Wiring loom 0.019.9829.4/20) D071 (M) - Wiring connector (Wiring loom 0.019.9829.4/20) 40-245

+30

D014

3A

4

15A

CAN-l

3

3

Bf008

CAN-H

2

Bb009

H007

120 ohm

C003a

To Can Bus Standard

O013c

+15

Wiring diagrams

17

9

18

14

13

8

7

5

15

16

1

2

3

6

D060

10

7

3

4

D071

6

1

2

17

5

6

3

4

9

10

8

4

8

9

21

22

23

24

4

3

2

1

CAN-L

CAN-H ISOBUS

CAN-L ISOBUS

CAN-H VEHICLE

CAN-L VEHICLE

CAN-H AUX

CAN-L AUX

GND

GND

+15 MONITOR

+30 MONITOR

M009

E005a

4

5

O013b

3 CAN-H

O013

D062

16

N012

2

3

120 ohm

O012

D0078550

Fig. 3170 - Visual guidance Can Bus line - Version without ISO11783 - System l l l l l l l l l l l

D071 (F) - Wiring connector (Wiring loom 0.019.9827.4/10) D071 (F) - Wiring connector (Wiring loom 0.019.9828.4/10) E005a - I-Monitor H007 - Monitor controls M009 - “AGROSKY” antenna N012 - Electronically controlled hydraulic power steering O012 - CAN line termination connector O012a - CAN line termination connector O013 - CAN line termination connector O013b - Not used O013c - CAN line termination connector

40-246

Wiring diagrams Table 578 Sys- P/N tem

Description

Characteristics/Notes

Position

Wiring loom

40-571

3A Fuse - iMonitor + MMI (F1-A/9, +15) 15A Fuse - iMonitor (F1-B/8, +30) Cab ground

D014

Wiring connector

D014

Wiring connector

D060

Wiring connector

D060

Wiring connector

40-571 40-571

Fig. 3171

Fig. 3172

Fig. 3173

Fig. 3174

40-559

40-571

40-559

40-561 40-563

Fig. 3175

40-247

Wiring diagrams Sys- P/N tem

Description

D062

Wiring connector

D062

Wiring connector

D071

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-559

Fig. 3176

Fig. 3177

I-Monitor

H007

Monitor controls

M009

“AGROSKY” Antenna Electronically controlled hydraulic power steering

N012

Fig. 3178

Fig. 3179

40-565 40-561 40-563 40-542

40-559

40-565 40-559

Fig. 3180

40-248

40-542

Wiring diagrams Sys- P/N tem

O012

Description

Position

Wiring loom

40-559

CAN line termination connector

CAN line termination connector

O013

Characteristics/Notes

CAN line termination connector

Not used CAN line termination connector

Fig. 3181

Fig. 3181

Fig. 3182

40-559

40-559

40-561 40-561

40-249

Wiring diagrams 40.3.21 - S018 - CAN BUS Line - Version with ISO 11783

+30

+30

GND

GND

GND

+15 HLHP

CAN-L AUX

CAN-H AUX

49

5

3

1

6

4

2

8

27

28

3

10

9

1

8

3

5

14

12

13

2

1

7.5A

4

15A

+30

Bf018

C003

+15

C003a

+30

3A

Bb014

5A

Ba007 CAN-L DISTR.

CAN-H DISTR.

CAN-L VEHIC.

CAN-H VEHIC.

CAN-L ENG.

CAN-H ENG.

GND

GND

GND

GND

+30

+30

+30

M

L

D

C

K

J

86

85

83

82

58

6

2

4

3

5

1

5

4

D016

+30

C003

To Webasto

CAN-H VEHIC.

E

C003a

CAN-L VEHIC.

F

+30

CAN-H ENG.

N

7.5A

CAN-L ENG.

P

Bf002

CAN-H AUTOG.

B

30A

CAN-L AUTOG.

A

Bm013

CAN-L ISO

M002

CAN-H ISO

R002

CAN-L AUX

+15

+15

7.50A

5A

Bb016

Bb002

24

B A3

CAN-H AUX

+15

2

Ba004

B A4

5A

A D5

D009

A C7

3

H002

D078

To Can bus standard

B C1

O004

+15

C003

+30

2

Bm003

O003

Bb005

+30

50

20A

30

CAN-H VEHIC

CAN-L DISTR

32

CAN-L VEHIC

CAN-H DISTR

M003

6

7

3

12

7

8

9

10

4

3

C003a

10A

1

2

CAN RES

CAN RES

CAN-H VEHIC.

Ba002

3A

3

9

10

20

O002

19

5

4

2

1

+30

+15 I INSTUMENT

3

+30 WOOD

FUSE PDU3

E002

2

GND

14

GND

15

CAN-H AUX

11

CAN-L AUX

12

CAN-L VEHIC.

21

CAN-H VEHIC.

5 GND

Bb004

To Can bus standard

+15 CLUSTER

To fig. 2/3

+30

11

3A

13

+15

14

C003a

D014

D021

Bb001

+15

To Can bus standard

E003

2

1

3

4

H001a D0078610

Fig. 3183 - CAN BUS line - Version with ISO 11783 - System (1/3) l l l l l l l l l

D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D016 (M) - Wiring connector (Wiring loom 0.019.5311.4/10) D016 (F) - Wiring connector (Wiring loom 0.020.8658.4) D021 (M) - Wiring connector (Wiring loom 0.019.2571.4/10) D021 (F) - Wiring connector (Wiring loom 0.020.8658.4) D078 (F) - Wiring connector (Wiring loom 0.020.8658.4)

40-250

Wiring diagrams

CAN L VEHICLE

CAN H VEHICLE

+30

GND

J

H

D

C

B

A

4 50 9

1

5

3

4

2

6

81

28

27

30

32

84

D064

J013

CAN H ISOBUS FRONT

3

4

CAN L ISOBUS FRONT

120 ohm

M011

R004

O015

FRONT RELAY COIL

l

CAN H AUTOG.

l

CAN L AUTOG.

l

CAN1 L

l

CAN1 H

l

+ ANT

l

GND

l

GND

l

GND

l

+30

l

+30

l

+30

l

E002 - Instrument panel E003 - Work display H001a - Armrest H002 - Work light control M002 - Engine ECU M003 - HLHP control unit M003 - HLHP unit - USA version O002 - CAN line termination connector O002a - CAN line termination connector O003 - CAN line termination connector O003a - CAN line termination connector O004 - CAN line termination connector O004a - CAN line termination connector R002 - CANBUS diagnostic connector

CAN L VEHICLE

l

CAN H VEHICLE

l

J014

87a

A8

D3

D8

C003a

Bb009

To fig. 1/3

D2

A6

A3

C8

D064

A2

To fig. 3/3

D014

D1

D064

A1

D064

A7

15A

Bf008

To fig. 3/3

+30

86 87

20A

85

Bm009

30

To fig. 3/3

87a

+15

86 87

3A

85

+30

30

To fig.3/3

A5

6

16

15

5

1

14

13

11

12

7

8

9

10

17

18

2

4

D015

To fig. 3/3

3

D013

D069

4

5

6

8

2

5

64 8

47

7

F

3

10

C

2

D062

To fig. 3/3

15

16

17

6

5

3

4

1

2

8

9

3

O012

1

4 3

2

1

4 5

2

H007

N012

3

120 ohm

O013

77

92

M003

D060

D086

2

120 ohm

13

D062a

P021

E

D062

9

D062a

1

13

D063

3

14

+ MONITOR (HLHP2)

2

SUPPLY CUT OFF AS

9

1

D069a

3

1

4

2 4 7

6

9

10

8

D086a

1

4

1

2

D0078780

O014

Fig. 3184 - CAN BUS line - Version with ISO 11783 - System (2/3) l l l l l l l

D013 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D013 (F) - Wiring connector (Wiring loom 0.020.8658.4) D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D015 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D015 (F) - Wiring connector (Wiring loom 0.020.8658.4) D060 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) 40-251

Wiring diagrams GND

GND

GND

+ ANT

CAN1 H

CAN1 L

CAN L AUTOG.

CAN H AUTOG.

FRONT RELAY COIL

A

+30

B

+30

GND

C

+30

+30

D

CAN L VEHICLE

CAN H VEHICLE

H

CAN H VEHICLE

CAN L VEHICLE

J

4 50 9

1

5

3

4

2

6

81

28

27

30

32

84

D064

J013

CAN H ISOBUS FRONT

3

4

CAN L ISOBUS FRONT

120 ohm

M011

R004

O015

J014

87a

A8

D3

D8

C003a

Bb009

To fig. 1/3

D2

A6

A3

C8

D064

A2

To fig. 3/3

D014

D1

D064

A1

D064

A7

15A

Bf008

To fig. 3/3

+30

86 87

20A

85

Bm009

30

To fig. 3/3

87a

+15

86 87

3A

85

+30

30

To fig.3/3

A5

6

16

15

5

1

14

13

11

12

7

8

9

10

17

18

2

4

D015

To fig. 3/3

3

D013

D069

4

5

6

8

2

5

64 8

47

7

F

2

D062

To fig. 3/3

15

16

17

6

5

3

4

1

2

8

9

D060

D086

4

2 4 7

6

D086a 4

1

2

D0078780

O014

Fig. 3184 - CAN BUS line - Version with ISO 11783 - System (2/3) l l l l l l l l l l l l l l l l l l l l

D060 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) D062a (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D063 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D063 (F) - Wiring connector (Wiring loom 0.019.3658.4/20) D064 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D064 (F) - Wiring connector (Wiring loom 0.018.9843.4/20) D069 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D069a (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D086 (M) - Configuration connector (Wiring loom 0.019.2617.4/70) D086a (F) - Configuration connector (Wiring loom 0.019.2617.4/70) H007 - Monitor controls J013 - CAN-L CANBUS ISO11783 configuration relay J014 - CAN-H CANBUS ISO11783 configuration relay M003 - HLHP control unit M003 - HLHP unit - USA version M011 - ISO 11783 control unit N012 - Electronically controlled hydraulic power steering O012 - CAN line termination connector

40-252

2

1

4 3

2

1

4 5

120 ohm

13

1

l

3

O012

1

l

3

10

C

D062a

P021

E

D062

9

9

10

8

2

D062a

1

13

D063

3

14

H007

N012

3

120 ohm

O013

77

92

+ MONITOR (HLHP2)

2

SUPPLY CUT OFF AS

9

1

D069a

3

M003

Wiring diagrams GND

GND

GND

+ ANT

CAN1 H

CAN1 L

CAN L AUTOG.

CAN H AUTOG.

FRONT RELAY COIL

A

+30

B

+30

GND

C

+30

+30

D

CAN L VEHICLE

CAN H VEHICLE

H

CAN H VEHICLE

CAN L VEHICLE

J

4 50 9

1

5

3

4

2

6

81

28

27

30

32

84

D064

J013

CAN H ISOBUS FRONT

3

4

CAN L ISOBUS FRONT

120 ohm

M011

R004

O015

J014

87a

A8

D3

D8

C003a

Bb009

To fig. 1/3

D2

A6

A3

C8

D064

A2

To fig. 3/3

D014

D1

D064

A1

D064

A7

15A

Bf008

To fig. 3/3

+30

86 87

20A

85

Bm009

30

To fig. 3/3

87a

+15

86 87

3A

85

+30

30

To fig.3/3

A5

6

16

15

5

1

14

13

11

12

7

8

9

10

17

18

2

4

D015

To fig. 3/3

3

D013

D069

4

5

6

8

2

5

64 8

47

7

F

3

10

C

2

D062

To fig. 3/3

15

16

17

6

5

3

4

1

2

8

9

3

O012

1

4 3

2

1

4 5

2

H007

N012

3

120 ohm

O013

77

92

M003

D060

D086

2

120 ohm

13

D062a

P021

E

D062

9

D062a

1

13

D063

3

14

+ MONITOR (HLHP2)

2

SUPPLY CUT OFF AS

9

1

D069a

3

1

4

2 4 7

6

9

10

8

D086a

1

4

1

2

D0078780

O014

Fig. 3184 - CAN BUS line - Version with ISO 11783 - System (2/3) l l l l l l l

O012a - CAN line termination connector O013 - CAN line termination connector O014 - Diode connector O014a - Diode board O015 - CAN line termination connector P021 - ISO 11783 socket in cab R004 - ISO11783 diagnostic socket

40-253

Wiring diagrams M002a

O001

M011

J020

J021

J022

J023

16

10

CAN-H2 CAN-H ENG

3

98

77

83

79

77

29

30

85

86 87

30

87a

85

86 87

30

87a

85

86

87

30

87a

D012

D011 11

18

4

85

86

87

87a

D089

C003

2

CAN-L2 CAN-H ENG

120 ohm

5

1D

6C

2

5C

D063

To fig. 2/3 To Can bus standard

E

B3

C

B5

B4

B2

4

3

1

D064

F

4

3

2

1

4

3

1 CAN-L

5

3

1

4

3 GND

2

CAN-H

D095

2

120 ohm ECU

K037

O018

M

M013a

M014 M001b

A5 30

85

86 87

+15 CLUSTER

A3

GND

A2

CAN L TRANSMISSION

A6

CAN H TRANSMISSION

D2

CAN L TRANSMISSION

D3

CAN H TRANSMISSION

D8

+15 TRANSMISSION

A8

+30 ECU

D1

GND

A1

R002

CAN L VEICHLE

D064 A7

M001c

CAN H VEICHLE

J016

To fig. 2/3

3

2

13

14

10

17

18

G

H

U

V

87a

F

E

C

2

4

1

3

17

1

Fig. 3185 - CAN BUS line - Version with ISO 11783 - System (3/3) l l l l l l l l l

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D011 (M) - Wiring connector (Wiring loom 0.020.8658.4) D011 (F) - Wiring connector (Wiring loom 04218107) D012 (M) - Wiring connector (Wiring loom 0.018.9992.4/10) D012 (F) - Wiring connector (Wiring loom 0.020.8658.4) D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D015a (M) - Wiring connector (Wiring loom 0.020.8658.4) D063 (M) - Wiring connector (Wiring loom 0.019.2617.4/70)

40-254

C003a

3A

+15

Bb004

+30

+15 5A

7.5A

Bb017

Bf001

Bb015

5A A B3

A B2

A B5

A B6

2

P023

l

18

To fig. 2/3

4

To fig. 2/3

3

+15

+30

P024

D008

B

D014

D

+30

A

5A

4

Bf003

50A

C003a

3

250A

C002

120 ohm

D067

B001

B019

D015

To Can bus standard

D0078620

Wiring diagrams l l l l l l l l l l l l l l l l l l l l l l l l l

D063 (F) - Wiring connector (Wiring loom 0.019.3658.4/20) D064 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D064 (F) - Wiring connector (Wiring loom 0.018.9843.4/20) D067 (M) - Wiring connector (Wiring loom 0.017.8887.4/10) D067 (F) - Wiring connector (Wiring loom 0.018.9843.4/20) D089 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D095 (F) - Wiring connector (Wiring loom 0.018.9843.4/20) E002 - Instrument panel J016 - ISOBUS relay (30A) J020 - Stoll application relay J021 - Stoll application relay J022 - Stoll application relay J023 - Stoll application relay K037 - Steering wheel angle sensor M001b - Transmission control unit M001c - Transmission control unit M002a - Engine control unit M011 - ISO 11783 control unit M013a - Electronically controlled hydraulic power steering (grey connector) M014 - Turbocharger O018 - CAN line termination connector O018a - CAN line termination connector P023 - Front ISOBUS 11783 socket P024 - Rear ISOBUS 11783 socket R002 - CANBUS diagnostic connector

Table 579 Sys- P/N tem

Description

B001

Fuse (250A)

B019

Fuse (30A) 3A Fuse - Work Display Fuse (F3/2, +30) 5A fuse - Tierra fuse (F3/4, +30) 5A fuse - Tierra fuse (F3/7, +15) 10A Fuse - ISO 11786 (F1-A/1, +15) 5A Fuse - EPB (F1A/2, +15) 3A Fuse - Cluster (F1-A/4, +15) 7.5A Fuse - HLHP control unit (F1-A/5, +15) 3A Fuse - iMonitor + MMI (F1-A/9, +15)

Characteristics/Notes

Position

Wiring loom

40-514

Fig. 3186

40-512 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

40-255

Wiring diagrams Sys- P/N tem

Description

C002

3A Fuse - Work light display (F1A/14, +15) 5A Fuse - Transmission (F1-A/15, +15) 7.5A Fuse - Radar/ PTO/distributors (F1-A/16, +15) 5A Fuse - SGR Transmission (F1A/17, +15) 7.5A Fuse - SGR Transmission (F1A/1, +30) 7.5A Fuse - Air conditioning system fuse (F1/2, +30) 5A Fuse - Transmission control unit (F1-B/3, +30) 15A Fuse - iMonitor (F1-B/8, +30) 15A Fuse - Work light display (F1A/18, +30) 20A Fuse - HLHP control unit (F2/3-6, +30) 20A Fuse - Steering (F2/9-12, +30) 30A Fuse - Engine (F2/13-14, +30) Engine ground

C003

Cab ground

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-512

Fig. 3187

Fig. 3188

40-256

40-571

Wiring diagrams Sys- P/N tem

Description

D008

Wiring connector

D009

Wiring connector

D011

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571

Cab ground

Fig. 3189

Fig. 3190

Fig. 3191

40-571 40-576

40-571 40-583

40-571 40-590

40-257

Wiring diagrams Table 580 Sys- P/N tem

Description

D012

Wiring connector

D012

Wiring connector

D013

Wiring connector

D013

Wiring connector

D014

Wiring connector

D014

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-518

Fig. 3192

Fig. 3193

Fig. 3194

Fig. 3195

Fig. 3196

Fig. 3197

40-258

40-571

40-571

40-537

40-571

40-537

Wiring diagrams Sys- P/N tem

Description

D015

Wiring connector

D015

Wiring connector

Configuration connector

D016

Wiring connector

D021

Wiring connector

D060

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 3198

Fig. 3199

Fig. 3199

Fig. 3200

Fig. 3201

40-537

40-571

40-556 40-571

40-535 40-571

40-537 40-561 40-563

Fig. 3202

40-259

Wiring diagrams Sys- P/N tem

Description

D062

Wiring connector

D062

Wiring connector

D063

Wiring connector Wiring connector

D063

Wiring connector

D064

Wiring connector

D067

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-542

Fig. 3203

Fig. 3204

Fig. 3205

Fig. 3206

Fig. 3207

Fig. 3208

40-260

40-537

40-537 40-537

40-540

40-512 40-537

40-510 40-512

Wiring diagrams Sys- P/N tem

D069 D071 D078

D086

Description

Characteristics/Notes

Position

Wiring loom

40-537 40-537 40-565 40-571

Wiring connector Wiring connector Wiring connector Wiring connector

Configuration connector

Configuration connector

Fig. 3209

Fig. 3210

40-537

40-537

Fig. 3210

40-261

Wiring diagrams Table 581 Sys- P/N tem

Description

D089 D095 E002

Wiring connector Wiring connector Instrument panel

E003

Work Display

Armrest

H002

Work light switch

H007

Monitor controls

J013

CAN-L CANBUS ISO11783 configuration relay CAN-H CANBUS ISO11783 configuration relay

J014

40-262

Characteristics/Notes

Position

Wiring loom

40-537 40-512 40-571

Fig. 3211

Fig. 3212

Fig. 3213

Fig. 3214

Fig. 3215

40-571

40-571

40-571

40-537

40-537 40-537

Wiring diagrams Sys- P/N tem

J016 J020 J021 J022 J023

K037

Description

Characteristics/Notes

Position

Wiring loom

40-512

ISOBUS relay (30A) Stoll application relay Stoll application relay Stoll application relay Stoll application relay Steering wheel an- Pin 1: CAN-L signal Pin 2: 9 - 32V power feed gle sensor

Transmission control unit

Transmission control unit

M002 02959593

Engine control unit

02959593

Engine control unit

40-537 40-537 40-537 40-537 40-540

Pin 3: ground Pin 4: CAN-H signal

40-571

Fig. 3217

Fig. 3217

Fig. 3218

40-571

40-571

40-571

Fig. 3218

40-263

Wiring diagrams Sys- P/N tem

Description

M003

HLHP unit

M003

HLHP unit - USA version

M011

ISO 11783 control unit

Electronically controlled hydraulic power steering (grey connector)

M014 04509411 N012

Turbocharger Electronically controlled hydraulic power steering

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 3219

Fig. 3219

Fig. 3220

Fig. 3221

Fig. 3222

40-264

40-571

40-537

40-540

40-590 40-537

Wiring diagrams Table 582 Sys- P/N tem

O001 O002

Description

CAN line termination connector

CAN line termination connector

O004

Position

Wiring loom

40-571

CAN line termination connector CAN line termination connector

CAN line termination connector

O003

Characteristics/Notes

CAN line termination connector

40-571

Fig. 3223

Fig. 3223

Fig. 3224

Fig. 3224

40-571

40-571

40-571

40-571

Fig. 3225

40-265

Wiring diagrams Sys- P/N tem

Description

O012

CAN line termination connector

Characteristics/Notes

Position

Wiring loom

40-571

CAN line termination connector

CAN line termination connector

O013

CAN line termination connector

O013

CAN line termination connector

O014

Diode connector

Fig. 3225

Fig. 3226

Fig. 3226

Fig. 3227

Fig. 3227

Fig. 3228

40-266

40-537

40-537

40-537

40-537

40-537

Wiring diagrams Sys- P/N tem

Description

O015

CAN line termination connector

O018

CAN line termination connector

Characteristics/Notes

Position

Wiring loom

40-537

Diode board

CAN line termination connector

P021

ISO 11783 socket in cab

P023

Front ISOBUS 11783 socket

Fig. 3228

Fig. 3229

Fig. 3230

Fig. 3230

Fig. 3231

40-537

40-540

40-540

40-537

40-510

40-267

Wiring diagrams Sys- P/N tem

Description

P024

Rear ISOBUS 11783 socket

R002

CANBUS diagnostic connector

R004

ISO11783 diagnostic socket

Characteristics/Notes

Position

Wiring loom

40-512

Fig. 3232

Fig. 3233

Fig. 3234

40-268

40-571

40-537

Wiring diagrams 40.3.22 - S018A - ISO11783 Can Bus line - Version with visual guidance

P021

CAN-H ISOBUS

CAN-L Autog.

CAN-H Autog.

CAN-L Vehicle

CAN-H Vehicle

27

28

30

32

49

50

J013 1

2

3

4

5

1

2

3

4

5

17

16

87a

87

86 85

30

11

12

A3

A2

6

10

F

9

E

6

To fig. 2/2

D014

D062

D062

D063 7

2

5

1

To fig. 2/2

P023

D015

To Can Bus Standard

To fig. 2/2

4

3

4

To fig. 2/2

2

4

15

16

4

E

F

D064

3

To Can Bus Standard

D062

D014

O015

14

17

3

120 ohm

13

10

C003

7

To Can Bus Standard

8

D067

9

To Can Bus Standard

18

D060

D064

D014

D069

D069a

CAN-L ISOBUS

M011

3

2

To fig. 2/2

P024

2

3

3

4 CAN-l

2

CAN-H

4

O013

D2

5

4

C

D

H

D3

J

30

85

86 87

87a

120 ohm

O012

H007

N012

R004

J014

D0078570

Fig. 3235 - ISO11783 Can Bus line - Version with visual guidance - System (1/2) l l l l l l l l l

D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D015 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D015 (F) - Wiring connector (Wiring loom 0.020.8658.4) D060 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D060 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) 40-269

Wiring diagrams l l l l l l l l l l l l l l l l l l l l l l

D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) D063 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D063 (F) - Wiring connector (Wiring loom 0.019.3658.4/20) D064 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D064 (F) - Wiring connector (Wiring loom 0.018.9843.4/20) D067 (M) - Wiring connector (Wiring loom 0.017.8887.4/10) D067 (F) - Wiring connector (Wiring loom 0.018.9843.4/20) D069 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D069a (M) - Wiring connector (Wiring loom 0.019.2617.4/70) H007 - Monitor controls J013 - CAN-L CANBUS ISO11783 configuration relay J014 - CAN-H CANBUS ISO11783 configuration relay M011 - ISO 11783 control unit N012 - Electronically controlled hydraulic power steering O012 - CAN line termination connector O012a - CAN line termination connector O013b - Wiring connector O015 - CAN line termination connector P021 - ISO 11783 socket in cab P023 - Front ISOBUS 11783 socket P024 - Rear ISOBUS 11783 socket R004 - ISO11783 diagnostic socket

40-270

Wiring diagrams

O013c 120 ohm

To fig. 1/2

3

2

3

10

6

+30 15A

7

D014

9

3A

D060

Bb009

C003a

To fig. 1/2

Bf008

+15

O013b

2

16

15

5

1

6

1

2

17

5

6

3

4

9

10

8

4

8

9

21

22

23

24

4

3

2

1

CAN-L

CAN-H ISOBUS

CAN-L ISOBUS

CAN-H VEHICLE

CAN-L VEHICLE

CAN-H AUX

CAN-L AUX

GND

GND

+15 MONITOR

+30 MONITOR

D071

To fig. 1/2

3

4

3

D062

2

CAN-H

16 1

M009

E005a

D0078560

Fig. 3236 - ISO11783 Can Bus line - Version with visual guidance - System (2/2) l l l l l l l l l l l l l l l l l

D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D060 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D060 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) D071 (M) - Wiring connector (Wiring loom 0.019.9829.4/20) D071 (M) - Wiring connector (Wiring loom 0.019.9829.4/20) D071 (F) - Wiring connector (Wiring loom 0.019.9827.4/10) D071 (F) - Wiring connector (Wiring loom 0.019.9828.4/10) E005a - I-Monitor M009 - “AGROSKY” antenna O013 - CAN line termination connector O013c - CAN line termination connector O015 - CAN line termination connector 40-271

Wiring diagrams

O013c 120 ohm

To fig. 1/2

3

2

3

10

6

+30 15A

7

D014

9

3A

D060

Bb009

C003a

To fig. 1/2

Bf008

+15

O013b

2

16

15

5

1

6

1

2

17

5

6

3

4

9

10

8

4

8

9

21

22

23

24

4

3

2

1

CAN-L

CAN-H ISOBUS

CAN-L ISOBUS

CAN-H VEHICLE

CAN-L VEHICLE

CAN-H AUX

CAN-L AUX

GND

GND

+15 MONITOR

+30 MONITOR

D071

To fig. 1/2

16 2

4

3

D062

3

CAN-H

1

M009

E005a

D0078560

Fig. 3236 - ISO11783 Can Bus line - Version with visual guidance - System (2/2) l l l l

P021 - ISO 11783 socket in cab P023 - Front ISOBUS 11783 socket P024 - Rear ISOBUS 11783 socket R004 - ISO11783 diagnostic socket

Table 583 Sys- P/N tem

40-272

Description

3A Fuse - iMonitor + MMI (F1-A/9, +15) 15A Fuse - iMonitor (F1-B/8, +30)

Characteristics/Notes

Position

Wiring loom

40-571 40-571

Wiring diagrams Sys- P/N tem

C003

Description

Characteristics/Notes

Position

Wiring loom

40-571

Cab ground

Cab ground

D014

Wiring connector

D014

Wiring connector

D015

Wiring connector

D060

Wiring connector

Fig. 3237

Fig. 3238

Fig. 3239

Fig. 3240

Fig. 3241

40-571

40-571

40-537

40-571 40-537

40-537 40-561 40-563

Fig. 3242

40-273

Wiring diagrams Sys- P/N tem

Description

D062

Wiring connector

D062

Wiring connector

D063

Wiring connector

D064

Wiring connector

D064

Wiring connector

D067

Wiring connector

D067

Wiring connector

40-274

Characteristics/Notes

Position

Wiring loom

40-542

Fig. 3243

Fig. 3244

Fig. 3245

Fig. 3246

Fig. 3247

Fig. 3248

40-537

40-537 40-540

40-512

40-537

40-510

40-512

Wiring diagrams Sys- P/N tem

D069 D071

Description

Characteristics/Notes

Position

Wiring loom

40-537 40-537 40-565 40-561 40-563 40-542

Wiring connector Wiring connector Wiring connector I-Monitor

H007

Monitor controls

J013

CAN-L CANBUS ISO11783 configuration relay CAN-H CANBUS ISO11783 configuration relay

J014

Fig. 3249

Fig. 3250

40-537

40-537 40-537

Table 584 Sys- P/N tem

M009 M011

N012

Description

Characteristics/Notes

Position

Wiring loom

40-565

“AGROSKY” Antenna ISO 11783 control unit

Electronically controlled hydraulic power steering

40-537

Fig. 3251

40-537

Fig. 3252

40-275

Wiring diagrams Sys- P/N tem

O012

Description

Position

Wiring loom

40-537

CAN line termination connector

CAN line termination connector

O013

Characteristics/Notes

CAN line termination connector

Wiring connector CAN line termination connector

O015

CAN line termination connector

P021

ISO 11783 socket in cab

Fig. 3253

Fig. 3253

Fig. 3254

Fig. 3254

Fig. 3255

Fig. 3256

40-276

40-537

40-537

40-561 40-561

40-537

40-537

Wiring diagrams Sys- P/N tem

P023 P024

R004

Description

Characteristics/Notes

Position

Wiring loom

40-510

Front ISOBUS 11783 socket Rear ISOBUS 11783 socket

ISO11783 diagnostic socket

40-512

Fig. 3257

40-537

Fig. 3258

40-277

Wiring diagrams 40.3.23 - S018B - ISO11783 Can Bus line - Version with assisted steering

P021

CAN-H ISOBUS

CAN-L Autog.

CAN-H Autog.

CAN-L Vehicle

CAN-H Vehicle

27

28

30

32

49

50

J013 1

2

3

4

5

1

2

3

4

5

17

16

87a

87

86 85

30

11

12

A3

A2

6

10

F

9

E

6

To fig. 2/2

D014

D062

D062

D063 7

2

5

1

To fig. 2/2

P023

D015

To Can Bus Standard

To fig. 2/2

4

3

4

To fig. 2/2

2

4

15

16

4

E

F

D064

3

To Can Bus Standard

D062

D014

O015

14

17

3

120 ohm

13

10

C003

7

To Can Bus Standard

8

D067

9

To Can Bus Standard

18

D060

D064

D014

D069

D069a

CAN-L ISOBUS

M011

3

2

To fig. 2/2

P024

2

3

3

4 CAN-l

2

CAN-H

4

O013

D2

5

4

C

D

H

D3

J

30

85

86 87

87a

120 ohm

O012

H007

N012

R004

J014

D0078570

Fig. 3259 - ISO11783 Can Bus line - Version with assisted steering - System (1/2) l l l l l l l l l

D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D015 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D015 (F) - Wiring connector (Wiring loom 0.020.8658.4) D060 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D060 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (M) - Wiring connector (Wiring loom 0.019.2617.4/70)

40-278

Wiring diagrams l l l l l l l l l l l l l l l l l l l l l l

D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) D063 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D063 (F) - Wiring connector (Wiring loom 0.019.3658.4/20) D064 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D064 (F) - Wiring connector (Wiring loom 0.018.9843.4/20) D067 (M) - Wiring connector (Wiring loom 0.017.8887.4/10) D067 (F) - Wiring connector (Wiring loom 0.018.9843.4/20) D069 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D069a (M) - Wiring connector (Wiring loom 0.019.2617.4/70) H007 - Monitor controls J013 - CAN-L CANBUS ISO11783 configuration relay J014 - CAN-H CANBUS ISO11783 configuration relay M011 - ISO 11783 control unit N012 - Electronically controlled hydraulic power steering O012 - CAN line termination connector O012a - CAN line termination connector O013b - Wiring connector O015 - CAN line termination connector P021 - ISO 11783 socket in cab P023 - Front ISOBUS 11783 socket P024 - Rear ISOBUS 11783 socket R004 - ISO11783 diagnostic socket

40-279

Wiring diagrams

O013c 120 ohm

To fig. 1/2

3

2

3

10

6

+30 15A

7

D014

9

3A

D060

Bb009

C003a

To fig. 1/2

Bf008

+15

O013b

2

16

15

5

1

6

2

17

5

6

3

4

9

10

8

6

8

9

21

22

23

24

4

3

2

1

CAN-H ISOBUS

CAN-L ISOBUS

CAN-H VEHICLE

CAN-L VEHICLE

CAN-H AUX

CAN-L AUX

GND

GND

+15 MONITOR

+30 MONITOR

3

4

3

4

5

CAN-H ISOBUS

D062

2

CAN-H ISOBUS

16 1

CAN-L ISOBUS

1

CAN-L ISOBUS

D071

To fig. 1/2

M009a

E005a

D0078580

Fig. 3260 - ISO11783 Can Bus line - Version with assisted steering - System (2/2) l l l l l l l l l l l l l l l l l

D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D060 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D060 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) D071 (M) - Wiring connector (Wiring loom 0.019.9829.4/20) D071 (M) - Wiring connector (Wiring loom 0.019.9829.4/20) D071 (F) - Wiring connector (Wiring loom 0.019.9827.4/10) D071 (F) - Wiring connector (Wiring loom 0.019.9828.4/10) E005a - I-Monitor M009 - “AGROSKY” antenna O013 - CAN line termination connector O013b - Wiring connector O013c - CAN line termination connector

40-280

Wiring diagrams

O013c 120 ohm

To fig. 1/2

3

2

3

10

6

+30 15A

7

D014

9

3A

D060

Bb009

C003a

To fig. 1/2

Bf008

+15

O013b

2

16

15

5

1

6

2

17

5

6

3

4

9

10

8

6

8

9

21

22

23

24

4

3

2

1

CAN-H ISOBUS

CAN-L ISOBUS

CAN-H VEHICLE

CAN-L VEHICLE

CAN-H AUX

CAN-L AUX

GND

GND

+15 MONITOR

+30 MONITOR

3

4

3

4

5

CAN-H ISOBUS

D062

2

CAN-H ISOBUS

16 1

CAN-L ISOBUS

1

CAN-L ISOBUS

D071

To fig. 1/2

M009a

E005a

D0078580

Fig. 3260 - ISO11783 Can Bus line - Version with assisted steering - System (2/2) l l l l l

O015 - CAN line termination connector P021 - ISO 11783 socket in cab P023 - Front ISOBUS 11783 socket P024 - Rear ISOBUS 11783 socket R004 - ISO11783 diagnostic socket

Table 585 Sys- P/N tem

Description

3A Fuse - iMonitor + MMI (F1-A/9, +15) 15A Fuse - iMonitor (F1-B/8, +30)

Characteristics/Notes

Position

Wiring loom

40-571 40-571

40-281

Wiring diagrams Sys- P/N tem

C003

Description

Characteristics/Notes

Position

Wiring loom

40-571

Cab ground

Cab ground

D014

Wiring connector

D014

Wiring connector

D015

Wiring connector

D060

Wiring connector

Fig. 3260

Fig. 3260

Fig. 3260

Fig. 3260

Fig. 3260

Fig. 3260

40-282

40-571

40-571

40-537

40-571 40-537

40-537 40-561 40-563

Wiring diagrams Sys- P/N tem

Description

D062

Wiring connector

D062

Wiring connector

D063

Wiring connector

D064

Wiring connector

D064

Wiring connector

D067

Wiring connector

D067

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-542

Fig. 3260

Fig. 3260

Fig. 3260

Fig. 3260

Fig. 3260

Fig. 3260

40-537

40-537 40-540

40-512

40-537

40-510

40-512 40-283

Wiring diagrams Sys- P/N tem

D069 D071

Description

Characteristics/Notes

Position

Wiring loom

40-537 40-537 40-565 40-561 40-563 40-542

Wiring connector Wiring connector Wiring connector I-Monitor

H007

Monitor controls

J013

CAN-L CANBUS ISO11783 configuration relay CAN-H CANBUS ISO11783 configuration relay

J014

Fig. 3260

Fig. 3260

40-537

40-537 40-537

Table 586 Sys- P/N tem

M009 M011

N012

Description

Characteristics/Notes

Position

Wiring loom

40-565

“AGROSKY” Antenna ISO 11783 control unit

Electronically controlled hydraulic power steering

40-537

Fig. 3260

Fig. 3260

40-284

40-537

Wiring diagrams Sys- P/N tem

O012

Description

Position

Wiring loom

40-537

CAN line termination connector

CAN line termination connector

O013

Characteristics/Notes

CAN line termination connector

Wiring connector CAN line termination connector

O015

CAN line termination connector

P021

ISO 11783 socket in cab

Fig. 3260

Fig. 3260

Fig. 3260

Fig. 3260

Fig. 3260

40-537

40-537

40-561 40-561

40-537

40-537

Fig. 3260

40-285

Wiring diagrams Sys- P/N tem

P023 P024

R004

Description

Characteristics/Notes

Position

Wiring loom

40-510

Front ISOBUS 11783 socket Rear ISOBUS 11783 socket

ISO11783 diagnostic socket

40-512

Fig. 3260

Fig. 3260

40-286

40-537

Wiring diagrams 40.3.24 - S018C - ISO11783 Can Bus line - Version with performance steering

P021

CAN-H Autog.

30

32

J013

5 49 0

1

2

3

4

5

1

2

3

4

5

17

16

87a

87

86 85

30

11

12

A3

A2

6

10

F

9

E

6

To fig. 2/2

D014

2

5

1

4

3

P023 4

To fig. 2/2

2

4

5 1

16

4

E

F

D064

3

To Can Bus Standard

D062

D014

O015

14

17

3

120 ohm

13

10

To fig. 2/2

To fig. 2/2

D015

To Can Bus Standard

D062

D062

D063 7

C003

7

To Can Bus Standard

8

D067

9

To Can Bus Standard

18

D060

D064

D014

D069

D069a

CAN-L Autog.

28

CAN-H Vehicle

CAN-H ISOBUS

27

CAN-L Vehicle

CAN-L ISOBUS

M011

3

2

To fig. 2/2

P024

2

3

3

45 CAN-l

2

CAN-H

4

O013

D2

4

C

D

H

D3

J

30

85

86 87

87a

120 ohm

O012

H007

N012

R004

J014 D0078600

Fig. 3261 - ISO11783 Can Bus line - Version with performance steering - System (1/2) l l l l l l l l l

D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D015 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D015 (F) - Wiring connector (Wiring loom 0.020.8658.4) D060 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D060 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) 40-287

Wiring diagrams l l l l l l l l l l l l l l l l l l l l l l

D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) D063 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D063 (F) - Wiring connector (Wiring loom 0.019.3658.4/20) D064 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D064 (F) - Wiring connector (Wiring loom 0.018.9843.4/20) D067 (M) - Wiring connector (Wiring loom 0.017.8887.4/10) D067 (F) - Wiring connector (Wiring loom 0.018.9843.4/20) D069 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D069a (M) - Wiring connector (Wiring loom 0.019.2617.4/70) H007 - Monitor controls J013 - CAN-L CANBUS ISO11783 configuration relay J014 - CAN-H CANBUS ISO11783 configuration relay M011 - ISO 11783 control unit N012 - Electronically controlled hydraulic power steering O012 - CAN line termination connector O012a - CAN line termination connector O013 - CAN line termination connector O015 - CAN line termination connector P021 - ISO 11783 socket in cab P023 - Front ISOBUS 11783 socket P024 - Rear ISOBUS 11783 socket R004 - ISO11783 diagnostic socket

40-288

Wiring diagrams

M013a

O013c

K037

O018

120 ohm

120 ohm

To fig. 1/2 1

3

4

1

4

2

3

+30

2

+15

3

10

6

7

15A

3A

C003a

Bb009

F

E

D014

9

D063

D060

To fig. 1/2

Bf008

O013b

2

To fig. 1/2

16

15

5

1

6

2

17

5

6

3

4

9

10

8

6

8

9

21

22

23

24

4

3

2

1

CAN-H ISOBUS

CAN-L ISOBUS

CAN-H VEHICLE

CAN-L VEHICLE

CAN-H AUX

CAN-L AUX

GND

GND

+15 MONITOR

+30 MONITOR

3

4

3

4

5

CAN-H ISOBUS

D062

2

CAN-H ISOBUS

16 1

CAN-L ISOBUS

1

CAN-L ISOBUS

D071

To fig. 1/2

M009a

E005a

D0078590

Fig. 3262 - ISO11783 Can Bus line - Version with performance steering - System (2/2) l l l l l l l l l l l l l l l l l

D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D060 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D060 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) D063 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D063 (F) - Wiring connector (Wiring loom 0.019.3658.4/20) D071 (M) - Wiring connector (Wiring loom 0.019.9825.4/10) D071 (F) - Wiring connector (Wiring loom 0.019.9827.4/10) D071 (F) - Wiring connector (Wiring loom 0.019.9828.4/10) D071 (M) - Wiring connector (Wiring loom 0.019.9825.4/10) E005a - I-Monitor K037 - Steering wheel angle sensor M009a - “AGROSKY” Antenna 40-289

Wiring diagrams

M013a

O013c

K037

O018

120 ohm

120 ohm

To fig. 1/2 1

3

4

1

4

2

3

+30

2

+15

3

10

6

7

15A

3A

C003a

Bb009

F

E

D014

9

D063

D060

To fig. 1/2

Bf008

O013b

2

To fig. 1/2

16

15

5

1

6

2

17

5

6

3

4

9

10

8

6

8

9

21

22

23

24

4

3

2

1

CAN-H ISOBUS

CAN-L ISOBUS

CAN-H VEHICLE

CAN-L VEHICLE

CAN-H AUX

CAN-L AUX

GND

GND

+15 MONITOR

+30 MONITOR

3

4

3

4

5

CAN-H ISOBUS

D062

2

CAN-H ISOBUS

16 1

CAN-L ISOBUS

1

CAN-L ISOBUS

D071

To fig. 1/2

M009a

E005a

D0078590

Fig. 3262 - ISO11783 Can Bus line - Version with performance steering - System (2/2) l l l l l

M013a - Electronically controlled hydraulic power steering (grey connector) O013b - Wiring connector O013c - CAN line termination connector O018 - CAN line termination connector O018a - CAN line termination connector

Table 587 Sys- P/N tem

40-290

Description

3A Fuse - iMonitor + MMI (F1-A/9, +15) 15A Fuse - iMonitor (F1-B/8, +30)

Characteristics/Notes

Position

Wiring loom

40-571 40-571

Wiring diagrams Sys- P/N tem

C003

Description

Characteristics/Notes

Position

Wiring loom

40-571

Cab ground

Cab ground

D014

Wiring connector

D014

Wiring connector

D015

Wiring connector

D015

Wiring connector

Fig. 3263

Fig. 3264

Fig. 3265

Fig. 3266

Fig. 3267

40-571

40-571

40-537

40-571

40-537

Fig. 3268

40-291

Wiring diagrams Sys- P/N tem

Description

D060

Wiring connector

D062

Wiring connector

D062

Wiring connector

D063

Wiring connector

D063

Wiring connector

D064

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-537 40-561 40-563 40-537

Fig. 3269

Fig. 3270

Fig. 3271

Fig. 3272

Fig. 3273

Fig. 3274

40-292

40-542

40-537

40-537

40-540

40-512

Wiring diagrams Sys- P/N tem

Description

D064

Wiring connector

D067

Wiring connector

D069

Wiring connector Wiring connector Wiring connector

D071

Characteristics/Notes

Position

Wiring loom

40-537

Fig. 3275

Fig. 3276

I-Monitor

H007

Monitor controls

J013

CAN-L CANBUS ISO11783 configuration relay CAN-H CANBUS ISO11783 configuration relay

J014

Fig. 3277

Fig. 3278

40-510 40-512

40-537 40-537 40-558 40-561 40-563 40-558 40-542

40-537

40-537 40-537

40-293

Wiring diagrams Table 588 Sys- P/N tem

K037

M011

Description

Characteristics/Notes

Position

Wiring loom

40-540

Steering wheel an- Pin 1: CAN-L signal Pin 2: 9 - 32V power feed gle sensor

“AGROSKY” Antenna ISO 11783 control unit

Electronically controlled hydraulic power steering (grey connector)

N012

Electronically controlled hydraulic power steering

O012

CAN line termination connector

CAN line termination connector

Pin 3: ground Pin 4: CAN-H signal

40-558 40-537

Fig. 3280

Fig. 3281

Fig. 3282

Fig. 3283

Fig. 3283

40-294

40-540

40-537

40-537

40-537

Wiring diagrams Sys- P/N tem

O013

O015

O018

Description

Characteristics/Notes

Position

Wiring loom

40-537

CAN line termination connector

Wiring connector CAN line termination connector CAN line termination connector

CAN line termination connector

CAN line termination connector

P021

ISO 11783 socket in cab

P023

Front ISOBUS 11783 socket

Fig. 3284

40-561 40-561 40-537

Fig. 3285

Fig. 3286

Fig. 3286

Fig. 3287

40-540

40-540

40-537

40-510

40-295

Wiring diagrams Sys- P/N tem

Description

P024

Rear ISOBUS 11783 socket

R004

ISO11783 diagnostic socket

Characteristics/Notes

Position

Wiring loom

40-512

Fig. 3288

Fig. 3289

40-296

40-537

Wiring diagrams 40.3.25 - S019 - CAN BUS line - Version without I-Monitor M003

+30

+30

+30

GND

GND

GND

+15 HLHP

CAN-L AUX

CAN-H AUX

30

50

49

5

3

1

6

4

2

8

27

28

H002

7.5A

O004

+15

+30

C003

20A

Bb005

CAN-L VEHIC

32

Bm003

CAN-H VEHIC

3

CAN-L DISTR

2

CAN-H DISTR

O003

3

24

2

14

12

13

2

1

To fig. 2/3 1

8

5

CAN-L VEHIC.

CAN-H VEHIC.

CAN-L ENG.

CAN-H ENG.

GND

GND

GND

GND

+30

+30

+30

86

85

83

82

58

6

2

4

3

5

1

C003

15A

3A

Bf018 5

4

D016

+30

3

To Can bus standard

C003a

+15

7

10A

Bb001

6

B2

C2

B8

C8

Ba002

Bb004

CAN L

To fig. 2/3

+30

2

3A

1

C003a

3

+15

4

3A

10

GND

9

+15

14

CAN H

D021

D014

To Webasto

CAN-H DISTR.

J

C003a

CAN-L DISTR.

K

+30

CAN-H VEHIC.

C

7.5A

CAN-L VEHIC.

D

Bf002

CAN-H ENG.

L

30A

CAN-L ENG.

M

Bm013

CAN-L AUX

A

D014a

C003

Bb014

M002

R002

B

13

+30

+30

+15

+15

C003a

Ba007

+15

4

CAN-L AUX

+15

3

7.50A

5A

Bb016

Bb002

9

5A

B A3

Ba004

B A4

5A

A D5

D009

A C7

D078

10 B C1

CAN RES

CAN-H VEHIC.

9

10

20

19

5

4

2

1

+30

CAN RES

3

+30 WOOD

+15 I INSTUMENT

3

GND

FUSE PDU3

E002

2

GND

14

CAN-H AUX

15

CAN-L AUX

11

CAN-L VEHIC.

12

CAN-H VEHIC.

21

+15 CLUSTER

5 GND

M008

O002

E003

2

1

3

H001a

4

D0078640

Fig. 3290 - CAN BUS line - Version without I-Monitor - System (1/3) l l l l l l l l l

D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D014a (M) - Wiring connector (Wiring loom 0.020.8658.4) D016 (M) - Wiring connector (Wiring loom 0.019.5311.4/10) D016 (F) - Wiring connector (Wiring loom 0.020.8658.4) D021 (M) - Wiring connector (Wiring loom 0.019.2571.4/10) D021 (F) - Wiring connector (Wiring loom 0.020.8658.4) D078 (F) - Wiring connector (Wiring loom 0.020.8658.4) 40-297

Wiring diagrams l l l l l l l l l l l l l l l l

E002 - Instrument panel E003 - Work display H001a - Armrest H002 - Work light control M002 - Engine ECU M002a - Engine control unit M003 - HLHP control unit M003 - HLHP unit - USA version M008 - ISO 11786 control unit O002 - CAN line termination connector O002a - CAN line termination connector O003 - CAN line termination connector O003a - CAN line termination connector O004 - CAN line termination connector O004a - CAN line termination connector R002 - CANBUS diagnostic connector

40-298

Wiring diagrams P012

2

3

1

2

GND

CAN-H

CAN-L

SUPPLY

4

3

4

3

4

5

6

7

8

9

A8

C8

B8

A1 30A

2

+30

1

C004 T004

10

3

A

-31

CAN-H

4

B

4

11

12

D035

3

GND

2 CAN-L

SUPPLY

1

2

A

C002

5 1

P013

B016

1

GND

CAN-H

CAN-L

SUPPLY

4

D032

3

30A

2

GND

CAN-H

CAN-L

SUPPLY

1

4

D033

3

3A

2

B017

1

GND

CAN-H

CAN-L

SUPPLY

GND

4

B008

3

D031

2

CAN-H

CAN-L

SUPPLY

1

+30

P010

P007

30A

P011

+30

P008

B C1

A C7

A D5

B A4

C3

C2

CAN L 2

CAN H 2

GND

C1 +15 EPB

D009

C002

C002

P009

B A3

N004

D090

To fig. 2/3

4

1

GND

+30 ECU

+15 TRANSMISSION

CAN H TRANSMISSION

CAN L TRANSMISSION

CAN H TRANSMISSION

CAN L TRANSMISSION

R002

CAN L VEICHLE

1 SUPPLY

2 GND

3 CAN-H

CAN-L

4

M001c

CAN H VEICHLE

M001b

3

2

13

14

10

17

18

G

H

17

18

+15 CLUSTER

2

GND

3

U V U

3A

Bb004

+15

C003a

+15

+30 7.5A

Bb017

Bf001

5A

5A

5A

Bb015

+15 A B3

A B2

A B5

A B6

3

1

2

12

13

+30 SGR

+15 TRASMISSION

4

10

CAN L

3

9

CAN H

14

C002

13

GND

D014a

D014

D008

To fig. 1/3

+30

C003a

Bf003

K039

120 ohm

D077

M005

D0078370

Fig. 3291 - CAN BUS line - Version without I-Monitor - System (2/3) l l l l l l l l l l

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D014a (M) - Wiring connector (Wiring loom 0.020.8658.4) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D032 (M) - Wiring connector (Wiring loom 0.021.0396.4) D032 (F) - Wiring connector (Wiring loom 0.018.9992.4/10) 40-299

Wiring diagrams l l l l l l l l l l l l l l l l l

D033 (M) - Wiring connector (Wiring loom 0.021.0396.4) D033 (F) - Wiring connector (Wiring loom 0.018.9992.4/10) D035 (M) - Wiring connector (Wiring loom 0.018.9990.4/10) D035 (F) - Wiring connector (Wiring loom 0.021.0396.4) D090 (M) - Wiring connector (Wiring loom 0.020.5056.4) D090 (F) - Wiring connector (Wiring loom 0.021.0396.4) K039 - Brake hydraulic system pressure sensor-60 Km/h M001b - Transmission control unit M001c - Transmission control unit M005 - Internal transmission control unit N004 - E.P.B. device P007 - Utility distributor N° 1 P008 - Utility distributor N° 2 P009 - Utility distributor N° 3 P010 - Utility distributor N° 4 P011 - Utility distributor N° 5 P012 - Utility distributor N° 6 P013 - Utility distributor N° 7 R002 - CANBUS diagnostic connector M002a

O001

3

16

10

18

4

5

5

4

3

2

1

98

77

6C

5C

15A

C002

B013

+15

+15

10A

1D

B010

11

D012

D011

C003

2

CAN-H2 CAN-H ENG

l

CAN-L2 CAN-H ENG

l

M

M014

O009

Fig. 3292 - CAN BUS line - Version without I-Monitor - System (3/3) l l l l l l l l l

D011 (M) - Wiring connector (Wiring loom 0.020.8658.4) D011 (F) - Wiring connector (Wiring loom 04218107) D012 (M) - Wiring connector (Wiring loom 0.018.9992.4/10) D012 (F) - Wiring connector (Wiring loom 0.020.8658.4) K034 - NOX sensor ahead of catalytic converter K036 - NOX sensor after catalytic converter M002a - Engine control unit M014 - Turbocharger O001 - CAN line termination connector

40-300

K034

3 GND

2 CAN-L

1

K036

4 SUPPLY

ECU

4

CAN-H

3

SUPPLY

2

GND

1

CAN-L

3

CAN-H

2

D0078650

Wiring diagrams

16

10

18

4

5

5

4

3

2

1

CAN-H2 CAN-H ENG

3

98

77

6C

5C

15A

C002

B013

+15

+15

10A

1D

B010

11

D012

D011

C003

2

CAN-L2 CAN-H ENG

M002a

O001

M

M014

O009

K034

3 GND

2 CAN-L

1

K036

4 SUPPLY

ECU

4

CAN-H

3

SUPPLY

2

GND

1

CAN-L

3

CAN-H

2

D0078650

Fig. 3292 - CAN BUS line - Version without I-Monitor - System (3/3) l l

O001a - CAN line termination connector O009 - CAN line termination connector

Table 589 Sys- P/N tem

Description

B008

Fuse (3A)

B010 B013 B016 B017

Fuse (10A) Fuse (15A) Fuse (30A) Fuse (30A) 3A Fuse - Work Display Fuse (F3/2, +30) 5A fuse - Tierra fuse (F3/4, +30) 5A fuse - Tierra fuse (F3/7, +15)

Characteristics /Notes

Position

Wiring loom

40-514

Fig. 3293

40-518 40-518 40-518 40-518 40-571 40-571 40-571

40-301

Wiring diagrams Sys- P/N tem

C002

Description

Characteristics /Notes

Position

Wiring loom

40-571

10A Fuse - ISO 11786 (F1-A/1, +15) 5A Fuse - EPB (F1A/2, +15) 3A Fuse - Cluster (F1-A/4, +15) 7.5A Fuse - HLHP control unit (F1-A/5, +15) 3A Fuse - Work light display (F1A/14, +15) 5A Fuse - Transmission (F1-A/15, +15) 7.5A Fuse - Radar/ PTO/distributors (F1-A/16, +15) 5A Fuse - SGR Transmission (F1A/17, +15) 7.5A Fuse - SGR Transmission (F1A/1, +30) 7.5A Fuse - Air conditioning system fuse (F1/2, +30) 5A Fuse - Transmission control unit (F1-B/3, +30) 15A Fuse - Work light display (F1A/18, +30) 20A Fuse - HLHP control unit (F2/3-6, +30) 30A Fuse - Engine (F2/13-14, +30) Engine ground

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-518 40-583

Fig. 3294

40-302

Wiring diagrams Sys- P/N tem

C003

Description

Position

Wiring loom

40-571

Cab ground

Cab ground

C004

Characteristics /Notes

D008

Negative terminal of the auxiliary battery Wiring connector

D009

Wiring connector

Fig. 3295

Fig. 3296

40-571

40-583 40-571 40-576

Fig. 3297

40-571 40-583

Fig. 3298

40-303

Wiring diagrams Table 590 Sys- P/N tem

Description

D011

Wiring connector

D012

Wiring connector

D012

Wiring connector

D014

Wiring connector

D016

Wiring connector Wiring connector

D021

Wiring connector

D031

Wiring connector

D032

Wiring connector

D033

Wiring connector

40-304

Characteristics/Notes

Position

Wiring loom

40-571 40-590 40-518

Fig. 3299

Fig. 3300

Fig. 3301

Fig. 3302

Fig. 3303

40-571

40-571

40-571 40-556 40-571

40-535 40-571

40-583 40-514 40-518 40-583 40-518 40-583

Wiring diagrams Sys- P/N tem

Description

D035

Wiring connector

D077

D078

Configuration connector Configuration connector Wiring connector

D090

Wiring connector

E002

Instrument panel

E003

Work Display

Armrest

H002

Work light switch

K034 04218185

NOX sensor upline from catalytic converter

Characteristics/Notes

Position

Wiring loom

40-516 40-583 40-571 40-571 40-571

Fig. 3304

Fig. 3305

Fig. 3306

Fig. 3307

Fig. 3308

40-583 40-570 40-571

40-571

40-571

40-571

40-518

40-305

Wiring diagrams Sys- P/N tem

K036 04218186 K039

Description

Characteristics/Notes

Position

Wiring loom

40-518

NOX sensor downline of catalytic converter Brake hydraulic system pressure sensor - 60 Km/h

40-570

Table 591 Sys- P/N tem

Description

Position

Wiring loom

40-571

Transmission control unit

Transmission control unit

M002 02959593

Engine control unit

02959593

Engine control unit

M003

Characteristics/Notes

HLHP unit

Fig. 3309

Fig. 3309

Fig. 3310

Fig. 3310

Fig. 3311

40-306

40-571

40-571

40-571

40-571

Wiring diagrams Sys- P/N tem

Description

M003

HLHP unit - USA version

M005

Internal transmission control unit ISO 11786 control unit

M008

M014 04509411 N004 O001

O002

O003

Turbocharger E.P.B. device CAN line termination connector CAN line termination connector CAN line termination connector

CAN line termination connector CAN line termination connector

CAN line termination connector

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 3311

40-576 40-535

Fig. 3312

40-590 40-583 40-571 40-571 40-571

Fig. 3313

40-571 40-571

Fig. 3314

40-571

40-307

Wiring diagrams Sys- P/N tem

O004

O009 P007 P008 P009 P010 P011 P012 P013 R002

T004

40-308

Description

Characteristics/Notes

Position

Wiring loom

40-571

CAN line termination connector

CAN line termination connector CAN line termination connector Utility distributor 1 Utility distributor 2 Utility distributor 3 Utility distributor 4 Utility distributor 5 Utility distributor 6 Utility distributor 7 CANBUS diagnostic connector

Positive terminal of the auxiliary battery

Fig. 3315

40-571 40-518 40-516 40-516 40-516 40-516 40-516 40-516 40-516 40-571

Fig. 3316

40-583

Wiring diagrams 40.3.26 - S020 - PTO

1

10

3

9

2

1

L006

3

1

2

1

7.5A

1

1

D043

2

3

B A6

A D2

B A7

A A6

5

6

8

9

10

11

13

14

EV PTO 1400

EV PTO 540E

EV PTO 1000N

EV REAR PTO PROP.

+15 TRANSMISSION

REAR PTO SENSOR

GND

+30 ECU

Bb016

D043

+15

C002

C002

C003a

C003a

2

4

6

19

58

80

89

8

+30

+30

GND

GND

GND

FRONT PTO SPEED SENSOR

PTO SELECTION

FRONT PTO EV

EXTERNAL PTO

+15 HLHP

1

3

I019

M003

C002 D009

D009

D008

2

A C7

A D4

1

2 freq

3 SUPPLY

2

1

SIG.

5

7

GND

3

10

Bf003

Bb015

+15

C003a D026

1 +30

A D7

C003a

10

D008

D008

2

1

4

2

7.5A

Bf010

+15 7.5A

Bb005

D023

D045

C002

1

20A

B A4

2

1

+58

C002

7

C003

+30

2

Bm003

2

D008

D045

A D3

1

L010

D040

8

7

+30

1

D023

2

L011

5A

freq SIG.

3

2

L009

I024

GND

SUPPLY

1

I010

K030

5A

L014

K009

M001b D0068670

Fig. 3317 - PTO - System l l l l l l l l l l l l l l l l l

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D023 (M) - Wiring connector (Wiring loom 0.020.8658.4) D023 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D026 (M) - Wiring connector (Wiring loom 0.020.8658.4) D026 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D040 (M) - Wiring connector (Wiring loom 0.019.2474.4/10) D040 (F) - Wiring connector (Wiring loom 0.020.8664.4) D043 (M) - Wiring connector (Wiring loom 0.019.2474.4/10) D043 (F) - Wiring connector (Wiring loom 0.020.8664.4) D045 (M) - Wiring connector (Wiring loom 0.020.8664.4) D045 (F) - Wiring connector (Wiring loom 0.900.0816.0) I010 - PTO selection switch I019 - RH rear PTO control button (on mudguard) I024 - LH rear PTO control button (on mudguard) 40-309

Wiring diagrams

freq

2

1

10

3

9

2

L006

3

1

2

1

7.5A

1

1

D043

1

2

C002

C002

C003a

C003a

2

B A6

A D2

B A7

A A6

5

6

8

9

10

11

13

14

EV PTO 540E

EV PTO 1000N

EV REAR PTO PROP.

+15 TRANSMISSION

REAR PTO SENSOR

GND

+30 ECU

D043

3

EV PTO 1400

7.5A

Bb016

4

2

4

6

19

58

80

89

8

+30

+30

GND

GND

GND

FRONT PTO SPEED SENSOR

PTO SELECTION

FRONT PTO EV

EXTERNAL PTO

+15 HLHP

1

3

I019

C002 D009

D009

D008

2

1

2

3 SUPPLY

2

A C7

A D4

SIG.

5

1

GND

3

7

Bf003

Bb015

+15

C003a D026

1 +30

A D7

10

C003a

10

D008

D008

2

+15

+15 7.5A

Bb005

D023

D045

C002

1

20A

B A4

2

1

+58

C002

Bf010

D008

D045

1

7

C003

+30

2

Bm003

L010

D040

8

7

+30

1

D023

2

A D3

1

L011

GND

SIG.

3

2

L009

I024

5A

SUPPLY

1

I010

K030

5A

L014

freq

K009

M001b

M003

D0068670

Fig. 3317 - PTO - System l l l l l l l l l l

K009 – PTO speed sensor K030 - Front PTO speed sensor L006 - Rear PTO control solenoid valve L009 - PTO 1,000 E engagement control solenoid valve L010 - PTO 1,000 N engagement control solenoid valve L011 - PTO 540 E engagement control solenoid valve L014 - Front PTO control solenoid valve M001b - Transmission control unit M003 - HLHP control unit M003 - HLHP unit - USA version

Table 592 Sys- P/N tem

40-310

Description

7.5A Fuse - HLHP control unit (F1-A/5, +15)

Characteristics/Notes

Position

Wiring loom

40-571

Wiring diagrams Sys- P/N tem

Description

C002

5A Fuse - Transmission (F1-A/15, +15) 7.5A Fuse - Radar/ PTO/distributors (F1-A/16, +15) 5A Fuse - Transmission control unit (F1-B/3, +30) 7.5A Fuse - Left hand sidelights (F1B/10, +30) 20A Fuse - HLHP control unit (F2/3-6, +30) Engine ground

C003

Cab ground

Cab ground

D008

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571 40-571 40-571 40-583 40-576

Fig. 3318

Fig. 3319

Fig. 3320

40-571

40-571

40-571 40-576

Fig. 3321

40-311

Wiring diagrams Sys- P/N tem

Description

D009

Wiring connector

D023

Wiring connector

D026

Wiring connector

D040

Wiring connector

D043

Wiring connector

D045

Wiring connector

I010

PTO switch

Characteristics/Notes

Position

Wiring loom

40-571 40-583

Fig. 3322

Fig. 3323

Fig. 3324

Fig. 3325

selector

Fig. 3326

40-312

40-571 40-520

40-571 40-522

40-531 40-576

40-531 40-576 40-588 40-576 40-571

Wiring diagrams Sys- P/N tem

I019

Description

RH rear PTO button (on mudguard)

Characteristics/Notes

Position

Wiring loom

40-522 0 1

3 2 1

Pos

Pin

1

2

0

3 270 Ohm

1

220 Ohm

2.7659.350.0

I024

LH rear PTO button (on mudguard)

Fig. 3327

40-520

0 1

3 2 1

Pos

Pin

1

2

0 1

3 270 Ohm

220 Ohm

2.7659.350.0

Fig. 3327

Table 593 Sys- P/N tem

K009 04438352

K030 L006

L009

Description

Characteristics/Notes

Position

Wiring loom

40-583

PTO speed sensor Pin 1 = ground Pin 2 = square wave signal Pin 3 = 12 V power input Resistance between Pin 2 and Pin 3: approx.18 kOhm High level: 3.5-5.5 V Low level: 0.6-1.2 V Front PTO speed sensor Rear PTO control solenoid valve

PTO 1,000 E engagement control solenoid valve

40-576 40-531

Fig. 3328

40-531

Fig. 3329

40-313

Wiring diagrams Sys- P/N tem

Description

L010

PTO 1,000N engagement control solenoid valve

L011

PTO 540E engagement control solenoid valve

L014

Front PTO control solenoid valve Transmission control unit

M003

HLHP unit

M003

HLHP unit - USA version

40-314

Characteristics/Notes

Position

Wiring loom

40-531

Fig. 3330

Fig. 3331

40-531

40-588 40-571

Fig. 3332

Fig. 3333

40-571

40-571

Wiring diagrams 40.3.27 - S021 - Front and rear hitches

K025

1

2

1

1

2

1

2

1

7

7

0

2

1

1

2

D026

2

0

1

D023

1

3

2

1

I013 1

I018

I023

I022 0

SIG.

GND RADAR

I017

0

SUPPLY

pos GND

3

2

1

SUPPLY

p

3

SIG.

2

1

GND

2

3

SIG.

1

pos GND

1

2

SUPPLY

p

1

L008

K023

V

V

SIG.

RADAR SIGNAL

K029 SUPPLY

+15 RADAR

K008 GND

3

2

L001

0

M006

1

6

A D3

1

B A6

D009 3

5

2

4

6

7

9

53

20

26

70

31

35

37

38

59

71

51

60

73

8

42

29

41

GND

EV UP-

SENSOR GND HLHP

SENSOR GND HLHP

RADAR SIGNAL

REAR HITCH POS

+5V HLHP

SENSOR GND HLHP

FRONT HITCH POSITION

RIGHT DRAFT SIGNAL

LEFT DRAFT SIGNAL

CONFORT PK UP

+5 HLHP

EV UP+

CONFORT PK DOW

EV DOWN+

+15 HLHP

EXTERNAL UP

EV DOWN-

DW

A A2

GND

B B2

GND

B B6

+30

A A7

1

M003

8

9

8

+58

D023

D023

D008

7.5A

D026 9

+30

A B8

A D4

+30

B B5

Bb005

D044 2

B B1

7

8

2

1

3

C003a

A B8

D008

D009

D008 A A4

7.5A

A A5

Bf010

B A5

D009

A B4

D008

A C8

D008

A A6

D008

D009

D008

C003

C002

20A

Bm003

+30

+15

2

Bb016

1

0

D044

D008

+15

I014

7.5A

C002

1

10

9

I011 D0068680

Fig. 3334 - Front and rear hitches - System l l l l l l l l l l l l l l

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D023 (M) - Wiring connector (Wiring loom 0.020.8658.4) D023 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D026 (M) - Wiring connector (Wiring loom 0.020.8658.4) D026 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D044 (M) - Wiring connector (Wiring loom 0.015.5429.4/20) D044 (F) - Wiring connector (Wiring loom 0.020.8664.4) I011 - Rear hitch control switch I013 - Front hitch down button I014 - Front hitch up button I017 - Right hand rear hitch DOWN button (on mudguard) 40-315

Wiring diagrams

1

2

1

1

2

1

2

1

7

7

0

2

1

1

2

D026

2

D023

1

0

GND RADAR

1

3

2

1

I013 1

I018

I023

I022 0

pos SIG.

RADAR SIGNAL

I017

0

SUPPLY

3

2

1

GND

3

SUPPLY

2

1

SIG.

3

p GND

pos SIG.

2

1

2

SUPPLY

p

1

L008

K023

V

GND

+15 RADAR

K025

V

SIG.

1

K029 SUPPLY

2

K008 GND

3

L001

0

M006

1

6

A D3

1

B A6

D009

l l l l l l l l l l

5

2

4

6

7

9

53

20

26

70

31

35

37

38

59

71

51

60

73

8

42

29

41

EV UP-

SENSOR GND HLHP

SENSOR GND HLHP

RADAR SIGNAL

REAR HITCH POS

+5V HLHP

SENSOR GND HLHP

FRONT HITCH POSITION

RIGHT DRAFT SIGNAL

LEFT DRAFT SIGNAL

CONFORT PK UP

+5 HLHP

EV UP+

CONFORT PK DOW

EV DOWN+

+15 HLHP

EXTERNAL UP

EV DOWN-

DW

I018 - Right hand rear hitch UP button (on mudguard) I022 - LH rear hitch DOWN button (on mudguard) I023 - LH rear hitch UP button (on mudguard) K008 - Rear hitch draft sensor (left) K023 - Rear hitch position sensor K025 - Rear hitch draft sensor (right) K029 - Hitch position sensor L001 - Rear hitch up control solenoid valve L008 - Rear hitch down control solenoid valve M003 - HLHP control unit M003 - HLHP unit - USA version M006 - Radar

40-316

8

9

8

+58

D023

D023

D026

D008

7.5A

Bb005

D044

3

GND

A A2

GND

B B2

GND

B B6

+30

A A7

1

Fig. 3334 - Front and rear hitches - System l

9

+30

A B8

A D4

+30

B B5

M003

l

2

B B1

7

8

2

1

3

C003a

A B8

D008

D009

D008 A A4

7.5A

A A5

Bf010

B A5

D009

A B4

D008

A C8

D008

A A6

D008

D009

D008

C003

C002

20A

Bm003

+30

+15

2

Bb016

1

0

D044

D008

+15

I014

7.5A

C002

1

10

9

I011 D0068680

Wiring diagrams Table 594 Sys- P/N tem

Description

C002

7.5A Fuse - HLHP control unit (F1-A/5, +15) 7.5A Fuse - Radar/ PTO/distributors (F1-A/16, +15) 7.5A Fuse - Left hand sidelights (F1B/10, +30) 20A Fuse - HLHP control unit (F2/3-6, +30) Engine ground

C003

Cab ground

Cab ground

D008

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571 40-571 40-576

Fig. 3335

Fig. 3336

Fig. 3337

40-571

40-571

40-571 40-576

Fig. 3338

40-317

Wiring diagrams Sys- P/N tem

Description

D009

Wiring connector

D023

Wiring connector

D026

Wiring connector

D044

Wiring connector

I011

Rear hitch control switch

I013

Front hitch DOWN control pushbutton

Characteristics/Notes

Position

40-571 40-583

Fig. 3339

Fig. 3340

Fig. 3341

Fig. 3342 0 1

2 1

Pos

Pin

1

2

3

0 1 2.7659.347.0

Fig. 3343

40-318

Wiring loom

40-571 40-520

40-571 40-522

40-500 40-576 40-571

40-500

Wiring diagrams Sys- P/N tem

I014

Description

Front hitch UP control pushbutton

Characteristics/Notes

Position

Wiring loom

40-500 1

0

2 1

Pos

Pin

1

2

3

0 1 2.7659.348.0

I017

RH rear hitch DOWN button (on mudguard)

Fig. 3344

40-522

0 1

2 1

Pos

Pin

1

2

3

0 1 2.7659.347.0

I018

RH rear hitch UP button (on mudguard)

Fig. 3344 1

40-522

0

2 1

Pos

Pin

1

2

3

0 1 2.7659.348.0

I022

LH rear hitch DOWN button (on mudguard)

Fig. 3344

40-520

0 1

2 1

Pos

Pin

1

2

3

0 1 2.7659.347.0

I023

LH rear hitch UP button (on mudguard)

Fig. 3344 1

40-520

0

2 1

Pos

Pin

1

2

3

0 1 2.7659.348.0

Fig. 3344

40-319

Wiring diagrams Sys- P/N tem

K008

Description

Characteristics/Notes

Position

Wiring loom

40-583

Hitch draft sensor Pin 1 = ground Pin 2 = analogue signal (LH) Pin 3 = 8V power Signal with no implement hitched: 4V ± 0.2 V

Table 595 Sys- P/N tem

K023 04438667 K025

K029 L001 04451764 L008 04451764 M003

Description

Position

Wiring loom

40-576

Rear lifter position Pin 1 = ground Pin 2 = 5V DC power supply sensor Pin 3 = signal output Hitch draft sensor Pin 1 = ground Pin 2 = analogue signal (RH) Pin 3 = 8V power Signal with no implement hitched: 4V ± 0.2 V Front hitch position sensor Rear hitch ‘UP’ control solenoid valve Rear hitch DOWN control solenoid valve HLHP unit

M003

HLHP unit - USA version

M006

Radar

40-320

Characteristics/Notes

40-576

40-576 40-583 40-576 40-571

Fig. 3345

Pin 1 = ground Pin 2 = pulse signal (100 pulses/ metre) Pin 3 = power 12 V With the radar powered on, the voltage at pin 2 should change when a hand is passed in front of the sensor Radar nominal frequency: 24125 MHz ± 75 MHz

Fig. 3345

40-571

40-576

Wiring diagrams Sys- P/N tem

M006

Description

Characteristics/Notes

Position

Radar

Pin 1 = ground Pin 2 = pulse signal (100 pulses/ metre) Pin 3 = power 12 V With the radar powered on, the voltage at pin 2 should change when a hand is passed in front of the sensor Radar nominal frequency: 24300 MHz ± 75 MHz

Wiring loom

40-576

40.3.28 - S022 - Brakes

Jh002

30

54

M001b

2

3

5

1

A A6

20A

+30

Bm003

C003

7.5A

Bb005

6

+15

+15

+15

Be002

1

B C8

12

A B1

7

9

8

A A8

6

3

6

C002

3

GNDCOM BRAKES BODY

P006

M001c

D092

D091

A C3

BRAKE SENSOR

14 +50 ECU

13

4

D034 A C1

BRAKE BODY +5V

D008

M001a

10

GND

14

+15 TRANSMISSION

BRAKE SWITCH RH

13

BRAKE SWITCH LEFT

+BRAKE SWITCH

6

6

D009

C002

C003a

C003a

8

+30

86 85

WARNING LAMP

87

HLHP 87a

+30

6

+30

C003a

3

11

5A

Bf003

+15 5A

Bb015

2

30A

1

1

Bb013

3

3

B021

2

D031

1

D026

A

D013

C

15A

B

1

2

D023

3

p

C003a

4

0

D009

1

2

To ISO 11783

3

1

0

GND

4

1

0

SIG.

1

0

SUPPLY

1

+30

M003 +30

F023

GND

F019

V

GND

K022

GND

I003

30A

I004

A

B

3

1

2

1

4

5

2

3

P027 D0078350

Fig. 3346 - Brakes - System (1/2) l

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) 40-321

Wiring diagrams Jh002

87

86 85

30

54

M001b

2

3

5

1

A A6

A B1

7

9

8

6

3

6

GNDCOM BRAKES BODY

P006

M001c

A A8

D092 A

B

3

1

2

1

4

5

2

3

P027 D0078350

Fig. 3346 - Brakes - System (1/2) l l l l l l l l l l l l l l l l

D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D013 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D013 (F) - Wiring connector (Wiring loom 0.020.8658.4) D023 (M) - Wiring connector (Wiring loom 0.020.8658.4) D023 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D026 (M) - Wiring connector (Wiring loom 0.020.8658.4) D026 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D034 (M) - Wiring connector (Wiring loom 0.017.8425.4/10) D034 (F) - Wiring connector (Wiring loom 0.021.0396.4) D091 (M) - Wiring connector (Wiring loom 0.021.0490.4) D091 (F) - Wiring connector (Wiring loom 0.021.0396.4) D092 (M) - Wiring connector (Wiring loom 0.021.0490.4)

40-322

20A

+30 +15 Be002 B C8

12

C002

3

Bm003

C003

7.5A

+15

Bb005

6

+30

1

D091

A C3

BRAKE SENSOR

14 +50 ECU

13

4

D034 A C1

BRAKE BODY +5V

D008

M001a

10

GND

14

+15 TRANSMISSION

BRAKE SWITCH RH

13

BRAKE SWITCH LEFT

+BRAKE SWITCH

6

6

D009

C002

C003a

C003a

8

+30

87a

WARNING LAMP

3

30A

6

+30

C003a

2

11

5A

Bf003

+15 5A

Bb015

1

Bb013

1

To ISO 11783

3

3

B021

2

D026

1

D013

A

HLHP

p

C

D031

B

1

15A

0

2

+15

3

D023

1

0

4

C003a

1

D009

1

0

2

GND

3

SIG.

1

0

4

SUPPLY

1

+30

M003 +30

F023

GND

F019

V

GND

K022

GND

I003

30A

I004

Wiring diagrams Jh002

87

86 85

30

54

M001b

2

3

5

1

A A6

20A

+30

Bm003

C003

7.5A

+15

Bb005

6

+15

+30

Be002

1

B C8

12

A B1

7

9

8

A A8

6

3

6

C002

3

GNDCOM BRAKES BODY

P006

M001c

D092

D091

A C3

BRAKE SENSOR

14 +50 ECU

13

4

D034 A C1

BRAKE BODY +5V

D008

M001a

10

GND

14

+15 TRANSMISSION

BRAKE SWITCH RH

13

BRAKE SWITCH LEFT

+BRAKE SWITCH

6

6

D009

C002

C003a

C003a

8

+30

87a

WARNING LAMP

3

30A

6

+30

C003a

2

11

5A

Bf003

+15 5A

Bb015

1

Bb013

1

To ISO 11783

3

3

B021

2

D026

1

D013

A

HLHP

p

C

D031

B

1

15A

0

2

+15

3

D023

1

0

4

C003a

1

D009

1

0

2

GND

3

SIG.

1

0

4

SUPPLY

1

+30

M003 +30

F023

GND

F019

V

GND

K022

GND

I003

30A

I004

A

B

3

1

2

1

4

5

2

3

P027 D0078350

Fig. 3346 - Brakes - System (1/2) l l l l l l l l l l l l l

D092 (F) - Wiring connector (Wiring loom 0.021.0396.4) F019 - RH rear brake light F023 - LH rear brake light I003 - RH brake pedal switch I004 - LH brake pedal switch Jh002 - Brake lights relay (R3/2) K022 - Brake circuit pressure sensor M001a - Transmission control unit M001b - Transmission control unit M001c - Transmission control unit M003 - HLHP control unit P006 - Trailer socket P027 - Trailer socket

40-323

Wiring diagrams E003

+30

+30 WOOD

1

2

C002

+15

C004

+30 30A

B016

C002

+15 5A

Bb002

+30

B017

B C1

D033

D033

D009

D009

D009 B C3

D032

30A

C003

20A

Bm003

A B5

1

3A

A C8

2

Ba002

A B2

4

P 1

+30

B B7

GND

A C1

3

C003a

B C2

5

C003a

B D6

5

+15 CLUSTER

12

6

3A

HAND BRAKE LAMP

1

11

GND

GND COM SMART SW/LED

EPB LED

2

12

Bb004

SMART SW

3

EPB LEVER SIGNAL

4

GND COM EPB LEVER

13

+30

Bf005

14

D009

15

GND

+30 ARMREST

18

GND

+5V HLHP

17

+30 ARMREST

EPB SECONDARY LEVER

1

15A

SENSOR GND HLHP

16

P

K007 0

K006

+15 CLUSTER

H001

A

B

A

B C4

B4

C1

A8

A5

C6

B1

B3

A4

42

A1

B6

C8

B8

C7

+5V EPB LEVER

SMART SW

GND COM SMART SW

SPB LED

30 (MAIN BATTERY-30A)

HAND BRAKE LAMP

-31 (BACKUP BATTERY)

+30 (BACKUP BATTERY 30A)

BRAKES PRESSURE SENSOR

GND

PRESS. BRAKE SW

84

EPB LEVER SIGNAL

GND

72

GND COM EPB LEVER

GND

53

GND -31

+30

40

+15 EPB

+30

31

LIMP HOME EPB

16

LIMP HOME EPB

6

+5V HLHP

4

SENSOR GND HLHP

2

SENSOR GND HLHP

5

EPB SECONDARY LEVER

3

+30

T004 1

M003

Fig. 3347 - Brakes - System (2/2) l l l l l l l l l l l l

D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D032 (M) - Wiring connector (Wiring loom 0.021.0396.4) D032 (F) - Wiring connector (Wiring loom 0.018.9992.4/10) D033 (M) - Wiring connector (Wiring loom 0.021.0396.4) D033 (F) - Wiring connector (Wiring loom 0.018.9992.4/10) E003 - Work display H001 - Armrest K006 - Brake circuit alarm pressure switch (15 Bar) K007 - E.P.B. pressure sensor M003 - HLHP control unit N004 - E.P.B. device

40-324

N004

GND

BATTERY AUXILIARY

D0078360

+30

Wiring diagrams Table 596 Sys- P/N tem

B016 B017 B021

Description

C002

Fuse (30A) Fuse (30A) Fuse (30A) 3A Fuse - Work Display Fuse (F3/2, +30) 5A Fuse - EPB (F1A/2, +15) 3A Fuse - Cluster (F1-A/4, +15) 7.5A Fuse - HLHP control unit (F1-A/5, +15) 15A Fuse - Brake lights (F1-A/13, +15) 5A Fuse - Transmission (F1-A/15, +15) 15A fuse - ABS trailer socket (R6/26, +15) 5A Fuse - Transmission control unit (F1-B/3, +30) 15A Fuse - Armrest (F1-B/5, +30) 20A Fuse - HLHP control unit (F2/3-6, +30) Engine ground

C003

Cab ground

Characteristics/Notes

Position

Wiring loom

40-518 40-518 40-514 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-583

Fig. 3348

40-571

Fig. 3349

40-325

Wiring diagrams Sys- P/N tem

Description

C004 D008

Negative terminal of the auxiliary battery Wiring connector

D009

Wiring connector

D013

Wiring connector

D013

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571

Cab ground

Fig. 3350

40-571 40-576

Fig. 3351

Fig. 3352

Fig. 3353

Fig. 3354

40-326

40-583

40-571 40-583

40-571

40-537

Wiring diagrams Sys- P/N tem

Description

D023

Wiring connector

D026

Wiring connector

D031

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-520

Fig. 3355

Fig. 3356

40-571 40-522

40-583 40-514

Fig. 3357

Table 597 Sys- P/N tem

Description

D032

Wiring connector

D033

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-518 40-583

Fig. 3358

40-518 40-583

Fig. 3359

40-327

Wiring diagrams Sys- P/N tem

Description

D034

Wiring connector

D091

Wiring connector

D091

Wiring connector

D092

Wiring connector

D092

Wiring connector

E003

Work Display

F019

RH rear brake light

40-328

Characteristics/Notes

Position

Wiring loom

40-583 40-507

Fig. 3360

Fig. 3361

Fig. 3362

Fig. 3363

Fig. 3364

Fig. 3365

40-583

40-586

40-583

40-586

40-571

40-522

Wiring diagrams Sys- P/N tem

Description

F023 H001

LH rear brake light Armrest

I003

RH brake pedal Between Pin 1 and Pin 2: Normally closed (NC) contact switch Between Pin 3 and Pin 4: Normally open contact (NO) LH brake pedal Between Pin 1 and Pin 2: Normally closed (NC) contact switch Between Pin 3 and Pin 4: Normally open contact (NO) Brake lights relay (R3/2) Brake circuit alarm Normally open contact (NO) Switching pressure: 15 bar

I004

K006

Characteristics/Notes

Position

Wiring loom

40-520 40-571

Fig. 3366

40-571

40-571

40-571 40-583

40-329

Wiring diagrams Table 598 Sys- P/N tem

K007

Description

Characteristics/Notes

Position

Wiring loom

40-583

EPB pressure sen- Normally closed (NC) contact Resistance between pin 1 and pin sor 2: closed contact: 2200 ohms

K022

open contact: 3200 ohms Brakes circuit pres- Pin 1 = 5.0Vdc power Pin 2 = ground sure sensor Pin 3 = analogue signal Output 0.5Vdc (0 bar) Output 4.5Vdc (40 Bar) Transmission control unit

Transmission control unit

Transmission control unit

M003

HLHP unit

40-576

40-571

Fig. 3370

Fig. 3370

Fig. 3370

Fig. 3371

40-330

40-571

40-571

40-571

Wiring diagrams Sys- P/N tem

Description

M003

HLHP unit

N004 P006 P027

E.P.B. device Trailer socket Trailer socket

T004

Positive terminal of the auxiliary battery

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 3371

Fig. 3372

40-583 40-509 40-586

40-583

40-331

Wiring diagrams 40.3.29 - S023 - Hydraulic trailer braking E002 TRAILER LIGHT (HYDR)

+15 INSTRUMENT

FUSE PDU3 (INTRUM.+30)

+30 WOOD

+30

+15 CLUSTER

GND

GND

TRAILER INDICATOR

5

10

12

21

1

2

3

4

5

18

Jg004

87

87a

86 85

30

D009

GND

E003

C002 D008

20A

Bc003

C003a

+15

D009

D008

+30

+15

B B2

B D1

B D5

C004

D039

+15

B017

5A

Bb002

D039

30A

B016

C002

+30

3A

B D3

+30

1

4

2

1

30A

D033

D032

B C1

A

D033

3

2

D009

B C8

B008

D008

5

C003a

3A

Ba002

D031

3A

C003a

Bb004

A D5

B

A

C8

B8

-31 (BACKUP BATTERY)

K026

C1

+30(BACKUP BATTERY 30A)

K032

P

A8

+15 EPB

P

1

A2

GND -31

0

A1

TRAILER RELAY COIL EPB

1

1

30 (MAIN BATTERY-30A)

T004 2

GND

+30

L012 L017

D0078280

l l l l l l l l l l l l l l

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D032 (M) - Wiring connector (Wiring loom 0.021.0396.4) D032 (F) - Wiring connector (Wiring loom 0.018.9992.4/10) D033 (M) - Wiring connector (Wiring loom 0.021.0396.4) D033 (F) - Wiring connector (Wiring loom 0.018.9992.4/10) D039 (M) - Wiring connector (Wiring loom 0.020.8664.4) D039 (F) - Wiring connector (Wiring loom 0.019.2539.4/10) E002 - Instrument panel

40-332

1

BATTERY AUXILIARY

N004

Fig. 3373 - Hydraulic trailer braking - System

2

Wiring diagrams E002 TRAILER LIGHT (HYDR)

+15 INSTRUMENT

FUSE PDU3 (INTRUM.+30)

+30 WOOD

+30

+15 CLUSTER

GND

GND

TRAILER INDICATOR

5

10

12

21

1

2

3

4

5

18

Jg004

87

87a

86 85

30

D009

GND

E003

C002 D008

20A

Bc003

C003a

+15

D009

D008

+30

+15

B B2

B D1

B D5

C004

D039

+15

B017

5A

Bb002

D039

30A

B016

C002

+30

3A

B D3

+30

1

4

2

1

30A

D033

D032

B C1

A

D033

3

2

D009

B C8

B008

D008

5

C003a

3A

Ba002

D031

3A

C003a

Bb004

A D5

B

A

C1

C8

B8

-31 (BACKUP BATTERY)

A8

+30(BACKUP BATTERY 30A)

K026

A2

+15 EPB

K032

P

A1

GND -31

0

P

1

TRAILER RELAY COIL EPB

1

1

30 (MAIN BATTERY-30A)

T004 2

GND

+30

2

1

BATTERY AUXILIARY

L012 L017

N004 D0078280

Fig. 3373 - Hydraulic trailer braking - System l l l l l l l

E003 - Work display Jg004 - Trailer braking relay (R1-A/4) K026 - Compressed air pressure sensor K032 - Trailer braking low pressure switch L012 - Trailer parking brake control solenoid valve L017 - EPB Solenoid valve N004 - E.P.B. device

40-333

Wiring diagrams Table 599 Sys- P/N tem

Description

B008

Fuse (3A)

B016 B017

Fuse (30A) Fuse (30A) 3A Fuse - Work Display Fuse (F3/2, +30) 5A Fuse - EPB (F1A/2, +15) 3A Fuse - Cluster (F1-A/4, +15) 20A Fuse - Seat/ brakes (F4/3-6, +15) Engine ground

C002

Cab ground

C004 D008

Negative terminal of the auxiliary battery Wiring connector

Characteristics/Notes

Position

Wiring loom

40-514

Fig. 3374

40-571 40-571 40-571 40-583 40-576

Fig. 3375

Fig. 3376

40-571

40-583 40-571 40-576

Fig. 3377

40-334

40-518 40-518 40-571

Wiring diagrams Sys- P/N tem

Description

D009

Wiring connector

D031

Wiring connector

D032

Wiring connector

D033

Wiring connector

D039

Wiring connector

E002

Instrument panel

Characteristics/Notes

Position

Wiring loom

40-571 40-583

Fig. 3378

Fig. 3379

Fig. 3380

Fig. 3381

Fig. 3382

40-583 40-514

40-518 40-583

40-518 40-583

40-533 40-576

40-571

Fig. 3383

40-335

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

Position

Wiring loom

40-571

E003

Work Display

K026

Trailer braking relay (R1-A/4) Compressed air Power 12V DC Resistance at 0 bar 10-13 Ohm pressure sensor Resistance at 6 Bar 119-129 Ohm

Fig. 3384

40-571 40-576

Table 600 Sys- P/N tem

Description

K032

Trailer braking low pressure switch

L012

Trailer parking brake control solenoid valve

L017

“EPB” solenoid valve E.P.B. device Positive terminal of the auxiliary battery

N004 T004

40-336

Characteristics/Notes

Position

Wiring loom

40-533

Fig. 3385

Fig. 3386

40-533

40-576 40-583 40-583

Wiring diagrams 40.3.30 - S024 - Hydraulic distributors

7

6

8

9

12

11

2

P007

P010

+30

1

2 0

1 1

2 0

1 1

20A

+30

Bm003

2 0

1

I021

I015

I016

3

P012

2

GND

CAN-H

3

4

4 GND

2

CAN-H

1

CAN-L

4

SUPPLY

3

GND

2

CAN-H

1

CAN-L

4

SUPPLY

3

GND

2

CAN-H

1

CAN-L

CAN-H

P011

4

SUPPLY

3

GND

2 CAN-L

1 SUPPLY

CAN-H

P008

4

CAN-L

4

GND

3

CAN-L

SUPPLY

2

5

P013

1

1

7

1 1

I020

SUPPLY

3

3

1

GND

CAN-H

SUPPLY

CAN-L

2

2

C003

7.5A

+15

Bb005 D035

4

11

2 0

P009

1

2

1

5

4

D026

D023 D009

C002

A C7

3

6

To Can bus standard

7

10

+30

11

+30

2

GND

HLHP

8

GND

EXT. DISTR.

12

GND

EXT. DISTR.

13 7.5A

Bb016

+15

M003

D0078630

Fig. 3387 - Hydraulic distributors - System l l l l l l l l l l l l l l l

D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D023 (M) - Wiring connector (Wiring loom 0.020.8658.4) D023 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D026 (M) - Wiring connector (Wiring loom 0.020.8658.4) D026 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D035 (M) - Wiring connector (Wiring loom 0.018.9990.4/10) D035 (F) - Wiring connector (Wiring loom 0.021.0396.4) I015 - Right hand distributor DOWN button (on mudguard) I016 - Right hand distributor UP button (on mudguard) I020 - LH distributor DOWN button (on mudguard) I021 - LH distributor UP button (on mudguard) M003 - HLHP control unit M003 - HLHP unit - USA version P007 - Utility distributor N° 1 40-337

Wiring diagrams

+30

+30

11

+30

2

GND

HLHP

8

GND

EXT. DISTR.

12

GND

EXT. DISTR.

13

6

4

2

3

5

1

D009

C002

A C7

D035

1

3

5

4

7

6

8

9

12

11

2

P011

P007

P010

1 1

2 0

1 1

20A

+30

2 0

1

I021

I015

I016

3

P012

2

GND

CAN-H

3

4

4 GND

2

CAN-H

1

CAN-L

4

SUPPLY

3

GND

2

CAN-H

1

CAN-L

4

SUPPLY

3

GND

2

CAN-H

1

CAN-L

CAN-H

4

SUPPLY

3

GND

2 CAN-L

1 SUPPLY

CAN-H

P008

4

CAN-L

4

GND

3

CAN-L

SUPPLY

2

2 0

P013

1

1

1 1

I020

SUPPLY

3

7

1

GND

CAN-H

CAN-L

SUPPLY

2

11

2 0

P009

1

2

To Can bus standard

7

10

Bm003

C003

7.5A

D026

D023

+15

Bb005

7.5A

Bb016

+15

M003

D0078630

Fig. 3387 - Hydraulic distributors - System l l l l l l

P008 - Utility distributor N° 2 P009 - Utility distributor N° 3 P010 - Utility distributor N° 4 P011 - Utility distributor N° 5 P012 - Utility distributor N° 6 P013 - Utility distributor N° 7

Table 601 Sys- P/N tem

40-338

Description

7.5A Fuse - HLHP control unit (F1-A/5, +15) 7.5A Fuse - Radar/ PTO/distributors (F1-A/16, +15)

Characteristics/Notes

Position

Wiring loom

40-571 40-571

Wiring diagrams Sys- P/N tem

Description

C002

20A Fuse - HLHP control unit (F2/3-6, +30) Engine ground

C003

Cab ground

D009

Wiring connector

D023

Wiring connector

D026

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-583

Fig. 3388

Fig. 3389

Fig. 3390

Fig. 3391

40-571

40-571 40-583

40-571 40-520

40-571 40-522

Fig. 3392

40-339

Wiring diagrams Sys- P/N tem

Description

D035

Wiring connector

I015

RH distributor DOWN button (on mudguard)

Characteristics/Notes

Position

Wiring loom

40-516 40-583

Fig. 3393

Pos

Pin

1

2

40-522

3

0 1 2.7659.337.0

I016

Fig. 3394

RH distributor UP button (on mudguard)

Pos

Pin

1

2

40-522

3

0 1 2.7659.337.0

I020

Fig. 3394

LH distributor DOWN button (on mudguard)

Pos

Pin

1

2

40-520

3

0 1 2.7659.337.0

I021

Fig. 3394

LH distributor UP button (on mudguard)

Pos

Pin

1

2

3

0 1 2.7659.337.0

Fig. 3394

40-340

40-520

Wiring diagrams Sys- P/N tem

Description

M003

HLHP unit

M003

HLHP unit - USA version

P007 P008 P009 P010 P011 P012 P013

Utility distributor 1 Utility distributor 2 Utility distributor 3 Utility distributor 4 Utility distributor 5 Utility distributor 6 Utility distributor 7

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 3395

Fig. 3395

40-571

40-516 40-516 40-516 40-516 40-516 40-516 40-516

40-341

Wiring diagrams 40.3.31 - S025 - Windscreen wipers N011

FRONT WIPER CONTROL

M -31

N010

4

53

1

D059 2

53

4

4

6

5

1

3

2

4

1

3

1

2

12

3

2

C002

1

15A

Bb003

C003a

+15

7.5A

+58

D009

D075

+15

10A

6

Bf010

3

Bb012

C003a

7

B A7

B B1

86 31

85 T

1 I

87a 53S

87 15

1

2

M

1

2

M

N019 N018

2

1

2

Jn002

1

M

M

N003

N002

D0078270

Fig. 3396 - Windscreen wipers - System l l l l l l l l l l l l l l l l l

D001 (M) - Wiring connector (Wiring loom 0.020.8658.4) D001 (F) - Wiring connector (Wiring loom 0.014.0007.4/20) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D024 (M) - Wiring connector (yellow) (Wiring loom 0.020.8862.4) D024 (F) - Wiring connector (yellow) (Wiring loom 0.020.8658.4) D025 (M) - Wiring connector (brown) (Wiring loom 0.020.8862.4) D025 (F) - Wiring connector (brown) (Wiring loom 0.020.8658.4) D059 (M) - Wiring connector (Wiring loom 0.019.4688.4/10) D059 (M) - Wiring connector (Wiring loom 0.019.4913.4/10) D059 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D059 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D059 (F) - Wiring connector (Wiring loom 0.020.8862.4) D059 (F) - Wiring connector (Wiring loom 0.020.8862.4) D059 (F) - Wiring connector (Wiring loom 0.020.8862.4) D059 (F) - Wiring connector (Wiring loom 0.020.8862.4) D075 (M) - Wiring connector (Wiring loom 0.020.8854.4) D075 (F) - Wiring connector (Wiring loom 0.020.8658.4)

40-342

30 53M

R7

l

13

D024

C005

3

7

8

D001

3

D025

2

C005

53a

-31b

C005

1

3

I027

M -31

53a

-31b

2

FRONT WWSHER PUMP CONTROL

14

15

16

Wiring diagrams N011

FRONT WIPER CONTROL

M -31

N010

4

53

1

D059 2

53

4

4

6

5

1

3

2

4

1

3

1

2

12

13

14

15

16

D024

C005

3

7

8

D001

3

D025

2

C005

53a

3

2

C002

1

Bb003

C003a

+15

7.5A

+58

D009

D075

+15

10A

6

Bf010

3

Bb012

C003a

7

15A

-31b

C005

1

3

I027

M -31

53a

-31b

2

FRONT WWSHER PUMP CONTROL

B A7

B B1

86 31

85 T

1 I

87a 53S

87 15

30 53M

R7

1

2

M

1

2

M

N019 N018

2

1

2

Jn002

1

M

M

N003

N002

D0078270

Fig. 3396 - Windscreen wipers - System l l l l l l l l

I027 - Rear screen wiper switch Jn002 - Windscreen wiper relay (R7/2) N002 - Windscreen washer pump N003 - Rear windscreen washer pump N010 - Rear screen wiper motor N011 - Windscreen wiper motor N018 - Windscreen washer pump N019 - Rear windscreen washer pump

Table 602 Sys- P/N tem

Description

15A Fuse - Windscreen wiper (F1A/3, +15) 10A Fuse - Rear windscreen wiper (F1-A/12, +15)

Characteristics/Notes

Position

Wiring loom

40-571 40-571

40-343

Wiring diagrams Sys- P/N tem

C002

Description

Characteristics/Notes

Position

Wiring loom

40-571

7.5A Fuse - Left hand sidelights (F1B/10, +30) Engine ground

Cab ground

C005 D001

Cab ground (roof) Wiring connector

D009

Wiring connector

D024

Wiring connector (yellow)

40-583

Fig. 3397

Fig. 3398

Fig. 3399

Fig. 3400

Fig. 3401

40-344

40-571

40-580 40-496 40-571

40-571 40-583

40-571 40-580

Wiring diagrams Sys- P/N tem

Description

D025

Wiring connector (brown)

D059

Wiring connector

D075

Wiring connector

I027

Rear screen wiper switch Front windscreen wiper relay (R7/2) Windscreen washer pump Rear windscreen washer pump Rear screen wiper motor

N002 04414105 N003 04414105 N010 04413192

Characteristics/Notes

Position

Wiring loom

40-571 40-580

Fig. 3402

Fig. 3403

40-545 40-551 40-580 40-561 40-563 40-580 40-580 40-580 40-571 40-579

40-580 40-571 40-583 40-583 40-580

40-345

Wiring diagrams Table 603 Sys- P/N tem

Description

Characteristics/Notes

N011

Windscreen wiper motor

N018 04414105

Windscreen washer pump

N019 04414105

Rear windscreen washer pump

Position

Wiring loom

40-545 40-551 40-561 40-563 40-579

Fig. 3404

40-579

Fig. 3405

40.3.32 - S026 - Radio

1

1

P016 1

1

P002 1

2

1

2

6

7

16 12

13

9

5

7

8

9

12

8

14

10

15

11

2

8

+58

C005 D024

D025

D024

C005 5

6

15

4

2

3 0

P026

Fig. 3406 - Radio - System l l

D024 (M) - Wiring connector (yellow) (Wiring loom 0.020.8862.4) D024 (F) - Wiring connector (yellow) (Wiring loom 0.020.8658.4)

40-346

87

+15 5A

+30 5A

Bb018

Bf006 D025

D094 2

65

P001

1

1

LIGHT BAR

P017

D025

P028

COMANDO BAR LIGHT

M003

7

8

16

9

10

1

I031

D0078290

Wiring diagrams

1

1

P016 1

1

P002 1

2

1

2

6

7

16 12

13

9

5

7

8

9

12

8

14

10

15

11

2

8

+58

C005 D024

D025

D024

C005 5

87

+15 5A

+30 5A

Bb018

Bf006 D025

D094 2

65

P001

1

1

LIGHT BAR

P017

6

15

4

2

3 0

P026

D025

P028

COMANDO BAR LIGHT

M003

7

8

16

9

10

1

I031

D0078290

Fig. 3406 - Radio - System l l l l l l l l l l l l

D025 (M) - Wiring connector (brown) (Wiring loom 0.020.8862.4) D025 (F) - Wiring connector (brown) (Wiring loom 0.020.8658.4) D094 (F) - Wiring connector (Wiring loom 0.020.8862.4) I031 - Light Bar switch M003 - HLHP control unit M003 - HLHP unit - USA version P001 - Front LH loudspeaker P002 - Front RH loudspeaker P016 - Rear RH loudspeaker P017 - Rear LH loudspeaker P026 - Radio P028 - Electric aerial

Table 604 Sys- P/N tem

C005 D024

Description

Characteristics/Notes

Position

Wiring loom

40-571

5A Fuse - Radio (F1-A/18, +15) 5A Fuse - Radio (F1-B/6, +30) Cab ground (roof) Wiring connector (yellow)

40-571 40-580 40-571 40-580

Fig. 3407

40-347

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

D025

Wiring connector (brown)

D094

Wiring connector

I031 M003

Light Bar switch HLHP unit

M003

HLHP unit - USA version

P001

LH front loudspeaker

P002

RH front speaker

loud-

Position

Wiring loom

40-571 40-580

Fig. 3408

Fig. 3409

Fig. 3410

Fig. 3410

Fig. 3411

Fig. 3412

40-348

40-580

40-580 40-571

40-571

40-571

40-571

Wiring diagrams Sys- P/N tem

P016

Description

P026

RH rear loudspeaker LH rear loudspeaker Radio

P028

Electric aerial

P017

Characteristics/Notes

Position

Wiring loom

40-580 40-580 40-580

Fig. 3413

40-580

40-349

Wiring diagrams 40.3.33 - S027 - Accessories P014

3

20

22

23

1

2

87a

87

86 85

E007

1

2

30

E006

+15 ISO

14

I002

+30 DIN 2

10

Jg006

GND EXTERNAL SOCKET

SERVICE LIGHT

+58

4

BEACON

2

CAB LIGHT SW

MIRROR LED LIGHT

13

DOOR SW

GND

1

+15 WOLP

+30 WOLP

15

I028

F001

D024

AMBIENT LIGHT

+30 WOLP

H002

1

D

1

2

A

B

A

C

D008

7.5A

Bb019

20A

+15 LIGHT BAR

53

31

14

N013

P004

5A

16

P003 2

19 2 1 10

1

15 8

8

3

7 1

F013 F016

2

D079

+58

C005

+15

+30

C002 11

3

D024

G004

9

20A

Bm003

C003

B

2

D024

G007

70

D025

0

Bb018

C

B

D025

A

9 6

SENSOR GND HLHP

COMANDO BAR LIGHT

C003a +30 20A

Bm001

+15 7.5A

Bb019

C003a

C003a

10

6

G006

Bm002

+30 +30

65

SENSOR GND HLHP

+30

87

SENSOR GND HLHP

+30

5

+5V HLHP

GND

3

SIGNAL EXTERNAL LIGHT

GND

1

D009

2 -

C002

C005

GND

6

D036

1 +

A A8

+30 15A

Ba001

C003a

+15 Bc003

20A

C005 D024

D024

4

5A

Ba008

+15

+30 3A

Bf015 -

A D1

A A1

1

2

2

A A1

2

1

C005

C003a

+30

C003a

To ISO 11783

2

M003

11

1 +

D057

D054

15A

Bf004

D013

D025

To fig. 2/3

C003a

11

D076

9

4

C005

+58

C003a

7.5A

Bf010

3A

+15

D024

Bb014

C003

12

2 0

I031 D0078250

Fig. 3414 - Accessories - System (1/3) l l l l l l l l l l

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D013 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D013 (F) - Wiring connector (Wiring loom 0.020.8658.4) D024 (M) - Wiring connector (yellow) (Wiring loom 0.020.8862.4) D024 (F) - Wiring connector (yellow) (Wiring loom 0.020.8658.4) D025 (M) - Wiring connector (brown) (Wiring loom 0.020.8862.4) D025 (F) - Wiring connector (brown) (Wiring loom 0.020.8658.4)

40-350

Wiring diagrams P014

3

20

22

23

1

2

87a

87

86 85

E007

1

2

30

E006

+15 ISO

14

I002

+30 DIN 2

10

Jg006

GND EXTERNAL SOCKET

SERVICE LIGHT

+58

4

BEACON

2

CAB LIGHT SW

MIRROR LED LIGHT

13

DOOR SW

GND

1

+15 WOLP

+30 WOLP

15

I028

F001

D024

AMBIENT LIGHT

+30 WOLP

H002

1

D

1

2

A

B

A

C

D008

7.5A

Bb019

20A

+15 LIGHT BAR

53

31

14

N013

P004

5A

16

P003 2

19 2 1 10

1

15 8

8

3

7 1

F013 F016

2

D079

+58

C005

+15

+30

C002 11

3

D024

G004

9

20A

Bm003

C003

B

2

D024

G007

70

D025

0

Bb018

C

B

D025

A

9 6

SENSOR GND HLHP

COMANDO BAR LIGHT

C003a +30 20A

Bm001

+15 7.5A

Bb019

C003a

C003a

10

6

G006

Bm002

+30 +30

65

SENSOR GND HLHP

+30

87

SENSOR GND HLHP

+30

5

+5V HLHP

GND

3

SIGNAL EXTERNAL LIGHT

GND

1

D009

2 -

C002

C005

GND

6

D036

1 +

A A8

+30 15A

Ba001

C003a

+15 Bc003

20A

C005 D024

D024

4

5A

Ba008

+15

+30 3A

Bf015 -

A D1

A A1

1

2

2

A A1

2

1

C005

C003a

+30

C003a

To ISO 11783

2

M003

11

1 +

D057

D054

15A

Bf004

D013

D025

To fig. 2/3

C003a

11

D076

9

4

C005

+58

C003a

7.5A

Bf010

3A

+15

D024

Bb014

C003

12

2 0

I031 D0078250

Fig. 3414 - Accessories - System (1/3) l l l l l l l l l l l l

D036 (M) - Wiring connector (Wiring loom 0.021.0396.4) D036 (F) - Wiring connector (Wiring loom 0.019.2383.4/20) D054 (M) - Wiring connector (Wiring loom 0.020.8862.4) D054 (F) - Wiring connector (Wiring loom 04436707) D057 (M) - Wiring connector (Wiring loom 0.020.8862.4) D057 (F) - Wiring connector (Wiring loom 04436707) D076 (F) - Wiring connector (Wiring loom 0.020.8658.4) D079 (F) - Wiring connector (Wiring loom 0.020.8658.4) E006 - RH rotating beacon E007 - LH rotating beacon F001 - LH carpet light F013 - LH LED bar - on engine cowl 40-351

Wiring diagrams P014

3

20

22

23

1

2

87a

87

86 85

E007

1

2

30

E006

+15 ISO

14

I002

+30 DIN 2

10

Jg006

GND EXTERNAL SOCKET

SERVICE LIGHT

+58

4

BEACON

2

CAB LIGHT SW

MIRROR LED LIGHT

13

DOOR SW

GND

1

+15 WOLP

+30 WOLP

15

I028

F001

D024

AMBIENT LIGHT

+30 WOLP

H002

1

D

1

2

A

B

A

C

D008

7.5A

Bb019

20A

+15 LIGHT BAR

53

31

14

N013

P004

5A

16

P003 2

19 2 1 10

1

15 8

8

3

7 1

F013 F016

2

D079

+58

C005

+15

+30

C002 11

3

D024

G004

9

20A

Bm003

C003

B

2

D024

G007

70

D025

0

Bb018

C

B

D025

A

9 6

SENSOR GND HLHP

COMANDO BAR LIGHT

C003a +30 20A

Bm001

+15 7.5A

Bb019

C003a

C003a

10

6

G006

Bm002

+30 +30

65

SENSOR GND HLHP

+30

87

SENSOR GND HLHP

+30

5

+5V HLHP

GND

3

SIGNAL EXTERNAL LIGHT

GND

1

D009

2 -

C002

C005

GND

6

D036

1 +

A A8

+30 15A

Ba001

C003a

+15 Bc003

20A

C005 D024

D024

4

5A

Ba008

+15

+30 3A

Bf015 -

A D1

A A1

1

2

2

A A1

2

1

C005

C003a

+30

C003a

To ISO 11783

2

M003

11

1 +

D057

D054

15A

Bf004

D013

D025

To fig. 2/3

C003a

11

D076

9

4

C005

+58

C003a

7.5A

Bf010

3A

+15

D024

Bb014

C003

12

2 0

I031 D0078250

Fig. 3414 - Accessories - System (1/3) l l l l l l l l l l l l

F016 - RH LED bar - on engine cowl G004 - Cab courtesy light G006 - RH ambient light G007 - LH ambient light H002 - Work light control I002 - Switch for courtesy lights on steps I026 - Rear view mirror demister switch I028 - Door open warning light switch I031 - Light Bar switch Jg006 - Lights relay (R1-A/6) M003 - HLHP control unit M003 - HLHP unit - USA version

40-352

l

l

l

l

l -

G006 1 + 2 -

G007 A B 0 1

C

G004 D 1 2

N013 A B

P004 A C

2

B

2 11 14

F013 F016 A A1

P003 19 2 1 10 8

LIGHT BAR

6

7 1

2 4 6 1 3 5 87 65

16

3

SENSOR GND HLHP

SENSOR GND HLHP

9 6

+30

+15

7.5A

1 +15 ISO

+30 DIN 2

GND EXTERNAL SOCKET

E007

Bb019

D008

H002

20A

Bm002

C002

2

SENSOR GND HLHP

C005

1

+5V HLHP

D057

E006

SIGNAL EXTERNAL LIGHT

C005

2

D079

+15

2

5A

D054

I002

D025

COMANDO BAR LIGHT

30

Bb018

+30

C003a

86 85

+58

+30

15A

Jg006

C005

+30

D013

D025

Bf004

11

+30

C003a

To ISO 11783

C005

4

+30

GND

D076

87

20A

GND

5A

Ba008

GND

C003a

+15

87a

Bm003

C003

+30

+15

2

D025

D009

10

C002

20A

Bm001

7.5A

Bb019

C003a

1

C003a

C003a

23

+30

22

15A

SERVICE LIGHT

+58

20

Ba001

7.5A

BEACON

3

C003a

+58

9

+15

Bf010

CAB LIGHT SW

14

20A

Bc003

C005

+30

10

D036

11 3A

Bf015

3A

DOOR SW

4 +15 WOLP

MIRROR LED LIGHT

2

+15

D024

GND

13

I028

D024

2

Bb014

C003

+30 WOLP

1

D024

To fig. 2/3

D024

AMBIENT LIGHT

+30 WOLP

15

F001

D024

1 +

D024

C003a

Wiring diagrams P014

1

12

A A1 A D1

3

A A8

M003

70 9 53 31

2 1

8 15

0

2

I031

D0078250

Fig. 3414 - Accessories - System (1/3)

M008 - ISO 11786 control unit N013 - Pneumatic seat compressor P003 - Auxiliary cab power outlet socket (25A) P004 - Power outlet socket in cab P014 - Auxiliary power outlet socket (30A)

40-353

Wiring diagrams

87a

+58

9

+15 MIRROR DOWN BIG

2

GND

1

COMAND MIRROR UP/DOWN BIG (RH)

4

COMAND MIRROR DX/SX BIG (RH)

+58

6

COMAND MIRROR COMMON BIG (RH)

+15 MIRROR UP SMALL

8

COMAND MIRROR UP/DOWN SMALL (RH)

GND

3

COMAND MIRROR DX/SX SMALL (RH)

COMAND MIRROR UP/DOWN BIG (LT)

5

COMAND MIRROR COMMON SMALL (RH)

COMAND MIRROR DX/SX BIG (LT)

7

Jd003

87 86

7

5

3

8

6

4

1

2

9

85 30

D024

7

COMAND MIRROR COMMON BIG (LT)

8

COMAND MIRROR UP/DOWN SMALL (LT)

2

3

4

COMAND MIRROR DX/SX SMALL (LT)

1

2

I026

G005

H005

COMAND MIRROR COMMON SMALL (LT)

G001a

G001

H006

D024 13

9

1

D010

2

D024

D024

To fig. 1/3

C005

C003a

20A

7.5A

Bc008

14

+15

C005

C005

Bb011

10A

Bb012

+15

C005

15A

+30

Ba001

15

+30

C003a

D025

3

D059

D058

C005

4 1

1 +

2 -

G003

2 -

1 +

G002

1

2

1

13

2

O011

12

3

3 4

1

2

6

7

5

5

6

7

8

9

P018

Fig. 3415 - Accessories - System (2/3) l l l l l l l l l l l l

C005

C005

C005

C005

7.5A

+15

Bb006

C005

13

D010 (F) - Wiring connector (Wiring loom 0.020.8658.4) D024 (M) - Wiring connector (yellow) (Wiring loom 0.020.8862.4) D024 (F) - Wiring connector (yellow) (Wiring loom 0.020.8658.4) D025 (M) - Wiring connector (brown) (Wiring loom 0.020.8862.4) D025 (F) - Wiring connector (brown) (Wiring loom 0.020.8658.4) D058 (M) - Wiring connector (Wiring loom 0.019.4688.4/10) D058 (M) - Wiring connector (Wiring loom 0.019.4913.4/10) D058 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D058 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D058 (F) - Wiring connector (Wiring loom 0.020.8862.4) D058 (F) - Wiring connector (Wiring loom 0.020.8862.4) D058 (F) - Wiring connector (Wiring loom 0.020.8862.4)

40-354

4

11

10

12

17

16

15

13

1

2

4 3

11

12

9

10

5

6

7

8

P019

14

9

10

11

12

D0078230

Wiring diagrams

87a

+58

9

+15 MIRROR DOWN BIG

2

GND

1

COMAND MIRROR UP/DOWN BIG (RH)

4

COMAND MIRROR DX/SX BIG (RH)

+58

6

COMAND MIRROR COMMON BIG (RH)

+15 MIRROR UP SMALL

8

COMAND MIRROR UP/DOWN SMALL (RH)

GND

3

COMAND MIRROR DX/SX SMALL (RH)

COMAND MIRROR UP/DOWN BIG (LT)

5

COMAND MIRROR COMMON SMALL (RH)

COMAND MIRROR DX/SX BIG (LT)

7

Jd003

87 86

7

5

3

8

6

4

1

2

9

85 30

D024

7

COMAND MIRROR COMMON BIG (LT)

8

COMAND MIRROR UP/DOWN SMALL (LT)

2

3

4

COMAND MIRROR DX/SX SMALL (LT)

1

2

I026

G005

H005

COMAND MIRROR COMMON SMALL (LT)

G001a

G001

H006

D024 13

9

1

D010

2

D024

D024

To fig. 1/3

C005

C003a

20A

7.5A

Bc008

14

+15

C005

C005

Bb011

10A

Bb012

+15

C005

15A

+30

Ba001

15

+30

C003a

D025

3

C005

C005

C005

D058

D059

C005

C005

7.5A

+15

Bb006

C005

13

4 1

1 +

2 -

G003

2 -

1 +

G002

1

2

1

13

2

O011

12

3

3 4

1

2

6

7

5

5

6

7

8

9

P018

4

11

10

12

17

16

15

13

1

2

4 3

11

12

9

10

5

6

7

8

P019

14

9

10

11

12

D0078230

Fig. 3415 - Accessories - System (2/3) l l l l l l l l l l l l

D058 (F) - Wiring connector (Wiring loom 0.020.8862.4) D059 (M) - Wiring connector (Wiring loom 0.019.4688.4/10) D059 (M) - Wiring connector (Wiring loom 0.019.4913.4/10) D059 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D059 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D059 (F) - Wiring connector (Wiring loom 0.020.8862.4) D059 (F) - Wiring connector (Wiring loom 0.020.8862.4) D059 (F) - Wiring connector (Wiring loom 0.020.8862.4) D059 (F) - Wiring connector (Wiring loom 0.020.8862.4) G001 - Cab courtesy light G001a - Cab courtesy light G002 - RH courtesy light on cab roof 40-355

Wiring diagrams

87a

+58

9

+15 MIRROR DOWN BIG

2

GND

1

COMAND MIRROR UP/DOWN BIG (RH)

4

COMAND MIRROR DX/SX BIG (RH)

+58

6

COMAND MIRROR COMMON BIG (RH)

+15 MIRROR UP SMALL

8

COMAND MIRROR UP/DOWN SMALL (RH)

GND

3

COMAND MIRROR DX/SX SMALL (RH)

COMAND MIRROR UP/DOWN BIG (LT)

5

COMAND MIRROR COMMON SMALL (RH)

COMAND MIRROR DX/SX BIG (LT)

7

Jd003

87 86

7

5

3

8

6

4

1

2

9

85 30

D024

7

COMAND MIRROR COMMON BIG (LT)

8

COMAND MIRROR UP/DOWN SMALL (LT)

2

3

4

COMAND MIRROR DX/SX SMALL (LT)

1

2

I026

G005

H005

COMAND MIRROR COMMON SMALL (LT)

G001a

G001

H006

D024 13

9

1

D010

2

D024

D024

To fig. 1/3

C005

C003a

20A

7.5A

Bc008

14

+15

C005

C005

Bb011

10A

Bb012

+15

C005

15A

+30

Ba001

15

+30

C003a

D025

3

2 -

G003

2 -

1 +

G002

1

2

1

13

2

12

3

3 4

1

2

6

7

5

5

6

7

8

9

O011

Fig. 3415 - Accessories - System (2/3) l l l l l l l l l l

C005 D059

D058

C005

4 1

1 +

l

C005

C005

C005

7.5A

+15

Bb006

C005

13

G003 - LH courtesy light on cab roof G005 - Lateral instrument panel courtesy light H005 - RH electric rear view mirror control lever H006 - LH electric rear view mirror control lever I026 - Rear view mirror demister switch I028 - Door open warning light switch Jd001 - Hitch service light relay (R4/1) Jd003 - Rear defrost relay (R4/3) O011 - Rear defrost heater element P018 - LH rear view mirror P019 - RH rear view mirror

40-356

P018

4

11

10

12

17

16

15

13

1

2

4 3

11

12

9

10

5

6

7

8

P019

14

9

10

11

12

D0078230

Wiring diagrams Jd001

C003a

+15 1

2

1

F021

F017

P020a

B6

B7

B8

C8

5

4

3

2

6

1

PTO SPEED

WHEEL

RADAR

LIFT POS

-31 GND

B5

LIFT OFF/ON

B4

-31 GND

B3

+15

1

LIFT POS

2

RADAR

1

WHEEL

2

PTO SPEED

D080

1

10A

Bb001

D026

D021

+30

C003a

10A

D046

Bf017 C003

30

LIFT OFF/ON

1

2

1

D081

1

86 85

87

D080a

D023

D081a

2

C003a

D050

87a

M008

P020 D0078240

Fig. 3416 - Accessories - System (3/3) l l l l l l l l l l l l l l l l l l l l l

D021 (M) - Wiring connector (Wiring loom 0.019.2571.4/10) D021 (F) - Wiring connector (Wiring loom 0.020.8658.4) D023 (M) - Wiring connector (Wiring loom 0.020.8658.4) D023 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D026 (M) - Wiring connector (Wiring loom 0.020.8658.4) D026 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D046 (M) - Wiring connector (Wiring loom 0.020.8658.4) D046 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D050 (F) - Not used (Wiring loom 0.019.2378.4/40) D080 (F) - Configuration connector (Wiring loom 0.019.2378.4/40) D080a (M) - Wiring connector (Wiring loom 0.019.2378.4/40) D081 (F) - Configuration connector (Wiring loom 0.019.2378.4/40) D081a (M) - Wiring connector (Wiring loom 0.019.2378.4/40) F017 - RH rear cosmetic light F021 - LH rear cosmetic light Jd001 - Hitch service light relay (R4/1) M003 - HLHP control unit M003 - HLHP unit - USA version M008 - ISO 11786 control unit P020 - ISO 11786 socket P020a - ISO 11786 socket

Table 605 Sys- P/N tem

Description

15A Fuse - Lights fuse and power outlet socket (F3/1, +30) 5A fuse - Fuse (F3/8, +15)

Characteristics/Notes

Position

Wiring loom

40-571

40-571

40-357

Wiring diagrams Sys- P/N tem

40-358

Description

7.5A Fuse - Pneumatic seat (F1-A/6, +15) 7.5A Fuse - Rear view mirrors (F1A/11, +15) 10A Fuse - Rear windscreen wiper (F1-A/12, +15) 3A Fuse - Work light display (F1A/14, +15) 5A Fuse - Radio (F1-A/18, +15) 7.5A Fuse - External electric power outlet sockets (F1A/19, +15) 7.5A Fuse - External electric power outlet sockets (F1A/19, +15) 20A Fuse - Seat/ brakes (F4/3-6, +15) 20A Fuse - Rear defrost (F4/8-11) 15A Fuse - Turn indicator relay protection (F1-B/4, +30) 7.5A Fuse - Left hand sidelights (F1B/10, +30) 3A Fuse - Cab lights (F1-B/15, +30) 10A Fuse - Hitch relay protection (F1B/17, +30) 20A Fuse - Tractor electric power outlet sockets (F2/1-4, +30) 20A Fuse - Cab electric power outlet sockets (F2/2-5, +30) 20A Fuse - HLHP control unit (F2/3-6, +30)

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571 40-571 40-571 40-571

40-571

40-571 40-571 40-571

40-571 40-571 40-571 40-571

40-571

40-571

Wiring diagrams Sys- P/N tem

Description

C002

Engine ground

C003

Cab ground

Cab ground

C005 D008

Cab ground (roof) Wiring connector

D009

Wiring connector

D010

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-583 40-576

Fig. 3417

Fig. 3418

Fig. 3419

Fig. 3420

Fig. 3421

40-571

40-571

40-580 40-571 40-576

40-571 40-583

40-571

Fig. 3422

40-359

Wiring diagrams Sys- P/N tem

Description

D013

Wiring connector

D013

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 3423

40-537

Fig. 3424

Table 606 Sys- P/N tem

Description

D021

Wiring connector

D023

Wiring connector

D024

Wiring connector (yellow)

Characteristics/Notes

Position

Wiring loom

40-535 40-571

Fig. 3425

Fig. 3426

Fig. 3427

40-360

40-571 40-520

40-571 40-580

Wiring diagrams Sys- P/N tem

Description

D025

Wiring connector (brown)

D026

Wiring connector

D036

Wiring connector

D046

Wiring connector

D050 D054

Not used Wiring connector

D057

Wiring connector

D058

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-580

Fig. 3428

Fig. 3429

Fig. 3430

Fig. 3431

40-571 40-522

40-529 40-583

40-571 40-522

40-520 40-592 40-580 40-591 40-580 40-545 40-551 40-580 40-561 40-563 40-580

40-361

Wiring diagrams Table 607 Sys- P/N tem

Description

D059

Wiring connector

D076 D079 D080

Wiring connector Wiring connector Configuration connector Configuration connector Configuration connector Configuration connector RH rotating beacon LH rotating beacon LH carpet light

D081

E006 04414773 E007 04414773 F001

F013 F016 F017 F021 G001

LH LED bar - on engine cowl RH LED bar - on engine cowl RH rear cosmetic light LH rear cosmetic light Cab courtesy light

Cab courtesy light

G002 G003 40-362

Right hand courtesy light on cab roof Left hand courtesy light on cab roof

Characteristics/Notes

Position

Wiring loom

40-545 40-551 40-580 40-561 40-563 40-571 40-571 40-522 40-522 40-520 40-520 40-592 40-591 40-571

Fig. 3432

40-529 40-529 40-522 40-520 40-571

Fig. 3433

Fig. 3434

40-571

40-580 40-580

Wiring diagrams Sys- P/N tem

G004 G005 G006

Description

Position

Wiring loom

40-580 40-580

Cab courtesy light Side instrument panel courtesy light Right hand ambient light

G007

Left hand ambient light

H002

Work light switch

H005

Right hand electric rear view mirror control lever Left hand electric rear view mirror control lever

H006

Characteristics/Notes

40-571

Fig. 3435

Fig. 3436

Fig. 3437

40-571

40-571

40-580 40-580

40-363

Wiring diagrams Table 608 Sys- P/N tem

I002

Description

Characteristics/Notes

Position

Wiring loom

40-571

Switch for courtesy lights on the steps

Pos

Pin

1

2

3

0 1 2.7659.405.0

I026 I028 04414097 I031

M003

Rear view mirror demister switch Door open warning signal switch Light Bar switch Hitch service light relay (R4/1) Rear defrost relay (R4/3) Lights relay (R1A/6) HLHP unit

M003

HLHP unit - USA version

M008

ISO 11786 control unit

Fig. 3439

Fig. 3438

40-580 40-580 40-580 40-571 40-571 40-571 40-571

Fig. 3440

Fig. 3440

Fig. 3441

40-364

40-571

40-535

Wiring diagrams Sys- P/N tem

Description

N013

Pneumatic compressor

O011

Rear defrost heater element Auxiliary cab power outlet socket (25A)

P003

Characteristics/Notes

Wiring loom

40-571

seat

P004

Power outlet socket in cab

P014

Auxiliary power outlet socket (30A) LH rear view mirror LH rear view mirror LH rear view mirror LH rear view mirror RH rear view mirror RH rear view mirror RH rear view mirror RH rear view mirror ISO 11786 socket

P018 P018 P018 P018 P019 P019 P019 P019 P020

Position

Fig. 3442

40-580 40-571

Fig. 3443

Fig. 3444

40-571

40-576 40-545 40-551 40-561 40-563 40-545 40-551 40-561 40-563 40-535

Fig. 3445

40-365

l

l

40-366

11

12

8

16

18

14

R001

Fig. 3446 - Diagnostics - System

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4)

RX INSTRUMENT

ISO 9141

SENSOR GND HLHP

+5V HLHP

+30 ARMREST

15

11

12

13

19

ISO 9141

10

+15 CLUSTER

9

TX INSTRUMENT

15A

Bf005

B B5

RX INSTRUMENT

2

ISO SGR

3A

C003a

+30

D008

+15

C003a

+30

D031

5A

Bf003

5A

Bb015

7.5A

D009

+30

+30

+30

GND

GND

GND

+15 HLHP

ISO 9141

SENSOR GND HLHP

SENSOR GND HLHP

+5V HLHP

+15 TRANSMISSION

GND

+30 ECU

ISO 4191

GND

+15 INSTRUMENT

RX INSTRUMENT

FUSE PDU3 (INSTRUM.+30)

TX INSTRUMENT

12 15 1 3 5 2 4 6 8 21 31 53 72 10 13 14 15 5 12 20 21 22

M001b

3A

B008

C003a

+30

C003a

+15

+15

Bb005

ISO SGR

3

M003

TX INSTRUMENT

1

ISO 9141

Bb004

C003

20A

Bm003

+30 SGR

M005

GND SGR GROUP

Characteristics/Notes

+30 ARMREST

13

GND

A B5

+30

D008

Description

+15 CLUSTER

7.5A

C002

Sys- P/N tem

ISO 9141

+30

Bf001

Wiring diagrams

Position Wiring loom

ISO 11786 socket 40-535

Fig. 3445

40.3.34 - S028 - Diagnostics

E002

A D5

5

H001

D0068970

Wiring diagrams M003

E002

ISO SGR

+30

+30

+30

GND

GND

GND

+15 HLHP

ISO 9141

SENSOR GND HLHP

SENSOR GND HLHP

+5V HLHP

+15 TRANSMISSION

GND

+30 ECU

ISO 4191

GND

+15 INSTRUMENT

RX INSTRUMENT

FUSE PDU3 (INSTRUM.+30)

TX INSTRUMENT

3

12

15

1

3

5

2

4

6

8

21

31

53

72

10

13

14

15

5

12

20

21

22

5A

A D5

D031

C003a

+30

Bf003

5A

C003a

Bb015

+15

+15

7.5A

Bb005

Bm003

20A

C003

C002

A B5

+30

D008

D009

+30 SGR

M001b

GND SGR GROUP

M005

3A

B008

7.5A

8

16

18

14

ISO 9141

ISO SGR

TX INSTRUMENT

RX INSTRUMENT

ISO 9141

SENSOR GND HLHP

+5V HLHP

+30 ARMREST

15

11

12

13

19 ISO 9141

12

+15 CLUSTER

11

RX INSTRUMENT

10

TX INSTRUMENT

9

+30 ARMREST

2

R001

C003a

+30

1 GND

15A

Bf005

D008

+15

13

+15 CLUSTER

3A

B B5

ISO 9141

Bb004

C003a

+30

+30

Bf001

5

H001 D0068970

Fig. 3446 - Diagnostics - System l l l l l l l l l l l

D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) E002 - Instrument panel H001 - Armrest M001b - Transmission control unit M003 - HLHP control unit M003 - HLHP unit - USA version M005 - Internal transmission control unit R001 - Diagnostics connector

40-367

Wiring diagrams Table 609 Sys- P/N tem

Description

B008

Fuse (3A)

C002

3A Fuse - Cluster (F1-A/4, +15) 7.5A Fuse - HLHP control unit (F1-A/5, +15) 5A Fuse - Transmission (F1-A/15, +15) 7.5A Fuse - SGR Transmission (F1A/1, +30) 5A Fuse - Transmission control unit (F1-B/3, +30) 15A Fuse - Armrest (F1-B/5, +30) 20A Fuse - HLHP control unit (F2/3-6, +30) Engine ground

C003

Cab ground

Characteristics/Notes

Position

Wiring loom

40-514

Fig. 3447

40-571 40-571 40-571 40-571 40-571 40-571 40-576

Fig. 3448

Fig. 3449

40-368

40-571

40-571

Wiring diagrams Sys- P/N tem

Description

D008

Wiring connector

D009

Wiring connector

D031

Wiring connector

E002

Instrument panel

H001

Armrest

Characteristics/Notes

Position

Wiring loom

40-571

Cab ground

Fig. 3450

Fig. 3451

Fig. 3452

Fig. 3453

40-571 40-576

40-571 40-583

40-583 40-514 40-571

40-571

Fig. 3454

40-369

Wiring diagrams Sys- P/N tem

Description

M003

HLHP unit

M003

HLHP unit - USA version

M005

Internal transmission control unit Diagnostic socket

R001

Characteristics/Notes

Position

Wiring loom

40-571

Transmission control unit

Fig. 3455

Fig. 3456

Fig. 3456

40-571

40-576 40-571

Fig. 3457

40-370

40-571

Wiring diagrams 40.3.35 - S029 - Monitor

E005a +30 MONITOR

+15 MONITOR

GND

GND

MIC-

RS232 RX

RS232 TX

GROUND

CAN-H ISOBUS

CAN-L ISOBUS

CAN-H VEHICLE

CAN-L VEHICLE

CAN-H AUX

CAN-L AUX

MIC+

+ ANT

E005b

1

2

3

4

7

16

17

18

8

9

21

22

23

24

20

24

D062

D062

To Can Bus Standard

14 10

9

1

5

7

12

11

15

13

D014

8

C003a

3A

Bb009

+15

15A

+30

Bf008

6

D0068960

Fig. 3458 - Monitor - System l l l l l l l l l l

D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (M) - Wiring connector (Wiring loom 0.019.9826.4/30) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D062 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (M) - Wiring connector (Wiring loom 0.019.9826.4/30) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) E005a - I-Monitor E005b - I-Monitor

Table 610 Sys- P/N tem

Description

3A Fuse - iMonitor + MMI (F1-A/9, +15) 15A Fuse - iMonitor (F1-B/8, +30)

Characteristics/Notes

Position

Wiring loom

40-571 40-571

40-371

Wiring diagrams Sys- P/N tem

Description

D014

Wiring connector

D014

Wiring connector

D014

Wiring connector

D062

Wiring connector

D062

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571

Cab ground

Fig. 3459

Fig. 3460

Fig. 3461

Fig. 3462

Fig. 3463

Fig. 3464

40-372

40-571

40-537

40-559

40-542 40-537

40-559

Wiring diagrams Sys- P/N tem

D062

Description

Characteristics/Notes

Position

Wiring loom

40-542

Wiring connector

I-Monitor

I-Monitor

Fig. 3465

Fig. 3466

40-542

40-542

Fig. 3466

40-373

Wiring diagrams 40.3.36 - S030 - Agrosky - Version with visual guidance, without ISO11783 H007

MIC +

2

24

20

15

14

1

2

D086

D086b

3A

77

2

1

3

D014

+15

Bb009

M010 +Monitor (HLHP2)

1

C003

M003

D062

D014

1

+ ANT

+15 MONITOR + MMI

E005b

D013

D062

5

1

+30 9

8

7

6

D062

10

10

2

3

+15 MONITOR

GND

4

7

17

16

18 GROUND

1

RS232 RX

12

RS232 TX

6

MIC -

5

M009

13

7

+30 MONITOR

10

GND

8

D062

13

D062

14

RS232 RX

2

11

17

RS232 TX

1

Supply +12V

8

GND

5

18

GND

D071

D014

8

15A

2

13

Bf008

3

9

To Can Bus Standard

12

D060

11

E005a

D0078520

Fig. 3467 - Agrosky - Version with visual guidance, without ISO11783 ISO11783 - System l l l l l l l l l l l

D013 (M) - Wiring connector (Wiring loom 0.019.9826.4/30) D013 (F) - Wiring connector (Wiring loom 0.020.8658.4) D014 (M) - Wiring connector (Wiring loom 0.019.9826.4/30) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D060 (F) - Wiring connector (Wiring loom 0.019.9826.4/30) D060 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D060 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D060 (F) - Wiring connector (Wiring loom 0.019.9826.4/30) D062 (M) - Wiring connector (Wiring loom 0.019.9826.4/30) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) D071 (M) - Wiring connector (Wiring loom 0.019.9829.4/20)

40-374

Wiring diagrams H007

MIC +

2

24

20

15

14

1

2

D086

D086b

3A

77

2

1

3

D014

+15

Bb009

M010 +Monitor (HLHP2)

1

C003

M003

D062

D014

1

+ ANT

+15 MONITOR + MMI

E005b

D013

D062

5

8

11

10

+30

2

9

8

7

6

2

3

+15 MONITOR

GND

4

7

17

16

18 GROUND

1

RS232 RX

12

RS232 TX

6

MIC -

5

M009

13

7

+30 MONITOR

10

GND

8

D062

10

D062

13

D062

14

RS232 RX

2

17

RS232 TX

1

Supply +12V

18

GND

5

GND

D071

D014

8

15A

3

13

Bf008

1

9

To Can Bus Standard

12

D060

11

E005a

D0078520

Fig. 3467 - Agrosky - Version with visual guidance, without ISO11783 ISO11783 - System l l l l l l l l l l l l

D071 (M) - Wiring connector (Wiring loom 0.019.9829.4/20) D071 (F) - Wiring connector (Wiring loom 0.019.9827.4/10) D071 (F) - Wiring connector (Wiring loom 0.019.9828.4/10) D086 (M) - Configuration connector (Wiring loom 0.019.9826.4/30) D086b (F) - Configuration connector (Wiring loom 0.019.9826.4/30) E005a - I-Monitor E005b - I-Monitor H007 - Monitor controls M003 - HLHP control unit M003 - HLHP unit - USA version M009 - “AGROSKY” antenna M010 - Microphone 40-375

Wiring diagrams Table 611 Sys- P/N tem

Description

C003

3A Fuse - iMonitor + MMI (F1-A/9, +15) 15A Fuse - iMonitor (F1-B/8, +30) Cab ground

D013

Wiring connector

D013

Wiring connector

D014

Wiring connector

D014

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571

Fig. 3468

Fig. 3469

Fig. 3470

Fig. 3471

Fig. 3472

40-376

40-559

40-571

40-559

40-571

Wiring diagrams Sys- P/N tem

Description

D060

Wiring connector

D060

Wiring connector

D062

Wiring connector

D062

Wiring connector

D071

Wiring connector

D086

Configuration connector

Characteristics/Notes

Position

Wiring loom

40-559

Fig. 3473

Fig. 3474

Fig. 3475

Fig. 3476

40-561 40-563

40-559

40-542

40-565 40-561 40-563 40-559

Fig. 3477

40-377

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

Position

Wiring loom

40-559

Configuration connector

I-Monitor

I-Monitor

H007

Monitor controls

M003

HLHP unit

M003

HLHP unit - USA version

Fig. 3477

Fig. 3478

Fig. 3478

Fig. 3479

Fig. 3480

Fig. 3480

40-378

40-542

40-542

40-559

40-571

40-571

Wiring diagrams Sys- P/N tem

M009 M010

Description

“AGROSKY” tenna Microphone

Characteristics/Notes

Position

Wiring loom

40-565

An-

40-559

Fig. 3481

40-379

Wiring diagrams

To Direction indicators

M003 Monitor (HLHP2)

To Brakes

To Lights

To Lights

To work lights USA

To Accessories

To Direction indicators USA

40.3.37 - S031 - ISO 11783

D013

77

11

12

1

10

2

3

4

5

6

8

13

9

D062

7

To fig.2/2

10

30

86

85

3

16

15

24

C003

3A

Bb010

+15

Fig. 3482 - ISO 11783 - System (1/2) l l l l l l l l l l

D013 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D013 (F) - Wiring connector (Wiring loom 0.020.8658.4) D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D062 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) I030 - “Performance Steering” system activation switch M003 - HLHP control unit M011 - ISO 11783 control unit O016 - Diode board O017 - Diode board

40-380

75

13

12

41

8

89

88

42

23

22

35

37

36

34

M011

I030

l

7

Rear work light

6

Rear work light

4

Direction light LH

1

2

Direction light RH

10

Stop light

9

Full beam

8

Half beam

7

Supply +12V (+15)

0

6

Position light

4

Trailer WL USA

1

5

Direction light LH

0

3

CUT OFF EV

1

Supply +12V (+15) SASA PVED

2

87

GND

87

Supply +12V (+15) feedback

86

GND

85

O016

D014

30

87a

GND

O017

87a

D0078440

Wiring diagrams

2

1

4

2

5

3

13

1

8

2

4

3

D014

4

D060

1

D086a D086

O014

10

7

9

13

11

12

To fig. 1/2

15A

R004 2

D014

Bf008

+30

+15

D062

8

3A

14

15

Bb009

1

B

D

C

H

J

H007

TBC RTN-

3

4

1

3

Supply +12V (+30)

Supply +12V (+30)

Supply +12V (+30)

4

6

8

9

7

6

8

9

A4

A8

D8

D1

A1

50A

B018

A7

5

B

85

86 87

87a

30

85

86

87

16

15

D

D067

A

30

D069a

Supply +12V antenna

C002

30A

84

M011

A5

B019

74 Relay 50A command

5

Front relay command

3

C003

TBC PWR

1

1

D069

+15

2

C002

M010

D014

+30

P024

-31 BATT

2

R003

D064

P025 -31 KEY

1

1

P021 81

+30

1

250A

2

B001

-31 BATT

4

D066

3

-31 KEY

1

2

To Can Bus ISO 11783

+15

TBC RTN-

TBC PWR

3

P022

5

A

6

P023

1

87a

D0078210

J016

J015

Fig. 3483 - ISO 11783 - System (2/2) l l l l l l l l l l

D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D060 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D060 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) D064 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D064 (F) - Wiring connector (Wiring loom 0.018.9843.4/20) 40-381

Wiring diagrams l l l l l l l l l l l l l l l l l l l l l l

D066 (M) - Wiring connector (Wiring loom 0.018.9843.4/20) D066 (F) - Wiring connector (Wiring loom 0.017.8887.4/10) D067 (M) - Wiring connector (Wiring loom 0.017.8887.4/10) D067 (F) - Wiring connector (Wiring loom 0.018.9843.4/20) D069 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D069a (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D086 (M) - Configuration connector (Wiring loom 0.019.2617.4/70) D086a (F) - Configuration connector (Wiring loom 0.019.2617.4/70) H007 - Monitor controls J015 - ISOBUS relay (50A) J016 - ISOBUS relay (30A) M010 - Microphone M011 - ISO 11783 control unit O014 - Diode connector O014a - Diode board P021 - ISO 11783 socket in cab P022 - Front ISOBUS 11783 socket P023 - Front ISOBUS 11783 socket P024 - Rear ISOBUS 11783 socket P025 - Rear ISOBUS 11783 socket R003 - RS 232 connector R004 - ISO11783 diagnostic socket

Table 612 Sys- P/N tem

Description

B001

Fuse (250A)

B018 B019

Fuse (50A) Fuse (30A) 3A Fuse - iMonitor + MMI (F1-A/9, +15) 3A Fuse - ISOBUS 11783 (F1-A/10, +15) 15A Fuse - iMonitor (F1-B/8, +30) Engine ground

C002

Characteristics/Notes

Position

Wiring loom

40-514

Fig. 3484

40-571 40-571 40-510 40-512

Fig. 3485

40-382

40-512 40-512 40-571

Wiring diagrams Sys- P/N tem

Description

C003

Cab ground

D013

Wiring connector

D013

Wiring connector

D014

Wiring connector

D014

Wiring connector

D060

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 3486

Fig. 3487

Fig. 3488

Fig. 3489

Fig. 3490

40-571

40-537

40-571

40-537

40-537 40-561 40-563 40-537

Fig. 3491

40-383

Wiring diagrams Sys- P/N tem

Description

D062

Wiring connector

D062

Wiring connector

D064

Wiring connector

D066

Wiring connector

D067

Wiring connector

D069

Wiring connector Wiring connector

40-384

Characteristics/Notes

Position

Wiring loom

40-542

Fig. 3492

Fig. 3493

Fig. 3494

Fig. 3495

Fig. 3496

40-537

40-512 40-537

40-510 40-512

40-510 40-512

40-537 40-537

Wiring diagrams Sys- P/N tem

D086

Description

Characteristics/Notes

Position

Wiring loom

40-537

Configuration connector

Fig. 3497

Configuration connector

40-537

Fig. 3497

Table 613 Sys- P/N tem

Description

Characteristics/Notes

H007

Monitor controls

I030

“Performance Steering” system activation switch

Position

Wiring loom

40-537

Fig. 3498

40-537

0 1

Pos

Pin

1

2

3

4

5

6

7

4

5

6

9

8

1

2

3

10

7

8

9

10

1 2 2.7659.489.0

J015

ISOBUS (50A)

relay

J016

ISOBUS (30A)

relay

Fig. 3500

Fig. 3499

40-512

Fig. 3501

40-512

40-385

Wiring diagrams Sys- P/N tem

Description

M003

HLHP unit

M010

Microphone

M011

ISO 11783 control unit

O014

Diode connector

Diode board

O016 O017

40-386

Diode board Diode board

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 3502

Fig. 3503

Fig. 3504

Fig. 3505

Fig. 3505

40-537

40-537

40-537

40-537

40-537 40-537

Wiring diagrams Sys- P/N tem

Description

P021

ISO 11783 socket in cab

P022

Front ISOBUS 11783 socket Front ISOBUS 11783 socket Rear ISOBUS 11783 socket

P023 P024

P025

Rear ISOBUS 11783 socket

R003

RS 232 connector

R004

ISO11783 diagnostic socket

Characteristics/Notes

Position

Wiring loom

40-537

Fig. 3506

40-510 40-510 40-512

Fig. 3507

Fig. 3508

Fig. 3509

40-512

40-537

40-537

Fig. 3510

40-387

Wiring diagrams

To Direction indicators

M003 +Monitor (HLHP2)

To Brakes

To Lights

To Lights

To work lights USA

To Accessories

To Direction indicators USA

40.3.38 - S031A - ISO11783 Can Bus line - Version with visual guidance

D013

77

11

12

1

10

2

3

4

5

6

8

9

13

D062

7

To fig.2/2

10

3

16

15

I030

24

7

75

13

12

41

8

89

88

42

23

22

35

37

36 Rear work light

6

Rear work light

4

Direction light LH

2

Direction light RH

10

Stop light

9

Full beam

8

Half beam

7

1

Position light

6

Supply +12V (+15)

0

Trailer WL USA

4

87

Direction light LH

5

85

Supply +12V (+15) SASA PVED

1

86

CUT OFF EV

3

30

GND

0

87

Supply +12V (+15) feedback

1

86

GND

2

85

O016

D014

30

87a

GND

O017

87a

34

M011 C003

3A

+15

Bb010

D0078460

Fig. 3511 - ISO11783 Can Bus line - Version with visual guidance - System (1/2) l l l l l l l l l l

D013 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D013 (F) - Wiring connector (Wiring loom 0.020.8658.4) D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D062 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) I030 - “Performance Steering” system activation switch M003 - HLHP control unit M011 - ISO 11783 control unit O016 - Diode board

40-388

+15

2

l 1

0

3

1

5 4

0

6 7 8

O017

85 86

9 87

1

10

C003

30

D014

87a

3A

Bb010 86 85

3 16 15

I030 4 6 24 7 12 41 8 89 88 42

Position light

Half beam

Full beam

Stop light

To fig.2/2

D062

1 2 3 4

23

5

22 35 37 36

Rear work light

10

Rear work light

12

Direction light LH

11

Direction light RH

13

Supply +12V (+15)

75

Trailer WL USA

7

Direction light LH

Supply +12V (+15) SASA PVED

CUT OFF EV

2

GND

30

Supply +12V (+15) feedback

O016

GND

87a

GND

D013

+Monitor (HLHP2)

To Direction indicators

To Brakes

To Lights

To Lights

To work lights USA

To Accessories

To Direction indicators USA

Wiring diagrams

M003

77

6 8 9 13

10

87

34

M011 D0078460

Fig. 3511 - ISO11783 Can Bus line - Version with visual guidance - System (1/2)

O017 - Diode board

40-389

Wiring diagrams RS232 TX

RS232 RX

Supply +12V

GND

GND

M009 6

5

2

12

1

1

4

5

3

5

9

10

11

13

1

8

4

2

3

8

4

3

7

18

16

17

9

7

13

11

12

1

D062

Bb009 10

RS232 TX

14

RS232 RX

1

GROUND

2

MIC -

+30 MONITOR

20

GND

+15 MONITOR

24

GND

MIC+

E005a

+ANT

E005b

2

8

To fig. 1/2

15A

R004 2

D014

Bf008

+30

+15

15

3A

2

12

D014

4

D060

1

D086b D086

D071

O014

B

D

C

H

J

H007

3

84

Supply +12V (+30)

Supply +12V (+30)

Supply +12V (+30)

Relay 50A command

Front relay command

M011

6

8

9

7

6

8

9

A4

A7

A8

D8

D1

50A

B018

30A

C002

B019

A5

C002

4

B

86

87

87a

30

85

86 87

16

15

D

D067 85

A1

5

A

30

D069a

74

C003

1

5

D069

4

3

D014

3

1

87a

D0078470

J016

J015

Fig. 3512 - ISO11783 Can Bus line - Version with visual guidance - System (2/2) l l l l l l l l l l

D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D060 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D060 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) D064 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D064 (F) - Wiring connector (Wiring loom 0.018.9843.4/20)

40-390

1

M010

D064

1

TBC RTN-

+30

2

+15

-31 BATT

2

P024 TBC PWR

P025 -31 KEY

1

R003

P021 81 Supply +12V antenna

1

+30

2

250A

4

B001

-31 KEY

-31 BATT

3

+15

TBC RTN-

TBC PWR

1

2

To Can Bus ISO 11783

D066

3

P022

5

A

6

P023

1

Wiring diagrams l l l l l l l l l l l l l l l l l l l l l l l l l l l l l

D066 (M) - Wiring connector (Wiring loom 0.018.9843.4/20) D066 (F) - Wiring connector (Wiring loom 0.017.8887.4/10) D067 (M) - Wiring connector (Wiring loom 0.017.8887.4/10) D067 (F) - Wiring connector (Wiring loom 0.018.9843.4/20) D069 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D069a (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D071 (M) - Wiring connector (Wiring loom 0.019.9829.4/20) D071 (M) - Wiring connector (Wiring loom 0.019.9829.4/20) D071 (F) - Wiring connector (Wiring loom 0.019.9827.4/10) D071 (F) - Wiring connector (Wiring loom 0.019.9828.4/10) D086 (M) - Configuration connector (Wiring loom 0.019.2617.4/70) D086b (F) - Configuration connector (Wiring loom 0.019.2617.4/70) E005a - I-Monitor E005b - I-Monitor H007 - Monitor controls J015 - ISOBUS relay (50A) J016 - ISOBUS relay (30A) M009 - “AGROSKY” antenna M010 - Microphone M011 - ISO 11783 control unit O014 - Diode connector O014a - Diode board P021 - ISO 11783 socket in cab P022 - Front ISOBUS 11783 socket P023 - Front ISOBUS 11783 socket P024 - Rear ISOBUS 11783 socket P025 - Rear ISOBUS 11783 socket R003 - RS 232 connector R004 - ISO11783 diagnostic socket

Table 614 Sys- P/N tem

Description

B001 B018

Fuse (250A) Fuse (50A)

B019

Fuse (30A) 3A Fuse - iMonitor + MMI (F1-A/9, +15) 3A Fuse - ISOBUS 11783 (F1-A/10, +15) 15A Fuse - iMonitor (F1-B/8, +30) Engine ground

C002

Characteristics/Notes

Position

Wiring loom

40-514 40-512

Fig. 3513

40-512 40-571 40-571 40-571 40-510

40-391

Wiring diagrams Sys- P/N tem

Description

C002

Engine ground

C003

Cab ground

D013

Wiring connector

D013

Wiring connector

D014

Wiring connector

D014

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-512

Fig. 3514

Fig. 3515

Fig. 3516

Fig. 3517

Fig. 3518

Fig. 3519

40-392

40-571

40-571

40-537

40-571

40-537

Wiring diagrams Sys- P/N tem

Description

D060

Wiring connector

D062

Wiring connector

D062

Wiring connector

D064

Wiring connector

D066

Wiring connector

D067

Wiring connector

D069

Wiring connector Wiring connector Wiring connector

D071

Characteristics/Notes

Position

Wiring loom

40-537 40-561 40-563

Fig. 3520

Fig. 3521

Fig. 3522

Fig. 3523

40-542

40-537

40-512 40-537

40-510 40-512 40-510 40-512 40-537 40-537 40-565 40-561 40-563

40-393

Wiring diagrams Table 615 Sys- P/N tem

D086

Description

Position

Wiring loom

40-537

Configuration connector

Configuration connector

I-Monitor

I-Monitor

H007

Characteristics/Notes

Monitor controls

Fig. 3524

Fig. 3524

Fig. 3525

Fig. 3525

Fig. 3526

40-394

40-537

40-542

40-542

40-537

Wiring diagrams Sys- P/N tem

I030

Description

Characteristics/Notes

“Performance Steering” system activation switch

Position

Wiring loom

40-537 0 1

Pos

Pin

1

2

3

4

5

6

7

4

5

6

9

8

1

2

3

10

7

8

9

10

1 2 2.7659.489.0

J015

ISOBUS (50A)

relay

J016

ISOBUS (30A) HLHP unit

relay

M003

Fig. 3527

40-512

Fig. 3529

40-512 40-571

M003

HLHP unit - USA version

M009

“AGROSKY” tenna Microphone

M010

Fig. 3528

An-

Fig. 3530

Fig. 3530

40-571

40-565 40-537

Fig. 3531

40-395

Wiring diagrams Sys- P/N tem

Description

M011

ISO 11783 control unit

O014

Diode connector

Diode board

O016 O017 P021

Diode board Diode board ISO 11783 socket in cab

P022

Front ISOBUS 11783 socket Front ISOBUS 11783 socket Rear ISOBUS 11783 socket

P023 P024

Characteristics/Notes

Position

Wiring loom

40-537

Fig. 3532

Fig. 3533

Fig. 3533

Fig. 3534

40-537

40-537 40-537 40-537

40-510 40-510 40-512

Fig. 3535

40-396

40-537

Wiring diagrams Sys- P/N tem

Description

P025

Rear ISOBUS 11783 socket

R003

RS 232 connector

R004

ISO11783 diagnostic socket

Characteristics/Notes

Position

Wiring loom

40-512

Fig. 3536

Fig. 3537

40-537

40-537

Fig. 3538

40-397

Wiring diagrams

To Direction indicators

+Monitor (HLHP2)

To Brakes

To Lights

To Lights

To work lights USA

Supply CUT OFF

2

92

77

3

7

11

12

1

10

2

3

4

5

6

14

8

9

13

D014

1

M003

D013

N012

To Accessories

To Direction indicators USA

40.3.39 - S031B - ISO11783 Can Bus line - Version with assisted steering

2

D062

4

To fig.2/2

20A

+30

Bm009

10

3

16

15

I030

24

7

75

13

12

41

8

89

88

42

23

22

35

37

36

34

Rear work light

6

Rear work light

4

Direction light LH

2

Direction light RH

10

Stop light

9

Full beam

8

Half beam

7

1

Supply +12V (+15)

6

Position light

0

Trailer WL USA

4

87

Direction light LH

5

85

CUT OFF EV

1

86

Supply +12V (+15) SASA PVED

3

30

Supply +12V (+15) feedback

0

87

GND

1

86

GND

2

85

O016

D014

30

87a

GND

O017

87a

M011 C003

3A

+15

Bb010

D0078480

Fig. 3539 - ISO11783 Can Bus line - Version with assisted steering - System (1/2) l l l l l l l l l l l

D013 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D013 (F) - Wiring connector (Wiring loom 0.020.8658.4) D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D062 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) I030 - “Performance Steering” system activation switch M003 - HLHP control unit M003 - HLHP unit - USA version M011 - ISO 11783 control unit N012 - Electronically controlled hydraulic power steering

40-398

+15

2

l

l 1

0

3

1

5 4

0

6 7 8

O017

85 86

9 87

1

10

C003

30

D014

87a

3A

Bb010 86 85

3 16 15

I030 4 6 24 7 12 41 8 89 88 42

Full beam

Stop light

To fig.2/2

2

D062

1 2 3 4

23

5

22

6

35

14

37

Rear work light

10

Rear work light

12

Direction light LH

11

Direction light RH

13

Half beam

75

Supply +12V (+15)

7

Position light

3

Trailer WL USA

2

Direction light LH

4

20A

D014

36

To Direction indicators

To Brakes

To Lights

To Lights

To work lights USA

To Accessories

To Direction indicators USA

+Monitor (HLHP2)

8 Supply CUT OFF

D013

N012

Supply +12V (+15) SASA PVED

+30

Bm009 1

CUT OFF EV

2

Supply +12V (+15) feedback

30

GND

O016

GND

87a

GND

Wiring diagrams M003

92 77

9 13

10

87

34

M011 D0078480

Fig. 3539 - ISO11783 Can Bus line - Version with assisted steering - System (1/2)

O016 - Diode board O017 - Diode board

40-399

Wiring diagrams Supply +12V

GND

Shield

RS232 TX

RS232 RX

RS232 RX

RS232 TX

Shield

Shield

Supply +12V

1

9

12

11

10

10

11

9

12

1

12

8

5

9

7

6

10

11

1

4

5

3

13

1

8

4

11

12

2

3

3

7

18

16

17

9

7

13

11

12

D014

8

4

1

D062

Bb009 10

RS232 TX

14

RS232 RX

1

GROUND

2

MIC -

+30 MONITOR

20

GND

+15 MONITOR

24

GND

MIC+

E005a

+ANT

E005b

2

To fig. 1/2

15A

R004 2

D014

Bf008

+30

+15

15

3A

2

D060

4

D086a D086

1

2

D071

O014

M009

Supply +12V

M009a

B

D

C

H

J

H007

3

74

84

Supply +12V (+30)

Supply +12V (+30)

Supply +12V (+30)

Relay 50A command

Front relay command

M011

6

8

9

7

6

8

9

A4

A7

A8

D8

D1

50A

B018

30A

C002

B019

C002

4

5

B

85

86

87

J016

87a

30

85

86 87

16

15

D

D067 30

A1

C003

1

5

87a

J015

Fig. 3540 - ISO11783 Can Bus line - Version with assisted steering - System (2/2) l l l l l l l l

D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D060 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D060 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) D064 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D064 (F) - Wiring connector (Wiring loom 0.018.9843.4/20)

40-400

1

M010

D069 D069a

4

3

A

l

R003

D014

3

1

A5

l

2

D064

1

TBC RTN-

+30

2

+15

-31 BATT

2

P024 TBC PWR

P025 -31 KEY

1

2

P021 81 Supply +12V antenna

1

+30

2

250A

4

B001

-31 KEY

-31 BATT

3

+15

TBC RTN-

TBC PWR

1

3

To Can Bus ISO 11783

D066

3

P022

5

A

6

P023

1

D0078490

Wiring diagrams l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l

D066 (M) - Wiring connector (Wiring loom 0.018.9843.4/20) D066 (F) - Wiring connector (Wiring loom 0.017.8887.4/10) D067 (M) - Wiring connector (Wiring loom 0.017.8887.4/10) D067 (F) - Wiring connector (Wiring loom 0.018.9843.4/20) D069 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D069a (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D071 (M) - Wiring connector (Wiring loom 0.019.9825.4/10) D071 (F) - Wiring connector (Wiring loom 0.019.9827.4/10) D071 (F) - Wiring connector (Wiring loom 0.019.9828.4/10) D071 (M) - Wiring connector (Wiring loom 0.019.9825.4/10) D086 (M) - Configuration connector (Wiring loom 0.019.2617.4/70) D086a (F) - Configuration connector (Wiring loom 0.019.2617.4/70) E005a - I-Monitor E005b - I-Monitor H007 - Monitor controls J015 - ISOBUS relay (50A) J016 - ISOBUS relay (30A) M009 - “AGROSKY” antenna M009a - “AGROSKY” Antenna M010 - Microphone M011 - ISO 11783 control unit O014 - Diode connector O014a - Diode board P021 - ISO 11783 socket in cab P022 - Front ISOBUS 11783 socket P023 - Front ISOBUS 11783 socket P024 - Rear ISOBUS 11783 socket P025 - Rear ISOBUS 11783 socket R003 - RS 232 connector R004 - ISO11783 diagnostic socket

Table 616 Sys- P/N tem

Description

B001 B018

Fuse (250A) Fuse (50A)

B019

Fuse (30A) 3A Fuse - iMonitor + MMI (F1-A/9, +15) 3A Fuse - ISOBUS 11783 (F1-A/10, +15) 15A Fuse - iMonitor (F1-B/8, +30) 20A Fuse - Steering (F2/9-12, +30)

Characteristics/Notes

Position

Wiring loom

40-514 40-512

Fig. 3541

40-512 40-571 40-571 40-571 40-571

40-401

Wiring diagrams Sys- P/N tem

Description

C002

Engine ground

C003

Cab ground

D013

Wiring connector

D013

Wiring connector

D014

Wiring connector

D014

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-510 40-512

Fig. 3542

Fig. 3543

Fig. 3544

Fig. 3545

Fig. 3546

Fig. 3547

40-402

40-571

40-571

40-537

40-571

40-537

Wiring diagrams Sys- P/N tem

Description

D060

Wiring connector

D062

Wiring connector

D062

Wiring connector

D064

Wiring connector

D066

Wiring connector

D067

Wiring connector

D069

Wiring connector Wiring connector Wiring connector

D071

Characteristics/Notes

Position

Wiring loom

40-537 40-561 40-563

Fig. 3548

Fig. 3549

Fig. 3550

Fig. 3551

40-542

40-537

40-512 40-537

40-510 40-512 40-510 40-512 40-537 40-537 40-558 40-561 40-563

40-403

Wiring diagrams Table 617 Sys- P/N tem

D086

Description

Characteristics/Notes

Position

Wiring loom

40-537

Configuration connector Configuration connector I-Monitor

40-537 40-542

Fig. 3552

I-Monitor

H007

Monitor controls

I030

“Performance Steering” system activation switch

Fig. 3552

Fig. 3553

40-542

40-537

40-537

0 1

Pos

Pin

1

2

3

4

5

6

7

4

5

6

9

8

1

2

3

10

7

8

9

10

1 2 2.7659.489.0

J015

ISOBUS (50A)

relay

J016

ISOBUS (30A)

relay

40-404

Fig. 3555

Fig. 3554

40-512

Fig. 3556

40-512

Wiring diagrams Sys- P/N tem

Description

M003

HLHP unit

M003

HLHP unit - USA version

M009

“AGROSKY” tenna “AGROSKY” tenna Microphone

M010

Characteristics/Notes

Position

Wiring loom

40-571

An-

Fig. 3557

Fig. 3557

ISO 11783 control unit

N012

Electronically controlled hydraulic power steering

40-558 40-558

An-

M011

40-571

40-537

Fig. 3558

Fig. 3559

40-537

40-537

Fig. 3560

40-405

Wiring diagrams Sys- P/N tem

O014

Description

O016 O017 P021

Diode board Diode board ISO 11783 socket in cab

P022

Front ISOBUS 11783 socket Front ISOBUS 11783 socket Rear ISOBUS 11783 socket

P024

P025

Position

Wiring loom

40-537

Diode connector

Diode board

P023

Characteristics/Notes

Rear ISOBUS 11783 socket

Fig. 3561

Fig. 3561

Fig. 3562

40-537 40-537 40-537

40-510 40-510 40-512

Fig. 3563

Fig. 3564

40-406

40-537

40-512

Wiring diagrams Sys- P/N tem

Description

R003

RS 232 connector

R004

ISO11783 diagnostic socket

Characteristics/Notes

Position

Wiring loom

40-537

Fig. 3565

40-537

Fig. 3566

40-407

Wiring diagrams

To Direction indicators

M003 +Monitor (HLHP2)

To Brakes

To Lights

To Lights

To work lights USA

To Accessories

To Direction indicators USA

40.3.40 - S031C - ISO11783 Can Bus line - Version with performance steering

2

2

3

1

6

4

1

1

2

3

4

5

6

2

K016 3

2

3

13

8

9

37

36

34

D062

10

10

GND

Supply

Signal

5

12

Rear work light

1

GND

Black 3

V

11

1 To fig.2/2

2

7

Rear work light

3

V

Signal

Grey 2

K038

M013b Supply

K037 M013a L015

To Transmission

D013

77

87a

85

86

87

87a

O016

30

86

85

3

16

15

87

6

24

7

75

1

13

12

41

8

89

88

42

23

22 Direction light LH

4

Stop light

2

Direction light RH

10

Full beam

9

Half beam

8

Supply +12V (+15)

0

7

Position light

1

6

Trailer WL USA

0

4

Direction light LH

5

Supply +12V (+15) SASA PVED

3

CUT OFF EV

1

Supply +12V (+15) feedback

2

GND

A

GND

C

D014

B

GND

D063

30

O017

35

M011 C003

3A

Bb010

I030

+15

D0078500

Fig. 3567 - ISO11783 Can Bus line - Version with performance steering - System (1/2) l l l l l l l l l l l

D013 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D013 (F) - Wiring connector (Wiring loom 0.020.8658.4) D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D062 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) D063 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D063 (F) - Wiring connector (Wiring loom 0.019.3658.4/20) I030 - “Performance Steering” system activation switch K016 - Wiring connector K037 - Steering wheel angle sensor

40-408

To Direction indicators

M003 +Monitor (HLHP2)

To Brakes

To Lights

To Lights

To work lights USA

To Accessories

To Direction indicators USA

Wiring diagrams

2

2

3

1

6

4

1

1

2

3

4

5

6

2

K016 3

2

3

13

8

9

37

36

34

D062

10

10

GND

Supply

Signal

5

12

Rear work light

1

GND

Black 3

V

11

1 To fig.2/2

2

7

Rear work light

3

V

Signal

Grey 2

K038

M013b Supply

K037 M013a L015

To Transmission

D013

77

87a

85

86

87

87a

O016

30

86

85

3

16

15

87

6

24

7

75

13

12

41

8

89

88

42

23

22 Direction light LH

4

Stop light

1

2

Direction light RH

10

Full beam

9

Half beam

8

Supply +12V (+15)

0

7

Position light

1

6

Trailer WL USA

0

4

Direction light LH

5

Supply +12V (+15) SASA PVED

3

CUT OFF EV

1

Supply +12V (+15) feedback

2

GND

A

GND

C

D014

B

GND

D063

30

O017

35

M011 C003

3A

Bb010

I030

+15

D0078500

Fig. 3567 - ISO11783 Can Bus line - Version with performance steering - System (1/2) l l l l l l l l l

K038 - Steering angle sensor (Agrosky) L015 - AGROSKY control disable solenoid valve M003 - HLHP control unit M003 - HLHP unit - USA version M011 - ISO 11783 control unit M013a - Electronically controlled hydraulic power steering (grey connector) M013b - Electronically controlled hydraulic power steering (black connector) O016 - Diode board O017 - Diode board

40-409

Wiring diagrams Supply +12V

GND

Shield

RS232 TX

RS232 RX

RS232 RX

RS232 TX

Shield

Shield

Supply +12V

1

9

12

11

10

10

11

9

12

1

12

8

5

9

7

6

10

11

1

4

5

3

13

1

8

4

11

12

2

3

3

7

18

16

17

9

7

13

11

12

D014

8

4

1

D062

Bb009 10

RS232 TX

14

RS232 RX

1

GROUND

2

MIC -

+30 MONITOR

20

GND

+15 MONITOR

24

GND

MIC+

E005a

+ANT

E005b

2

To fig. 1/2

15A

R004 2

D014

Bf008

+30

+15

15

3A

2

D060

4

D086a D086

1

2

D071

O014

M009

Supply +12V

M009a

B

D

C

H

J

H007

3

5

74

84

Supply +12V (+30)

Supply +12V (+30)

Supply +12V (+30)

Relay 50A command

Front relay command

M011

4

6

8

9

7

6

8

9

A4

A7

A8

D8

D1

50A

B018

30A

B019

C002

C002 86

87

87a

30

A1

5

B

85

86 87

16

15

D

D067 85

J016

87a

J015

Fig. 3568 - ISO11783 Can Bus line - Version with performance steering - System (2/2)

l l l l l l l

D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D060 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D060 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) D064 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D064 (F) - Wiring connector (Wiring loom 0.018.9843.4/20)

40-410

M010

C003

1

30

l

R003

D069 D069a

4

3

A

l

1

D014

3

1

A5

l

2

D064

1

TBC RTN-

+30

2

+15

-31 BATT

2

P024 TBC PWR

P025 -31 KEY

1

2

P021 81 Supply +12V antenna

1

+30

2

250A

4

B001

-31 KEY

-31 BATT

3

+15

TBC RTN-

TBC PWR

1

3

To Can Bus ISO 11783

D066

3

P022

5

A

6

P023

1

D0078510

Wiring diagrams l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l

D066 (M) - Wiring connector (Wiring loom 0.018.9843.4/20) D066 (F) - Wiring connector (Wiring loom 0.017.8887.4/10) D067 (M) - Wiring connector (Wiring loom 0.017.8887.4/10) D067 (F) - Wiring connector (Wiring loom 0.018.9843.4/20) D069 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D069a (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D071 (M) - Wiring connector (Wiring loom 0.019.9825.4/10) D071 (F) - Wiring connector (Wiring loom 0.019.9827.4/10) D071 (F) - Wiring connector (Wiring loom 0.019.9828.4/10) D071 (M) - Wiring connector (Wiring loom 0.019.9825.4/10) D086 (M) - Configuration connector (Wiring loom 0.019.2617.4/70) D086a (F) - Configuration connector (Wiring loom 0.019.2617.4/70) E005a - I-Monitor E005b - I-Monitor H007 - Monitor controls J015 - ISOBUS relay (50A) J016 - ISOBUS relay (30A) M009 - “AGROSKY” antenna M009a - “AGROSKY” Antenna M010 - Microphone M011 - ISO 11783 control unit O014 - Diode connector O014a - Diode board P021 - ISO 11783 socket in cab P022 - Front ISOBUS 11783 socket P023 - Front ISOBUS 11783 socket P024 - Rear ISOBUS 11783 socket P025 - Rear ISOBUS 11783 socket R003 - RS 232 connector R004 - ISO11783 diagnostic socket

Table 618 Sys- P/N tem

Description

B001 B018

Fuse (250A) Fuse (50A)

B019

Fuse (30A) 3A Fuse - iMonitor + MMI (F1-A/9, +15) 3A Fuse - ISOBUS 11783 (F1-A/10, +15) 15A Fuse - iMonitor (F1-B/8, +30)

Characteristics/Notes

Position

Wiring loom

40-514 40-512

Fig. 3569

40-512 40-571 40-571 40-571

40-411

Wiring diagrams Sys- P/N tem

Description

C002

Engine ground

C003

Cab ground

D013

Wiring connector

D013

Wiring connector

D014

Wiring connector

D014

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-510 40-512

Fig. 3570

Fig. 3571

Fig. 3572

Fig. 3573

Fig. 3574

Fig. 3575

40-412

40-571

40-571

40-537

40-571

40-537

Wiring diagrams Sys- P/N tem

Description

D060

Wiring connector

D062

Wiring connector

D062

Wiring connector

D063

Wiring connector

D063

Wiring connector

D064

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-537 40-561 40-563

Fig. 3576

Fig. 3577

Fig. 3578

Fig. 3579

Fig. 3580

40-542

40-537

40-537

40-540

40-512 40-537

Fig. 3581

40-413

Wiring diagrams Sys- P/N tem

Description

D066

Wiring connector

D067

Wiring connector

D069

Wiring connector Wiring connector Wiring connector

D071

Characteristics/Notes

Position

Wiring loom

40-510 40-512 40-510 40-512 40-537 40-537 40-558 40-561 40-563

Table 619 Sys- P/N tem

D086

Description

Characteristics/Notes

Position

Wiring loom

40-537

Configuration connector Configuration connector I-Monitor

40-537 40-542

Fig. 3582

I-Monitor

H007

Monitor controls

I030

“Performance Steering” system activation switch

Fig. 3582

Fig. 3583 0 1

Pos

Pin

1

2

3

4

5

6

7

4

5

6

9

8

1

2

3

10

7

8

9

10

1 2 2.7659.489.0

Fig. 3584

40-414

Fig. 3585

40-542

40-537

40-537

Wiring diagrams Sys- P/N tem

Description

J015

ISOBUS (50A)

J016

ISOBUS relay (30A) Wiring connector

K016 K037

Characteristics/Notes

Position

Wiring loom

40-512

relay

Fig. 3586

40-540 40-583 40-540

Steering wheel an- Pin 1: CAN-L signal Pin 2: 9 - 32V power feed gle sensor

K038

Steering angle sensor (Agrosky)

L015

AGROSKY control disable solenoid valve

M003

HLHP unit

M003

HLHP unit - USA version

M009

“AGROSKY” tenna

Pin 3: ground Pin 4: CAN-H signal

40-540

Fig. 3588

Fig. 3589

An-

40-512

Fig. 3590

Fig. 3590

40-540

40-571

40-571

40-558

40-415

Wiring diagrams Sys- P/N tem

M010

M011

Description

“AGROSKY” tenna Microphone

Characteristics/Notes

Wiring loom

40-558

An-

ISO 11783 control unit

Electronically controlled hydraulic power steering (grey connector)

Electronically controlled hydraulic power steering (black connector)

O014

Position

Diode connector

40-537

Fig. 3591

Fig. 3592

Fig. 3593

Fig. 3594

Fig. 3595

40-416

40-537

40-540

40-540

40-537

Wiring diagrams Sys- P/N tem

Description

O016 O017 P021

Diode board Diode board ISO 11783 socket in cab

P022

Front ISOBUS 11783 socket Front ISOBUS 11783 socket Rear ISOBUS 11783 socket

P023 P024

Characteristics/Notes

Position

Wiring loom

40-537

Diode board

P025

Rear ISOBUS 11783 socket

R003

RS 232 connector

Fig. 3595

Fig. 3596

40-537 40-537 40-537

40-510 40-510 40-512

Fig. 3597

Fig. 3598

40-512

40-537

Fig. 3599

40-417

Wiring diagrams Sys- P/N tem

R004

Description

Characteristics/Notes

Position

Wiring loom

40-537

ISO11783 diagnostic socket

Fig. 3600

40-418

Wiring diagrams 40.3.41 - S032 - Webasto

A5

A8

A1

C7

3

9

12

6

2

1

2

2

1

2

1

2 FUEL POUMP

B5

N020

FUEL POUMP

B3

DIAGNOSTIC

B6

DIODO

C5

GND

C1

R005

+30 WEBASTO

A2

GND

A3

GND

B1

P029a GND

+30 CLIMA DENSO/WEBASTO

B2

THERMO CALL 86/30

+30 CLIMA DENSO/WEBASTO

A7

O019 THERMO CALL 86/30

+15 CLIMA DENSO/WEBASTO

C3

+15 CLIMA DENSO/WEBASTO

A6

DENSO ECU

A4

+15 WEBASTO RELAY

B4

DENSO FANS RELAY COILS

C8

THERMO CALL 85

M016

D093

P029b 7

9

8

6

5

2

B B7

B D6

B D4

B B8

B C1

B A8

A A3

10

3

4

Bc001

+30

20A

7.5A

+30

10

17

5

3

2

1

THERMO CALL 86/30

THERMO CALL 86/30

WEBASTO (THERMO CALL)

16

C005

18

THERMO ALL 85

+15KEY

D024

Bf019

4

17

B A1

5A

D073

D016

+30

7.5A

+15

3A

+15

A D8

Bf002

Ba009

Bb020

D008

C002

1

M015

M017

D0078260

Fig. 3601 - Webasto - System l l l l l l l l l

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D016 (M) - Wiring connector (Wiring loom 0.019.5311.4/10) D016 (F) - Wiring connector (Wiring loom 0.020.8658.4) D024 (M) - Wiring connector (yellow) (Wiring loom 0.020.8862.4) D024 (F) - Wiring connector (yellow) (Wiring loom 0.020.8658.4) D073 (F) - Wiring connector (Wiring loom 0.020.8658.4) D093 (M) - Wiring connector (Wiring loom 0.021.0489.4) D093 (F) - Wiring connector (Wiring loom 0.020.8664.4) 40-419

Wiring diagrams l l l l l l l l l

M015 - A/C control unit (blue connector) M016 - Relay unit M017 - Webasto ECU N020 - Webasto circuit pump O019 - LED carrier connector O019a - Diode P029a - Webasto unit P029b - Webasto unit R005 - Webasto diagnostic connector

Table 620 Sys- P/N tem

Description

C002

7.5A Fuse - Air conditioning fuse (F3/9, +15) 3A Fuse - Ignition key (F1-A/20, +15) 20A fuse - Webasto (heater) (F4/1-4, +30) 7.5A Fuse - Air conditioning system fuse (F1/2, +30) 5A fuse - Webasto (thermo call) (F1B/19, +30) Engine ground

C005 D008

Cab ground (roof) Wiring connector

D016

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571 40-571 40-571 40-576

Fig. 3602

Fig. 3603

Fig. 3604

40-420

40-580 40-571 40-576

40-556 40-571

Wiring diagrams Sys- P/N tem

Description

D024

Wiring connector (yellow)

D073

Wiring connector

D093

Wiring connector

D093

Wiring connector

M015

Air conditioning control unit (blue connector)

M016

Relay unit

Characteristics/Notes

Position

Wiring loom

40-571 40-580

Fig. 3605

Fig. 3606

Fig. 3607

Fig. 3608

Fig. 3609

40-571

40-576

40-585

40-556

40-585

Fig. 3610

40-421

Wiring diagrams Sys- P/N tem

Description

M017

Webasto ECU

N020

Webasto circuit pump LED carrier connector Diode Webasto unit

O019

R005

40-422

Webasto unit Webasto diagnostic connector

Characteristics/Notes

Position

Wiring loom

40-580

Fig. 3611

40-585 40-585 40-585 40-585

Fig. 3612

40-585 40-585

Wiring diagrams 40.3.42 - S033 - Lights - Version without front hitch (U.S.A.) Jd006

Jh003

87 86 85

30

87a

87 86 85

30

D009

87a

B A1

Jh001

Jh004

To fig. 2/2

LOW BEAM HIGH BEAM CONTROL

F026 Jh006

C003a

A D1

Jh005 87 86 85

87a

D009 A D8

30

D001

D001

D013

15A

D006

D013

3

2

1

2

11

13

14

23

5

6

12

16

21 FUSE PDU3 (INSTRUM.+30)

I009

3

FULL BEAM LIGHT

1

+15 INSTRUMENT

2

GND

10

POSITION

9

+58

I008

6

+15 WOLP

5

+30 WOLP

3

GND

2

FULL BEAM LIGHT

8

+30 WOLP

To fig. 2/2

To ISO 11783

H002

E002

D044

D003

5

3

6

1

P006

3

2

1

F005a

3

C002

D008

C003a

C002

2

7

B B3

A A2

D034

D009 A D5

D009

5

3A

C003

Bb004

C003a

+15

D031

3A

B008

3A

Bb014

5A

Bf018

C003a

+15 5A

Bf012

+30 5A

+30

1 9

10

Bf011

+15

+30

D001

To ISO 11783

+30

7.5A

Bf010

Bf014

4

10 11

Bf013

C003a

+30

87 86 85

87a

FL/AL LH 0

7.5A

A D7

1

30

15A

2

D023 15A

Bf007

30

Bf009

1

C003a

87 86 85

87a

+30

85 30

C003a

86

To fig. 2/2

87

D052

87a

3

2

F005

1

3

6

58L

31

P015 D0078410

Fig. 3613 - S033 - Lights - Version without front hitch (USA) - System (1/2) l l l l l l l l l

D001 (M) - Wiring connector (Wiring loom 0.020.8658.4) D001 (F) - Wiring connector (Wiring loom 0.014.0007.4/20) D003 (M) - Wiring connector (Wiring loom 0.020.1009.4) D003 (F) - Wiring connector (Wiring loom 0.020.8658.4) D006 (M) - Wiring connector (Wiring loom 0.020.1009.4) D006 (F) - Wiring connector (Wiring loom 0.020.8658.4) D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) 40-423

Wiring diagrams l l l l l l l l l l l l l l l l l l l l l l l l l l l l

D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D013 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D013 (F) - Wiring connector (Wiring loom 0.020.8658.4) D023 (M) - Wiring connector (Wiring loom 0.020.8658.4) D023 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D034 (M) - Wiring connector (Wiring loom 0.017.8426.4) D034 (F) - Wiring connector (Wiring loom 0.021.0396.4) D044 (M) - Wiring connector (Wiring loom 0.015.5429.4/20) D044 (F) - Wiring connector (Wiring loom 0.020.8664.4) D052 (M) - Wiring connector (Wiring loom 0.019.2378.4/40) D052 (F) - Wiring connector (Wiring loom 0.012.2018.4/20) E002 - Instrument panel F005 - Left hand sidelight F005a - LH sidelight F026 - License plate light H002 - Work light control I008 - Road lights switch I009 - Top lights switch Jd006 - Same bonnet relay (R4/6) Jh001 - Road lights/Top lights relay (R3/1) Jh003 - Road lights/Top lights relay (R3/3) Jh004 - High beam relay (R3/4) Jh005 - Sidelights relay (R3/5) Jh006 - Low beam relay (R3/6) P006 - Trailer socket P015 - Front implement power outlet socket

40-424

Wiring diagrams

D001

HORN CONTROL

15A

17

12

15

1

2

A D8

C003a To fig. 1/2

D009 A D1

A D7

D036

D006

B A1

C002

C002

D009

A B7

To fig. 1/2

To fig. 1/2

D009

+15

Bb003

12

16

1

2

1

E004

2

F009

13

1

F008

1

2

F007

1

2

F010

2

3

3

2

F003

1

3

2

1

F003a

D0078130

Fig. 3614 - S033 - Lights - Version without front hitch (USA) - System (2/2) l l l l l l l l l l l l l l l

D001 (M) - Wiring connector (Wiring loom 0.020.8658.4) D001 (F) - Wiring connector (Wiring loom 0.014.0007.4/20) D006 (M) - Wiring connector (Wiring loom 0.020.1009.4) D006 (F) - Wiring connector (Wiring loom 0.020.8658.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D036 (M) - Wiring connector (Wiring loom 0.021.0396.4) D036 (F) - Wiring connector (Wiring loom 0.019.2383.4/20) E004 - Horn F003 - Right hand sidelight F003a - RH sidelight F007 - Right hand high beam headlight F008 - Right hand low beam headlight F009 - Left hand low beam headlight F010 - Left hand high beam headlight

40-425

Wiring diagrams Table 621 Sys- P/N tem

B008

Bf011

C002

Description

Characteristics/Notes

Position

Wiring loom

40-514

Fuse (3A)

15A Fuse - Windscreen wiper (F1A/3, +15) 3A Fuse - Cluster (F1-A/4, +15) 3A Fuse - Work light display (F1A/14, +15) 15A Fuse - Lights relay protection (F1-B/7, +30) 15A Fuse - Lights relay protection (F1-B/9, +30) 7.5A Fuse - Left hand sidelights (F1B/10, +30) 5A Fuse - Road lights/Top lights relay protection (F1B/11, +30) 5A Fuse - Lights (F1-B/12, +15) 7.5A Fuse - Right hand sidelights (F1B/13, +30) 15A Fuse - Sidelights relay protection (F1-B/14, +30) 15A Fuse - Work light display (F1A/18, +30) Engine ground

Fig. 3615

40-571 40-571 40-571 40-571 40-571 40-571

40-571 40-571 40-571 40-571 40-583 40-576

Fig. 3616

40-426

40-571

Wiring diagrams Sys- P/N tem

C003

Description

Characteristics/Notes

Position

Wiring loom

40-571

Cab ground

Cab ground

D001

Wiring connector

D003

Wiring connector

D006

Wiring connector

D008

Wiring connector

Fig. 3617

Fig. 3618

Fig. 3619

Fig. 3620

Fig. 3621

40-571

40-496 40-571

40-566 40-571

40-567 40-571

40-571 40-576

Fig. 3622

40-427

Wiring diagrams Sys- P/N tem

Description

D009

Wiring connector

D013

Wiring connector

D013

Wiring connector

D023

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-583

Fig. 3623

Fig. 3624

Fig. 3625

Fig. 3626

40-428

40-571

40-537

40-571 40-520

Wiring diagrams Table 622 Sys- P/N tem

Description

D031

Wiring connector

D034

Wiring connector

D036

Wiring connector

D044

Wiring connector

D052

Wiring connector

E002

Instrument panel

E004 01169304 F003

Horn RH sidelight

RH sidelight

F005

LH sidelight

Characteristics/Notes

Position

Wiring loom

40-583 40-514 40-509 40-583

Fig. 3627

Fig. 3628

Fig. 3629

Fig. 3630

40-529 40-583 40-500 40-576 40-496 40-520 40-571

40-529 40-567

40-567

40-566

Fig. 3631

40-429

Wiring diagrams Sys- P/N tem

Description

F007

F026 04414115 H002

RH high beam headlight RH low beam headlight LH low beam headlight LH high beam headlight License plate light Work light switch

I008

Road lights switch

F008 F009 F010

Characteristics/Notes

Position

Wiring loom

40-566

LH sidelight

Fig. 3632

40-529 40-529 40-529 40-529 40-496 40-571

Fig. 3633

40-571

0 1 2

Pos

Pin

1

2

3

4

5

6

7

4

5

6

9

8

1

2

3

10

7

9

8

10

0 1 2 2.7659.376.0

I009

Fig. 3635

Fig. 3634

Top lights switch

40-571

0 1

Pos

Pin

1

2

3

4

5

7

4

5

6

9

8

1

2

3

10

6

7

8

0 1

2.7659.377.0

Same bonnet relay (R4/6) Road lights/Top lights relay (R3/1) Road lights/Top lights relay (R3/3) High beam relay (R3/4) 40-430

Fig. 3636

Fig. 3637

40-571 40-571 40-571 40-571

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

Position

Wiring loom

40-571

Sidelights relay (R3/5) Low beam relay (R3/6) Trailer socket Front implement power outlet socket

P006 P015

40-571 40-509 40-500

40.3.43 - S034 - Lights - Version with front hitch (U.S.A.) Jd006

Jh003

87 86 85

30

87 86 85

87a

30

D009

87a

B A1

Jh001

LOW BEAM HIGH BEAM CONTROL

Jh004

To fig. 2/2

F026

Jh006

C003a

A D1

Jh005 87

86

85 30

87a

87 86 85

30

87a

87 86 85

30

D052

87a

A D8

A D7

4

4

15A

Bf014

D013

11

13

14

23

5

6

12

16

21

C002

D008 D044

To fig. 2/2

1

2

C003a

D009

C002

D003

D009

D034

2

6

1

H002

To ISO 11783

B008

+15

D031 3

FULL BEAM LIGHT

I009

1

FUSE PDU3 (INSTRUM.+30)

2

+15 INSTRUMENT

8

GND

7

POSITION

10

+58

9

+15 WOLP

I008

6

B B3

A A2

3

+30 WOLP

5

3A

Bb004

C003a

C003a

C003 3

2

5

GND

2

1

A D5

FULL BEAM LIGHT

8

5

+30 WOLP

7

3A

+30

+15 3A

5A

To fig. 2/2

+15 5A

Bf012

5A

Bf011

+30

10

Bb014

3

Bf018

D013

9

+30

D006

D001

To ISO 11783

+30

7.5A

7.5A

Bf013

Bf010

+30

+30

10 11

5A

Bf011

D001 15A

Bf009

To fig. 2/2

C003a

To fig. 2/2

C003a

Bf007

15A

30

4

1

1

+30

87 86 85

87a

D001

FL/AL LH 0

D006

D003

D003

C003a

1

D009

D006

2

D023

1

P006

3

3

2

F005

1

3

6

58L

31

P015

E002 D0078420

Fig. 3638 - Lights - Version with front hitch (U.S.A.) - System (1/2) 40-431

Wiring diagrams l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l

D001 (M) - Wiring connector (Wiring loom 0.020.8658.4) D001 (F) - Wiring connector (Wiring loom 0.014.0007.4/20) D003 (M) - Wiring connector (Wiring loom 0.020.1009.4) D003 (F) - Wiring connector (Wiring loom 0.020.8658.4) D006 (M) - Wiring connector (Wiring loom 0.020.1009.4) D006 (F) - Wiring connector (Wiring loom 0.020.8658.4) D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D013 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D013 (F) - Wiring connector (Wiring loom 0.020.8658.4) D023 (M) - Wiring connector (Wiring loom 0.020.8658.4) D023 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D034 (M) - Wiring connector (Wiring loom 0.017.8426.4) D034 (F) - Wiring connector (Wiring loom 0.021.0396.4) D044 (M) - Wiring connector (Wiring loom 0.015.5429.4/20) D044 (F) - Wiring connector (Wiring loom 0.020.8664.4) D052 (M) - Wiring connector (Wiring loom 0.019.2378.4/40) D052 (F) - Wiring connector (Wiring loom 0.012.2018.4/20) E002 - Instrument panel F005 - Left hand sidelight F026 - License plate light H002 - Work light control I008 - Road lights switch I009 - Top lights switch Jd006 - Same bonnet relay (R4/6) Jh001 - Road lights/Top lights relay (R3/1) Jh003 - Road lights/Top lights relay (R3/3) Jh004 - High beam relay (R3/4) Jh005 - Sidelights relay (R3/5) Jh006 - Low beam relay (R3/6) P006 - Trailer socket P015 - Front implement power outlet socket

40-432

Wiring diagrams

F043 HORN CONTROL

2

4

3

4

3

2

4

3

4

3

2

3

2

1

1

To fig. 1/2

To fig. 1/2

D009 A D1

C002

B A1

12

15

1

2

A D8

A D7

D036

C002

D009

A B7

C003a

C003a

15A

D009

+15

Bb003

2

To fig. 1/2

To fig. 1/2

D001

1

12 17

1

F003

D006

D003

1

F044

16

1

2

1

E004

2

F009

13

1

F008

1

2

F007

1

2

F010 D0078140

Fig. 3639 - Lights - Version with front hitch (U.S.A.) - System (2/2) l l l l l l l l l l l l l l l l l

D001 (M) - Wiring connector (Wiring loom 0.020.8658.4) D001 (F) - Wiring connector (Wiring loom 0.014.0007.4/20) D003 (M) - Wiring connector (Wiring loom 0.020.1009.4) D003 (F) - Wiring connector (Wiring loom 0.020.8658.4) D006 (M) - Wiring connector (Wiring loom 0.020.1009.4) D006 (F) - Wiring connector (Wiring loom 0.020.8658.4) D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D013 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D013 (F) - Wiring connector (Wiring loom 0.020.8658.4) D023 (M) - Wiring connector (Wiring loom 0.020.8658.4) D023 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D034 (M) - Wiring connector (Wiring loom 0.017.8426.4) 40-433

Wiring diagrams

F043 HORN CONTROL

2

4

3

4

3

2

4

3

4

3

2

3

2

1

1

To fig. 1/2

To fig. 1/2

D009 A D1

C002

B A1

12

15

1

2

A D8

A D7

D036

C002

D009

A B7

C003a

C003a

15A

D009

+15

Bb003

2

To fig. 1/2

To fig. 1/2

D001

1

12 17

1

F003

D006

D003

1

F044

16

1

2

1

E004

2

F009

13

1

F008

1

2

F007

1

2

F010 D0078140

Fig. 3639 - Lights - Version with front hitch (U.S.A.) - System (2/2) l l l l l l l l l l l l l l l l l

D034 (F) - Wiring connector (Wiring loom 0.021.0396.4) D036 (M) - Wiring connector (Wiring loom 0.021.0396.4) D036 (F) - Wiring connector (Wiring loom 0.019.2383.4/20) D044 (M) - Wiring connector (Wiring loom 0.015.5429.4/20) D044 (F) - Wiring connector (Wiring loom 0.020.8664.4) D052 (M) - Wiring connector (Wiring loom 0.019.2378.4/40) D052 (F) - Wiring connector (Wiring loom 0.012.2018.4/20) E002 - Instrument panel E004 - Horn F003 - Right hand sidelight F005 - Left hand sidelight F007 - Right hand high beam headlight F008 - Right hand low beam headlight F009 - Left hand low beam headlight F010 - Left hand high beam headlight F026 - License plate light F043 - LH repeater light

40-434

Wiring diagrams

F043 HORN CONTROL

2

4

3

4

3

2

4

3

4

3

2

3

2

1

1

To fig. 1/2

To fig. 1/2

D009 A D1

C002

B A1

12

15

1

2

A D8

A D7

D036

C002

D009

A B7

C003a

C003a

15A

D009

+15

Bb003

2

To fig. 1/2

To fig. 1/2

D001

1

12 17

1

F003

D006

D003

1

F044

16

1

2

1

E004

2

F009

13

1

F008

1

2

F007

1

2

F010 D0078140

Fig. 3639 - Lights - Version with front hitch (U.S.A.) - System (2/2) l l l l l l l l l l l l

F044 - RH repeater light H002 - Work light control I008 - Road lights switch I009 - Top lights switch Jd006 - Same bonnet relay (R4/6) Jh001 - Road lights/Top lights relay (R3/1) Jh003 - Road lights/Top lights relay (R3/3) Jh004 - High beam relay (R3/4) Jh005 - Sidelights relay (R3/5) Jh006 - Low beam relay (R3/6) P006 - Trailer socket P015 - Front implement power outlet socket

40-435

Wiring diagrams Table 623 Sys- P/N tem

B008

Bf011

C002

Description

Characteristics/Notes

Position

Wiring loom

40-514

Fuse (3A)

15A Fuse - Windscreen wiper (F1A/3, +15) 3A Fuse - Cluster (F1-A/4, +15) 3A Fuse - Work light display (F1A/14, +15) 15A Fuse - Lights relay protection (F1-B/7, +30) 15A Fuse - Lights relay protection (F1-B/9, +30) 7.5A Fuse - Left hand sidelights (F1B/10, +30) 5A Fuse - Road lights/Top lights relay protection (F1B/11, +30) 7.5A Fuse - Right hand sidelights (F1B/13, +30) 15A Fuse - Sidelights relay protection (F1-B/14, +30) 15A Fuse - Work light display (F1A/18, +30) Engine ground

Fig. 3640

40-571 40-571 40-571 40-571 40-571 40-571

40-571 40-571 40-571 40-583

Fig. 3641

40-436

40-571

Wiring diagrams Sys- P/N tem

C003

Description

Characteristics/Notes

Position

Wiring loom

40-571

Cab ground

Cab ground

D001

Wiring connector

D003

Wiring connector

D006

Wiring connector

D008

Wiring connector

Fig. 3642

Fig. 3643

Fig. 3644

Fig. 3645

Fig. 3646

40-571

40-496 40-571

40-566 40-571

40-567 40-571

40-571 40-576

Fig. 3647

40-437

Wiring diagrams Sys- P/N tem

Description

D009

Wiring connector

D013

Wiring connector

D013

Wiring connector

D023

Wiring connector

D031

Wiring connector

40-438

Characteristics/Notes

Position

Wiring loom

40-571 40-583

Fig. 3648

Fig. 3649

Fig. 3650

40-571

40-537

40-571 40-520 40-583 40-514

Wiring diagrams Table 624 Sys- P/N tem

Description

D034

Wiring connector

D036

Wiring connector

D044

Wiring connector

D052

Wiring connector

E002

Instrument panel

E004 01169304 F003

Horn RH sidelight

F005

LH sidelight

F007

RH high beam headlight RH low beam headlight

F008

Characteristics/Notes

Position

Wiring loom

40-509 40-583

Fig. 3651

Fig. 3652

Fig. 3653

Fig. 3654

Fig. 3655

40-529 40-583

40-500 40-576 40-496 40-520 40-571

40-529 40-567

40-566

40-529 40-529

40-439

Wiring diagrams Sys- P/N tem

F009 F010

F026 04414115 F043

Description

Characteristics/Notes

Position

Wiring loom

40-529

LH low beam headlight LH high beam headlight License plate light Left hand repeater headlight

F043

Left hand repeater headlight

F044

Right hand repeater headlight

F044

Right hand repeater headlight

H002

Work light switch

40-529 40-496 40-566

Fig. 3656

Fig. 3656

Fig. 3657

Fig. 3657

Fig. 3658

40-440

40-566

40-567

40-567

40-571

Wiring diagrams Sys- P/N tem

I008

Description

Characteristics/Notes

Position

Wiring loom

40-571

Road lights switch 0 1 2

Pos

Pin

1

2

3

4

5

6

7

4

5

6

9

8

1

2

3

10

7

9

8

10

0 1 2 2.7659.376.0

I009

Fig. 3660

Fig. 3659

Top lights switch

40-571

0 1

Pos

Pin

1

2

3

4

5

7

4

5

6

9

8

1

2

3

10

6

7

8

0 1

2.7659.377.0

P006 P015

Same bonnet relay (R4/6) Road lights/Top lights relay (R3/1) Road lights/Top lights relay (R3/3) High beam relay (R3/4) Sidelights relay (R3/5) Low beam relay (R3/6) Trailer socket Front implement power outlet socket

Fig. 3661

Fig. 3662

40-571 40-571 40-571 40-571 40-571 40-571 40-509 40-500

40-441

Wiring diagrams 40.3.44 - S035 - Turn indicators (U.S.A.) DIRECTION LIGHT CONTR OL DIRECTION LEFT

TRAILER 2

TRAILER1

49A

49A

49A

49A

DIR. COM

49

DIRECTION LAMP LEFT

DIRECTION LAMP LEFT

DIRECTION LAMP RIGHT

DIRECTION LAMP RIGHT

4

3

1

2

11

10

6

5

9

2

7

8

3

12

D001

+15 INSTRUMENT

12

3

1

16

17

18

+15

2

D068

C003a

DIRECTION RIGHT

5

E001

0FF 0N 0N 0FF

3A

GND

21

Bb004

FUSE PDU3

E002

1

2

3

4

5

7

6

8

9

10

11

12

13

14

15

19

20

19

20

4

2

To fig. 2/2 To fig. 2/2

2

3

4

5

7

6

8

9

10

11

12

13

14

4

5

7

15

16

17

18

D008

D022

1

5

3

1

1

L

2

1

12

2

1

3

1

3

4

3

4

3

1

2

2

1

P015

P006

F041

F042

F006

F004

Fig. 3663 - Turn indicators (U.S.A.) - System (1/2) l l l l l l l l l

D001 (M) - Wiring connector (Wiring loom 0.020.8658.4) D001 (F) - Wiring connector (Wiring loom 0.014.0007.4/20) D004 (M) - Wiring connector (Wiring loom 0.020.1009.4) D004 (F) - Wiring connector (Wiring loom 0.020.8658.4) D007 (M) - Wiring connector (Wiring loom 0.020.1009.4) D007 (F) - Wiring connector (Wiring loom 0.020.8658.4) D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4)

40-442

20A

15A

Bm007

C003a

M004

D0078150

3 TRAILER 1

TRAILER 2

49A

49

D007

D004 1

1

GND

C003a

C003a 12

1

D028

3

D030

D034

D031 R

1

6

+30

31

4

3A

B008

5

C003a

A A4

D023

A A5

C003a

A D5

4

D026

5

C002

6

C003a

To iso 11783

D009

D044

C002

D013

Bb008

+30

B B4

+15

B D2

5 49a

6 L

7 R

2 30B(-)

I001

1 +15

3 +30

4 49(+)

Wiring diagrams l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l

D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D013 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D013 (F) - Wiring connector (Wiring loom 0.020.8658.4) D022 (F) - Wiring connector (Wiring loom 0.019.2380.4/30) D022 (M) - Configuration connector (Wiring loom 0.020.8658.4) D023 (M) - Wiring connector (Wiring loom 0.020.8658.4) D023 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D026 (M) - Wiring connector (Wiring loom 0.020.8658.4) D026 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D028 (M) - Wiring connector (Wiring loom 0.020.1026.4/10) D028 (F) - Wiring connector (Wiring loom 0.020.1009.4) D030 (M) - Wiring connector (Wiring loom 0.020.1026.4/10) D030 (F) - Wiring connector (Wiring loom 0.020.1009.4) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D034 (M) - Wiring connector (Wiring loom 0.017.8426.4) D034 (F) - Wiring connector (Wiring loom 0.021.0396.4) D044 (M) - Wiring connector (Wiring loom 0.015.5429.4/20) D044 (F) - Wiring connector (Wiring loom 0.020.8664.4) D068 (M) - Wiring connector (Wiring loom 0.019.2380.4/30) D068 (F) - Configuration connector (Wiring loom 0.020.8658.4) E001 - Instrument panel E002 - Instrument panel F004 - RH turn indicator F006 - LH turn indicator F041 - RH rear HAZARD warning light - USA version F042 - LH rear HAZARD warning light - USA version I001 - Hazard warning lights switch M004 - Hazard warning lights control unit P006 - Trailer socket P015 - Front implement power outlet socket

40-443

Wiring diagrams I029 To fig. 1/2

2

3

4

5

7

6

8

9

10

11

12

13

14

15

16

17

18

19

20

49(+)

+30

+15

30B(-)

R

L

49a

4

3

1

2

7

6

5

13

14

15

16

17

18

19

HAZARD RH (USA)

LAMP LT USA

B3

B2

A8

B4

A1

B8

C003

LAMP RH USA

A6

-31

EXTREMELY LT

B1

+30

TRAILER LT

EXTREMELY RH

A4

HAZARD IN

B6

+15

A2

RIGHT

B7

LEFT

C2

HAZARD LIGHT

C1

+15

A5

HAZARD LT

A3 TRAILER RH

D022

1

M012

2

3

4

5

7

6

8

9

10

11

12

20

D068

1

To fig. 1/2

D0078430

Fig. 3664 - Turn indicators (U.S.A.) - System (2/2) l l l l l l

D022 (F) - Wiring connector (Wiring loom 0.019.2380.4/30) D022 (M) - Configuration connector (Wiring loom 0.020.8658.4) D068 (M) - Wiring connector (Wiring loom 0.019.2380.4/30) D068 (F) - Configuration connector (Wiring loom 0.020.8658.4) I029 - Hazard warning lights switch M012 - Turn indicator control unit (USA)

Table 625 Sys- P/N tem

B008

Description

Position

Wiring loom

40-514

Fuse (3A)

3A Fuse - Cluster (F1-A/4, +15) 15A Fuse - EU/USA emergency lights (F1-A/8, +15)

40-444

Characteristics/Notes

Fig. 3665

40-571 40-571

Wiring diagrams Sys- P/N tem

Description

C002

20A Fuse - EU/USA emergency lights (F2/7-10, +30) Engine ground

C003

Cab ground

Cab ground

D001

Wiring connector

D004

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-583 40-576

Fig. 3666

Fig. 3667

Fig. 3668

Fig. 3669

40-528

40-571

40-496 40-571

40-566 40-571

Fig. 3670

40-445

Wiring diagrams Sys- P/N tem

Description

D007

Wiring connector

D008

Wiring connector

D009

Wiring connector

D013

Wiring connector

D013

Wiring connector

D022

Wiring connector

D022

Wiring connector

40-446

Characteristics/Notes

Position

Wiring loom

40-567 40-571

Fig. 3671

Fig. 3672

Fig. 3673

Fig. 3674

Fig. 3675

Fig. 3676

40-571 40-576

40-571 40-583

40-571

40-537

40-528

40-571

Wiring diagrams Sys- P/N tem

Description

D023

Wiring connector

D026

Wiring connector

D028

Wiring connector

D028

Wiring connector

D030

Wiring connector

D030

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-520

Fig. 3677

Fig. 3678

Fig. 3679

Fig. 3680

Fig. 3681

40-571 40-522

40-567

40-569

40-566

40-568

Fig. 3682

40-447

Wiring diagrams Sys- P/N tem

Description

D031

Wiring connector

D034

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-583 40-514 40-509 40-583

Fig. 3683

Table 626 Sys- P/N tem

Description

D044

Wiring connector

D068

Wiring connector

D068 E001

Configuration connector Instrument panel

E002

Instrument panel

F004

RH turn indicator

Characteristics/Notes

Position

Wiring loom

40-500 40-576 40-528

Fig. 3684

40-571

Fig. 3685

Fig. 3686

Fig. 3687

40-448

40-571

40-571

40-569

Wiring diagrams Sys- P/N tem

Description

F006

LH turn indicator

F041

RH rear hazard warning light - USA version LH rear hazard warning light - USA version Hazard warning lights switch

F042 I001

Characteristics/Notes

Position

Wiring loom

40-568

Fig. 3688

40-522 40-520

1

40-571

0

Pin

15 1

30 3

49 4

49a 5

2

15

49a L

1

R

6

Pos

30

30

49

5

b

3 4

7

L 6

R 7

0 1 2.7659.110.0

I029

Hazard warning lights switch

M004

Hazard lights flasher unit

M012

Turn indicator control unit (USA)

P006 P015

Trailer socket Front implement power outlet socket

Fig. 3690

Fig. 3689

40-528

Fig. 3691

Fig. 3692

Fig. 3693

40-571

40-528

40-509 40-500

40-449

Wiring diagrams 40.3.45 - S036 - Work lights (U.S.A.)

J003 Jg003

1

2

1

2

1

2

1

2

1

2

1

2

1

F032

F034

F035

2

F036

8

9

1

2

F033

40A

D031

+30 USA

To fig. 2/2

D031

+30 USA

D004 D007

To fig. 2/2

+58 D009

Bf010

+30 USA 15A

Bf018

+15 USA D009

Bb014

3A

+30 USA

C003

To ISO 11783 USA

A D2

19

21

2

7

5

14

1

13

6

17

18 FRONT ROOF

7

LEFT CORNER LIGHT RELAY

6

FRONT LOW

5

+30 WOLP

9

B D4

+30 WOLP

8

To fig. 2/2

+15 WOLP

4

2

RIGHT CORNER LIGHT RELAY

3

4

REAR ROOF

4

C003

20A

To fig. 2/2 15A

D031

Bf020

3

4

6

GND

2

4

30

1

9

23

H002 D0068790

Fig. 3694 - Work lights (U.S.A.) - System (1/2) l l l l l l l l l

D004 (M) - Wiring connector (Wiring loom 0.020.1009.4) D004 (F) - Wiring connector (Wiring loom 0.020.8658.4) D007 (M) - Wiring connector (Wiring loom 0.020.1009.4) D007 (F) - Wiring connector (Wiring loom 0.020.8658.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D013 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D013 (F) - Wiring connector (Wiring loom 0.020.8658.4) D023 (M) - Wiring connector (Wiring loom 0.020.8658.4)

40-450

B003

D031

86 85

B D1

D013 D058

1

F030

C005

C005

C005 D059

2

F029

87

30

85

C003a

15A

Be004

15A

Be001 D024

1

F031

87 86

12

1

2

5

C005 D056

D055

4

D058

C005

C005

C005 D056

13

15

10

87a

D009

+30 USA

+30 USA

15A

D025 11

8

30

15A

20A

D026 3

Bc002

D023

D034

C003

3

87a

To fig. 2/2

+15 USA

Ba010

B A8

15A

Ba006

87

85 86

2 87a

2

D009

C003

+30 USA

B D2

15A

Ba005

30

8

Jg001

To fig. 2/2

Jg002

7.5A

30

86 85

86 85

+58

87

87a

Je001

87

B004

2

30

D031

7

85

15A

1

30

86 85

86

AUX TRAILER

87

87a

B006

87

Bm008

P006

Je002

J002

Wiring diagrams J003 Jg003

1

2

1

2

1

2

1

2

1

2

1

2

1

F034

F035

2

F036

8

9

1

2

F033

40A

+30 USA

C003

D031

To fig. 2/2

D031

+30 USA

D004 D007

To fig. 2/2

+58 D009

Bf010

+30 USA 15A

Bf018

+15 USA D009

Bb014

3A

+30 USA

C003

To ISO 11783 USA

A D2

19

21

2

7

5

14

1

13

6

17

18 FRONT ROOF

7

LEFT CORNER LIGHT RELAY

6

FRONT LOW

5

B D4

+30 WOLP

9

To fig. 2/2

+30 WOLP

8

2

+15 WOLP

4

4

RIGHT CORNER LIGHT RELAY

3

4

6

REAR ROOF

4

B003

D031 20A

To fig. 2/2 15A

D031

Bf020

3

F032

9

GND

2

F030

1

D013 D058

1

F029

C005

C005

C005

2

4

30

B D1

C003a

15A

Be004

15A

Be001

D059

1

F031

86 85

30

85

12

1

2

5

C005 D056

D055

4

D058

C005

C005

C005 D056

13

15

10

87 86

D009

+30 USA

+30 USA D024

D025 11

8 87a

87

15A

20A

D026

Bc002

D023

D034

3

To fig. 2/2

+15 USA

Ba010

B A8

15A

Ba006

3

87a

15A

C003

+30 USA

87

85 86

2 87a

2

D009

C003

8

B D2

15A

Ba005

30

Jg001

To fig. 2/2

Jg002

30

7.5A

30

86 85

86 85

23 +58

87

87a

Je001

87

B004

2

30

D031

7

85

15A

1

30

86 85

86

AUX TRAILER

87

87a

B006

87

Bm008

P006

Je002

J002

H002 D0068790

Fig. 3694 - Work lights (U.S.A.) - System (1/2) l l l l l l l l l l l

D023 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D024 (M) - Wiring connector (yellow) (Wiring loom 0.020.8862.4) D024 (F) - Wiring connector (yellow) (Wiring loom 0.020.8658.4) D025 (M) - Wiring connector (brown) (Wiring loom 0.020.8862.4) D025 (F) - Wiring connector (brown) (Wiring loom 0.020.8658.4) D026 (M) - Wiring connector (Wiring loom 0.020.8658.4) D026 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D034 (M) - Wiring connector (Wiring loom 0.017.8426.4) D034 (F) - Wiring connector (Wiring loom 0.021.0396.4) 40-451

Wiring diagrams J003 Jg003

1

2

1

2

1

2

1

2

1

2

1

2

1

F034

F035

2

F036

8

9

1

2

F033

40A

+30 USA

C003

D031

To fig. 2/2

D031

+30 USA

D004 D007

To fig. 2/2

+58 D009

Bf010

+30 USA 15A

Bf018

+15 USA D009

Bb014

3A

+30 USA

C003

To ISO 11783 USA

A D2

19

21

2

7

5

14

1

13

6

17

18 FRONT ROOF

7

LEFT CORNER LIGHT RELAY

6

FRONT LOW

5

+30 WOLP

9

B D4

+30 WOLP

8

To fig. 2/2

+15 WOLP

4

2

RIGHT CORNER LIGHT RELAY

3

4

REAR ROOF

4

4

6

23

H002 D0068790

Fig. 3694 - Work lights (U.S.A.) - System (1/2) l l l l l l l l l l l

D055 (M) - Wiring connector (Wiring loom 0.019.4689.4/20) D055 (M) - Wiring connector (Wiring loom 0.019.4914.4/20) D055 (F) - Wiring connector (Wiring loom 0.020.8862.4) D055 (F) - Wiring connector (Wiring loom 0.020.8862.4) D056 (M) - Wiring connector (Wiring loom 0.019.4689.4/20) D056 (M) - Wiring connector (Wiring loom 0.019.4914.4/20) D056 (F) - Wiring connector (Wiring loom 0.020.8862.4) D056 (F) - Wiring connector (Wiring loom 0.020.8862.4) D058 (M) - Wiring connector (Wiring loom 0.019.4688.4/10) D058 (M) - Wiring connector (Wiring loom 0.019.4913.4/10) D058 (M) - Wiring connector (Wiring loom 0.019.9827.4/10)

40-452

B003

D031 20A

To fig. 2/2 15A

D031

Bf020

3

F032

9

GND

2

F030

1

D013 D058

1

F029

C005

C005

C005

2

4

30

B D1

C003a

15A

Be004

15A

Be001

D059

1

F031

86 85

30

85

12

1

2

5

C005 D056

D055

4

D058

C005

C005

C005 D056

13

15

10

87 86

D009

+30 USA

+30 USA D024

D025 11

8 87a

87

30

15A

20A

D026

Bc002

D023

D034

3

To fig. 2/2

+15 USA

Ba010

B A8

15A

Ba006

3

87a

15A

C003

+30 USA

87

85 86

2 87a

2

D009

C003

8

B D2

15A

Ba005

30

Jg001

To fig. 2/2

Jg002

7.5A

30

86 85

86 85

+58

87

87a

Je001

87

B004

2

30

D031

7

85

15A

1

30

86 85

86

AUX TRAILER

87

87a

B006

87

Bm008

P006

Je002

J002

Wiring diagrams J003 Jg003

1

2

1

2

1

2

1

2

1

2

1

2

1

F034

F035

2

F036

8

9

1

2

F033

40A

+30 USA

C003

D031

To fig. 2/2

D031

+30 USA

D004 D007

To fig. 2/2

+58 D009

Bf010

+30 USA 15A

Bf018

+15 USA D009

Bb014

3A

+30 USA

C003

To ISO 11783 USA

A D2

19

21

2

7

5

14

1

13

6

17

18 FRONT ROOF

7

LEFT CORNER LIGHT RELAY

6

FRONT LOW

5

B D4

+30 WOLP

9

To fig. 2/2

+30 WOLP

8

2

+15 WOLP

4

4

RIGHT CORNER LIGHT RELAY

3

4

6

REAR ROOF

4

B003

D031 20A

To fig. 2/2 15A

D031

Bf020

3

F032

9

GND

2

F030

1

D013 D058

1

F029

C005

C005

C005

2

4

30

B D1

C003a

15A

Be004

15A

Be001

D059

1

F031

86 85

30

85

12

1

2

5

C005 D056

D055

4

D058

C005

C005

C005 D056

13

15

10

87 86

D009

+30 USA

+30 USA D024

D025 11

8 87a

87

15A

20A

D026

Bc002

D023

D034

3

To fig. 2/2

+15 USA

Ba010

B A8

15A

Ba006

3

87a

15A

C003

+30 USA

87

85 86

2 87a

2

D009

C003

8

B D2

15A

Ba005

30

Jg001

To fig. 2/2

Jg002

30

7.5A

30

86 85

86 85

23 +58

87

87a

Je001

87

B004

2

30

D031

7

85

15A

1

30

86 85

86

AUX TRAILER

87

87a

B006

87

Bm008

P006

Je002

J002

H002 D0068790

Fig. 3694 - Work lights (U.S.A.) - System (1/2) l l l l l l l l l l l

D058 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D058 (F) - Wiring connector (Wiring loom 0.020.8862.4) D058 (F) - Wiring connector (Wiring loom 0.020.8862.4) D058 (F) - Wiring connector (Wiring loom 0.020.8862.4) D058 (F) - Wiring connector (Wiring loom 0.020.8862.4) D059 (M) - Wiring connector (Wiring loom 0.019.4688.4/10) D059 (M) - Wiring connector (Wiring loom 0.019.4913.4/10) D059 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D059 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D059 (F) - Wiring connector (Wiring loom 0.020.8862.4) D059 (F) - Wiring connector (Wiring loom 0.020.8862.4) 40-453

Wiring diagrams J003 Jg003

1

2

1

2

1

2

1

2

1

2

1

2

1

F034

F035

2

F036

8

9

1

2

F033

40A

+30 USA

C003

D031

To fig. 2/2

D031

+30 USA

D004 D007

To fig. 2/2

+58 D009

Bf010

+30 USA 15A

Bf018

+15 USA D009

Bb014

3A

+30 USA

C003

To ISO 11783 USA

A D2

19

21

2

7

5

14

1

13

6

17

18 FRONT ROOF

7

LEFT CORNER LIGHT RELAY

6

FRONT LOW

5

+30 WOLP

9

B D4

+30 WOLP

8

To fig. 2/2

+15 WOLP

4

2

RIGHT CORNER LIGHT RELAY

3

4

REAR ROOF

4

4

6

23

H002 D0068790

Fig. 3694 - Work lights (U.S.A.) - System (1/2) l l l l l l l l l l l

D059 (F) - Wiring connector (Wiring loom 0.020.8862.4) D059 (F) - Wiring connector (Wiring loom 0.020.8862.4) F029 - Right hand inner rear work light (on cab roof) F030 - Right hand outer rear work light (on cab roof) F031 - Left hand inner rear work light (on cab roof) F032 - Left hand outer rear work light (on cab roof) F033 - Left hand outer front work light (on cab roof) F033 - Left hand inner front work light (on cab roof) F034 - Left hand outer front work light (on cab roof) F034 - Left hand inner front work light (on cab roof) F035 - Right hand outer front work light (on cab roof)

40-454

B003

D031 20A

To fig. 2/2 15A

D031

Bf020

3

F032

9

GND

2

F030

1

D013 D058

1

F029

C005

C005

C005

2

4

30

B D1

C003a

15A

Be004

15A

Be001

D059

1

F031

86 85

30

85

12

1

2

5

C005 D056

D055

4

D058

C005

C005

C005 D056

13

15

10

87 86

D009

+30 USA

+30 USA D024

D025 11

8 87a

87

30

15A

20A

D026

Bc002

D023

D034

3

To fig. 2/2

+15 USA

Ba010

B A8

15A

Ba006

3

87a

15A

C003

+30 USA

87

85 86

2 87a

2

D009

C003

8

B D2

15A

Ba005

30

Jg001

To fig. 2/2

Jg002

7.5A

30

86 85

86 85

+58

87

87a

Je001

87

B004

2

30

D031

7

85

15A

1

30

86 85

86

AUX TRAILER

87

87a

B006

87

Bm008

P006

Je002

J002

Wiring diagrams J003 Jg003

1

2

1

2

1

2

1

2

1

2

1

2

1

F034

F035

2

F036

8

9

1

2

F033

40A

+30 USA

C003

D031

To fig. 2/2

D031

+30 USA

D004 D007

To fig. 2/2

+58 D009

Bf010

+30 USA 15A

Bf018

+15 USA D009

Bb014

3A

+30 USA

C003

To ISO 11783 USA

A D2

19

21

2

7

5

14

1

13

6

17

18 FRONT ROOF

7

LEFT CORNER LIGHT RELAY

6

FRONT LOW

5

B D4

+30 WOLP

9

To fig. 2/2

+30 WOLP

8

2

+15 WOLP

4

4

RIGHT CORNER LIGHT RELAY

3

4

6

REAR ROOF

4

B003

D031 20A

To fig. 2/2 15A

D031

Bf020

3

F032

9

GND

2

F030

1

D013 D058

1

F029

C005

C005

C005

2

4

30

B D1

C003a

15A

Be004

15A

Be001

D059

1

F031

86 85

30

85

12

1

2

5

C005 D056

D055

4

D058

C005

C005

C005 D056

13

15

10

87 86

D009

+30 USA

+30 USA D024

D025 11

8 87a

87

15A

20A

D026

Bc002

D023

D034

3

To fig. 2/2

+15 USA

Ba010

B A8

15A

Ba006

3

87a

15A

C003

+30 USA

87

85 86

2 87a

2

D009

C003

8

B D2

15A

Ba005

30

Jg001

To fig. 2/2

Jg002

30

7.5A

30

86 85

86 85

23 +58

87

87a

Je001

87

B004

2

30

D031

7

85

15A

1

30

86 85

86

AUX TRAILER

87

87a

B006

87

Bm008

P006

Je002

J002

H002 D0068790

Fig. 3694 - Work lights (U.S.A.) - System (1/2) l l l l l l l l l l l

F036 - Left hand outer front work light (on cab roof) F036 - Right hand inner front work light (on cab roof) H002 - Work light control J002 - Left hand work light relay (on engine cowl) J003 - Right hand work light relay (on engine cowl) Je001 - Relay for front work lights on cab roof (R6/1) Je002 - Relay for rear work lights on cab roof (R6/2) Jg001 - Relay for low front work lights (R1-A/1) Jg002 - Relay for trailer electrical power outlet sockets (R1-A/2) Jg003 - Relay for low rear work lights (R1-A/3) P006 - Trailer socket 40-455

5

6

7

4

1

2

1

2

F012

1

2

F015

1

2

F014

1

2

F011

1

1

2

F028

2

F040

1

2

F039

1

2

F027

C003a

D007

3

1

1

2

2

1

3

1

2

D028

D030

2

To fig. 1/2

To fig. 1/2

D004

C003a 1

3

D027

8

3

4

D027a

9

1

D029a

3

To fig. 1/2

D026 3

4

D029

D036 17

3

D047

1

1

9

To fig. 1/2

C003a

D031

D023

C002

To fig. 1/2

To fig. 1/2

C002

8

D051

2

D031

C002

To fig. 1/2

D031

C002

D031

To fig. 1/2

C003a

Wiring diagrams

1

F037

1

2

F038 D0078380

Fig. 3695 - Work lights (U.S.A.) - System (2/2) l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l

D004 (M) - Wiring connector (Wiring loom 0.020.1009.4) D004 (F) - Wiring connector (Wiring loom 0.020.8658.4) D007 (M) - Wiring connector (Wiring loom 0.020.1009.4) D007 (F) - Wiring connector (Wiring loom 0.020.8658.4) D023 (M) - Wiring connector (Wiring loom 0.020.8658.4) D023 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D026 (M) - Wiring connector (Wiring loom 0.020.8658.4) D026 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D027 (F) - Wiring connector (Wiring loom 0.020.1026.4/10) D027a (M) - Wiring connector (Wiring loom 0.020.1026.4/10) D028 (M) - Wiring connector (Wiring loom 0.020.1026.4/10) D028 (F) - Wiring connector (Wiring loom 0.020.1009.4) D029 (F) - Wiring connector (Wiring loom 0.020.1026.4/10) D029a (M) - Wiring connector (Wiring loom 0.020.1026.4/10) D030 (M) - Wiring connector (Wiring loom 0.020.1026.4/10) D030 (F) - Wiring connector (Wiring loom 0.020.1009.4) D031 (M) - Wiring connector (Wiring loom 0.021.0396.4) D031 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D036 (M) - Wiring connector (Wiring loom 0.021.0396.4) D036 (F) - Wiring connector (Wiring loom 0.019.2383.4/20) D047 (M) - Wiring connector (Wiring loom 0.017.0497.4/20) D047 (M) - Wiring connector (Wiring loom 0.016.0642.4/20) D047 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D047 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D051 (M) - Wiring connector (Wiring loom 0.017.0497.4/20) D051 (M) - Wiring connector (Wiring loom 0.016.0642.4/20) D051 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) D051 (F) - Wiring connector (Wiring loom 0.019.2378.4/40) F011 - RH front work light - on cowl F012 - Right hand front centre work light - on engine cowl F014 - Left hand front centre work light - on engine cowl F015 - LH front work light - on cowl

40-456

5

6

7

4

1

2

1

2

F012

1

2

F015

1

2

F014

1

2

F011

1

2

F028

1

2

F040

1

2

F039

1

2

F027

C003a

D007

3

1

1

2

2

1

3

1

2

D028

D030

2

To fig. 1/2

To fig. 1/2

D004

C003a 1

3

D027

8

3

4

D027a

9

1

D029a

3

To fig. 1/2

D026 3

4

D029

D036 17

3

D047

1

1

9

To fig. 1/2

C003a

D031

D023

C002

To fig. 1/2

C002

To fig. 1/2

8

D051

2

D031

C002

To fig. 1/2

D031

C002

D031

To fig. 1/2

C003a

Wiring diagrams

1

F037

1

2

F038 D0078380

Fig. 3695 - Work lights (U.S.A.) - System (2/2) l l l l l l

F027 - Low right hand rear work light F028 - Low left hand rear work light F037 - LH front work light (on arm) F038 - RH front work light (on arm) F039 - Low left hand rear work light F040 - Low right hand rear work light

Table 627 Sys- P/N tem

B003 B004 B006

Description

Fuse (40A) Fuse (15A) Fuse (15A) 15A Fuse - Rear work light fuse (F3/5) 15A Fuse - Rear work light fuse (F3/6) 15A Fuse - U.S.A. trailer lights fuse (F3/10, +15) 3A Fuse - Work light display (F1A/14, +15) 20A Fuse - Low rear work light relay protection (F4/2-5, +30)

Characteristics/Notes

Position

Wiring loom

40-514 40-514 40-514 40-571 40-571 40-571 40-571 40-571

40-457

Wiring diagrams Sys- P/N tem

Description

C002

15A Fuse - Front work lights (R6/1-5) 15A Fuse - Front work lights (R6/4-8) 7.5A Fuse - Left hand sidelights (F1B/10, +30) 15A Fuse - Work light display (F1A/18, +30) 15A Fuse - Trailer lights relay protection (F1-B/20, +30) 20A Fuse - Front work lights relay protection (F2/8-11) Engine ground

C003

Cab ground

Cab ground

C005 D004

Cab ground (roof) Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571 40-571 40-571 40-571 40-583

Fig. 3696

Fig. 3697

Fig. 3698

Fig. 3699

40-458

40-571

40-571

40-580 40-566

Wiring diagrams Sys- P/N tem

Description

D004

Wiring connector

D007

Wiring connector

D009

Wiring connector

D013

Wiring connector

D013

Wiring connector

D023

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571

Fig. 3700

Fig. 3701

Fig. 3702

Fig. 3703

Fig. 3704

40-567 40-571

40-571 40-583

40-571

40-537

40-571 40-520

Fig. 3705

40-459

Wiring diagrams Sys- P/N tem

D024

Description

Characteristics/Notes

Position

Wiring loom

40-571 40-580

Wiring connector (yellow)

Fig. 3706

Table 628 Sys- P/N tem

Description

D025

Wiring connector (brown)

D026

Wiring connector

D027 D028

Wiring connector Wiring connector Wiring connector

D028

Wiring connector

D029

Wiring connector Wiring connector

40-460

Characteristics/Notes

Position

Wiring loom

40-571 40-580

Fig. 3707

Fig. 3708

Fig. 3709

Fig. 3710

40-571 40-522

40-569 40-569 40-567

40-569

40-568 40-568

Wiring diagrams Sys- P/N tem

Description

D030

Wiring connector

D030

Wiring connector

D031

Wiring connector

D034

Wiring connector

D036

Wiring connector

D047

Wiring connector

D051

Wiring connector

D055

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-566

Fig. 3711

Fig. 3712

Fig. 3713

40-568

40-583 40-514 40-509 40-583

40-529 40-583 40-506 40-502 40-522 40-522 40-506 40-501 40-520 40-520 40-546 40-554 40-580 40-580

40-461

Wiring diagrams Table 629 Sys- P/N tem

Description

D056

Wiring connector

D058

Wiring connector

D059

Wiring connector

F011

Rh front work light on cowl RH centre front work light - on engine cowl LH centre front work light - on engine cowl Lh front work light on cowl RH lower rear work light LH lower rear work light Right hand inner rear work light (on cab roof) Right hand inner rear work light (on cab roof) Right hand outer rear work light (on cab roof) Right hand outer rear work light (on cab roof)

F012 F014 F015 F027 F028 F029 F029 F030 F030

Characteristics/Notes

Position

Wiring loom

40-547 40-552 40-580 40-580 40-545 40-551 40-580 40-561 40-563 40-580 40-580 40-580 40-545 40-551 40-580 40-561 40-563 40-580 40-580 40-580 40-529 40-529 40-529 40-529 40-506 40-506 40-546 40-554 40-546 40-554

Table 630 Sys- P/N tem

F031 F031

40-462

Description

Left hand inner rear work light (on cab roof) Left hand inner rear work light (on cab roof)

Characteristics/Notes

Position

Wiring loom

40-547 40-552

Wiring diagrams Sys- P/N tem

F032 F032 F033 F033 F033 F033 F034 F034 F034 F034 F035 F035 F035 F035 F036 F036 F036 F036 F037

Description

Left hand outer rear work light (on cab roof) Left hand outer rear work light (on cab roof) Left hand outer front work light (on cab roof) Left hand outer front work light (on cab roof) Left hand inner front work light (on cab roof) Left hand inner front work light (on cab roof) Left hand inner front work light (on cab roof) Left hand inner front work light (on cab roof) Left hand outer front work light (on cab roof) Left hand outer front work light (on cab roof) Right hand outer front work light (on cab roof) Right hand outer front work light (on cab roof) Right hand outer front work light (on cab roof) Right hand outer front work light (on cab roof) Left hand outer front work light (on cab roof) Right hand inner front work light (on cab roof) Right hand inner front work light (on cab roof) Right hand inner front work light (on cab roof) Lh front work light (on arm)

Characteristics/Notes

Position

Wiring loom

40-547 40-552 40-545 40-551 40-561 40-563 40-545 40-551 40-561 40-563 40-545 40-551 40-561 40-563 40-545 40-551 40-561 40-563 40-502

40-463

Wiring diagrams Sys- P/N tem

F037 F037

F038 F038 F038

F039 F040 H002

Description

Characteristics/Notes

Position

Wiring loom

40-568

Lh front work light (on arm) Lh front work light (on arm)

Rh front work light (on arm) Rh front work light (on arm) Rh front work light (on arm)

LH lower rear work light RH lower rear work light Work light switch

40-568

Fig. 3714

40-569 40-569

Fig. 3715

40-502 40-501 40-571

Fig. 3716

40-464

40-503

Wiring diagrams Table 631 Sys- P/N tem

Description

J002

Left hand work light relay (on engine cowl)

J003

Right hand work light relay (on engine cowl) Relay for front work lights on cab roof (R6/1) Relay for rear work lights on cab roof (R6/2) Relay for low front work lights (R1-A/1) Relay for trailer electrical power outlet sockets (R1A/2) Relay for low rear work lights (R1-A/3) Trailer socket

P006

Characteristics/Notes

Position

Wiring loom

40-514

Fig. 3717

40-514 40-571 40-571 40-571 40-571

40-571 40-509

40-465

Wiring diagrams 40.3.46 - S037 - +15 Positives (U.S.A.) Jn001

Ja001

I006 0 30

87a

87 86 85

40A

+30

40A

Bf016

Bm017

30

1 2 83

15

P

15

75

50

78

50

+30

3A

Bm015

Bb020

30

15A

30

+30

87 86 85

C003

87a

5A 3A 7.5A 10A 15A 5A 7.5A 5A

3A 5A 5A 5A

7.5A

Ba010

Bb004 Bb005 Bb006 Bb007

To Electronic engine governor

Bb008 Bb009 Bb010 Bf012 Ba007 Ba008

Ba009 Be002

8C

C002

15A

Bb019 Bc003

B015

3A

Bb018

20A

15A

Bb016

D012

7.5A

15A

Bb015

B010

7.5A

Bb003

Bb013

10A

3A 7.5A

20A

Bb011 Bb012

B013

5A 15A

7.5A

Bb002

Bb014

15A

10A

Bb001

Bb017

87a

87 86 85

J012

Fig. 3718 - +15 Positives (U.S.A.) - System l l l l l l

D012 (M) - Wiring connector (Wiring loom 0.018.9992.4/10) D012 (F) - Wiring connector (Wiring loom 0.020.8658.4) I006 - Ignition switch J012 - Nox sensor power relay Ja001 - Ignition key relay (F3/1) Jn001 - Ignition key relay (R7/1)

40-466

30

D0078450

Wiring diagrams Table 632 Sys- P/N tem

B010 B013 B015

Description

Fuse (10A) Fuse (15A) Fuse (20A) 5A fuse - Tierra fuse (F3/7, +15) 5A fuse - Fuse (F3/8, +15) 7.5A Fuse - Air conditioning fuse (F3/9, +15) 15A Fuse - U.S.A. trailer lights fuse (F3/10, +15) 10A Fuse - ISO 11786 (F1-A/1, +15) 5A Fuse - EPB (F1A/2, +15) 15A Fuse - Windscreen wiper (F1A/3, +15) 3A Fuse - Cluster (F1-A/4, +15) 7.5A Fuse - HLHP control unit (F1-A/5, +15) 7.5A Fuse - Pneumatic seat (F1-A/6, +15) 7.5A Fuse - Engine (F1-A/7, +15) 15A Fuse - EU/USA emergency lights (F1-A/8, +15) 3A Fuse - iMonitor + MMI (F1-A/9, +15) 3A Fuse - ISOBUS 11783 (F1-A/10, +15) 7.5A Fuse - Rear view mirrors (F1A/11, +15) 10A Fuse - Rear windscreen wiper (F1-A/12, +15) 15A Fuse - Brake lights (F1-A/13, +15) 3A Fuse - Work light display (F1A/14, +15) 5A Fuse - Transmission (F1-A/15, +15)

Characteristics/Notes

Position

Wiring loom

40-518 40-518 40-518 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-571

40-467

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

Position

Wiring loom

40-571

7.5A Fuse - Radar/ PTO/distributors (F1-A/16, +15) 5A Fuse - SGR Transmission (F1A/17, +15) 5A Fuse - Radio (F1-A/18, +15) 7.5A Fuse - External electric power outlet sockets (F1A/19, +15) 3A Fuse - Ignition key (F1-A/20, +15) 20A Fuse - Seat/ brakes (F4/3-6, +15) 15A fuse - ABS trailer socket (R6/26, +15) 5A Fuse - Lights (F1-B/12, +15) 15A Fuse - Ignition key (F1-A/16, +30) 40A Fuse - Ignition key relay protection (F2/15-16)

40-571 40-571 40-571

40-571 40-571 40-571 40-571 40-571 40-571

Table 633 Sys- P/N tem

Description

C002

40A Fuse - Ignition key relay protection (F2/17-18) Engine ground

C003

Cab ground

D012

Wiring connector

40-468

Characteristics/Notes

Position

Wiring loom

40-571 40-518

Fig. 3719

Fig. 3720

40-571

40-518 40-571

Wiring diagrams Sys- P/N tem

Description

I006

Characteristics/Notes

Position

Wiring loom

40-571

Starter switch 83 50

30

86s

15

75

Pin

Pos

30

15

50

75

83

0 1 2 0.015.0485.4

J012

Fig. 3721

Nox sensor power supply relay Ignition key relay (F3/1) Ignition key relay (R7/1)

40-518 40-571 40-571

250A

40A

B016

30A

30A 3A

Bm002

Bm001 20A

20A

Bm003

Bm007 85

To working lights 85

86 87

87a

86 87

B021

87a

B008

Je001

Je002

B015

7

+30a

T001b

a

T001

b

+30b GND

+30

C001

C002

6

J006a

5

T001a

20A

B014

30A

4

J006b 3

30

B003

B

To AdBlue

2

B002

D032

D+

A001

B+

20A

C003

B001

20A

20A

Bm008

20A

Bm013

Bm009

20A

30A

Bm017

Bm015

40A

40A

Bc001

Ba001

15A

20A

Bc002

Ba002 3A

20A

Bc008

20A

Bf001

Bc017

40A

30

D002

7.5A

Bf002

Bf003

5A

7.5A

Bf004

15A

Bf005

Bf006

5A

15A

Bf008

Bf009

Bf007

15A

15A

15A

Bf014

Bf011

5A

15A

Bf015

3A

Bf017

Bf016

15A

10A

Bf019

Bf020

Bf018

15A

5A

5A

15A

Bc013

30A

Ba004

40.3.47 - S038 - +30 Positives (U.S.A.)

BATTERY

D0078330

J006

Fig. 3722 - +30 Positives (U.S.A.) - System l l

A001 - Alternator “B+” D002 (M) - Wiring connector (Wiring loom 0.020.8658.4) 40-469

250A

40A

B016

30A

30A 3A

Bm002

Bm001 20A

20A

Bm003

Bm007 85

To working lights 85

86 87

87a

86 87

87a

B021 B008

Je001

Je002

B015

+30a

T001b

a

T001

b

7

+30b GND

+30

C001

C002

6

J006a

5

T001a

20A

B014

30A

4

J006b 3

30

B003

B

To AdBlue

2

B002

D032

D+

A001

B+

20A

C003

B001

20A

20A

Bm008

20A

Bm013

Bm009

20A

30A

Bm017

Bm015

40A

40A

Bc001

Ba001

15A

20A

Bc002

Ba002 3A

20A

Bc008

20A

Bf001

Bc017

40A

30

D002

7.5A

Bf002

Bf003

5A

7.5A

Bf004

15A

Bf005

Bf006

5A

15A

Bf008

Bf009

Bf007

15A

15A

15A

Bf014

Bf011

5A

15A

Bf015

3A

Bf017

Bf016

15A

10A

Bf019

Bf020

Bf018

15A

5A

5A

15A

Bc013

30A

Ba004

Wiring diagrams

BATTERY

D0078330

J006

Fig. 3722 - +30 Positives (U.S.A.) - System l l l l l l l l

D002 (F) - Wiring connector (Wiring loom 0.018.9845.4/10) D032 (M) - Wiring connector (Wiring loom 0.021.0396.4) D032 (F) - Wiring connector (Wiring loom 0.018.9992.4/10) J006 - Battery disconnect contactor J006a - Battery disconnect contactor J006b - Battery disconnect contactor Je001 - Relay for front work lights on cab roof (R6/1) Je002 - Relay for rear work lights on cab roof (R6/2)

Table 634 Sys- P/N tem

A001

40-470

Description

Alternator “B+”

Characteristics/Notes

Position

Wiring loom

40-589 40-512 40-514

Wiring diagrams Sys- P/N tem

Description

B001

Fuse (250A)

B002 B003 B008

Fuse (200A) Fuse (40A) Fuse (3A)

B014 B015 B016 B021

Fuse (30A) Fuse (20A) Fuse (30A) Fuse (30A) 15A Fuse - Lights fuse and power outlet socket (F3/1, +30) 3A Fuse - Work Display Fuse (F3/2, +30) 5A fuse - Tierra fuse (F3/4, +30) 20A fuse - Webasto (heater) (F4/1-4, +30) 20A Fuse - Low rear work light relay protection (F4/2-5, +30) 20A Fuse - Rear defrost (F4/8-11) 30A fuse - Heating unit (F4/13-14, +30) 40A Fuse - Heating system (F4/17-18, +30) 7.5A Fuse - SGR Transmission (F1A/1, +30) 7.5A Fuse - Air conditioning system fuse (F1/2, +30)

Characteristics/Notes

Position

Wiring loom

40-514

Fig. 3723

Fig. 3724

40-514 40-514 40-514

40-518 40-518 40-518 40-514 40-571

40-571 40-571 40-571 40-571

40-571 40-571 40-571 40-571 40-571

40-471

Wiring diagrams Sys- P/N tem

Bf011

Description

Characteristics/Notes

Position

Wiring loom

40-571

5A Fuse - Transmission control unit (F1-B/3, +30) 15A Fuse - Turn indicator relay protection (F1-B/4, +30) 15A Fuse - Armrest (F1-B/5, +30) 5A Fuse - Radio (F1-B/6, +30) 15A Fuse - Lights relay protection (F1-B/7, +30) 15A Fuse - iMonitor (F1-B/8, +30) 15A Fuse - Lights relay protection (F1-B/9, +30) 5A Fuse - Road lights/Top lights relay protection (F1B/11, +30) 15A Fuse - Sidelights relay protection (F1-B/14, +30) 3A Fuse - Cab lights (F1-B/15, +30)

40-571

40-571 40-571 40-571 40-571 40-571 40-571

40-571 40-571

Table 635 Sys- P/N tem

40-472

Description

15A Fuse - Ignition key (F1-A/16, +30) 10A Fuse - Hitch relay protection (F1B/17, +30) 15A Fuse - Work light display (F1A/18, +30) 5A fuse - Webasto (thermo call) (F1B/19, +30) 15A Fuse - Trailer lights relay protection (F1-B/20, +30) 20A Fuse - Tractor electric power outlet sockets (F2/1-4, +30) 20A Fuse - Cab electric power outlet sockets (F2/2-5, +30)

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571 40-571 40-571 40-571

40-571

Wiring diagrams Sys- P/N tem

Description

C002

20A Fuse - HLHP control unit (F2/3-6, +30) 20A Fuse - EU/USA emergency lights (F2/7-10, +30) 20A Fuse - Front work lights relay protection (F2/8-11) 20A Fuse - Steering (F2/9-12, +30) 30A Fuse - Engine (F2/13-14, +30) 40A Fuse - Ignition key relay protection (F2/15-16) 40A Fuse - Ignition key relay protection (F2/17-18) Battery negative terminal Engine ground

C003

Cab ground

D002

Wiring connector

D032

Wiring connector

J006

Battery disconnect contactor Battery disconnect contactor

C001

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-498 40-498

Fig. 3725

Fig. 3726

40-528

40-571 40-514 40-518 40-583 40-518 40-511

Fig. 3727

40-473

Wiring diagrams Sys- P/N tem

T001

Description

Position

Wiring loom

40-511

Battery disconnect contactor

Relay for front work lights on cab roof (R6/1) Relay for rear work lights on cab roof (R6/2) Battery positive terminal

Battery positive terminal Battery positive terminal

40-474

Characteristics/Notes

Fig. 3728

40-571 40-571 40-511

Fig. 3729

40-583 40-514

Wiring diagrams 40.3.48 - S039 - PTO (USA)

L014

freq

1

8

1

2

3

9

10

1

freq

L010

L006

3

2

3

2

1

2

1

2

1

1

2

2

+30 USA

3

C003a

4

+15 USA

C002

7.5A

Bb016

+15 USA

2

2

C002

C002

C003a

C002

7.5A

+58

C002 D045

C003 +30

+30

GND

GND

GND

FRONT PTO SPEED SENSOR

PTO SELECTION

FRONT PTO EV

+15 HLHP

46

M003

1

2 freq

K009

5A

Bf003 D009

D008

3

5

6

8

9

10

11

13

14 +30 ECU

8

GND

80

A D4

REAR PTO SENSOR

58

A A6

+15 TRANSMISSION

19

B A7

EV REAR PTO PROP.

6

A D2

EV PTO 1000N

4

B A6

EV PTO 540E

2

A C7

EV PTO 1400

D009

5

SIG.

3

GND

1 +30

A D7

SUPPLY

B A4

5A

Bb015

+15 USA

D008

Bb005

2 7.5A

20A

1

1

D043

+30 USA

C002

A D3

Bm003

Bf010

D008

1

D043

1

D040

D045

D042

7

L011

GND

2

SIG.

GND

SIG.

3

2

L009

K031 SUPPLY

SUPPLY

1

I010

K030

M001b D0068780

Fig. 3730 - P.T.O. (U.S.A.) - System l l l l l l l l l l l l l l l l l

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D040 (M) - Wiring connector (Wiring loom 0.019.2474.4/10) D040 (F) - Wiring connector (Wiring loom 0.020.8664.4) D042 (M) - Wiring connector (Wiring loom 0.015.4257.4/10) D042 (F) - Wiring connector (Wiring loom 0.020.8664.4) D043 (M) - Wiring connector (Wiring loom 0.019.2474.4/10) D043 (F) - Wiring connector (Wiring loom 0.020.8664.4) D045 (M) - Wiring connector (Wiring loom 0.020.8664.4) D045 (F) - Wiring connector (Wiring loom 0.900.0816.0) I010 - PTO selection switch K009 – PTO speed sensor K030 - Front PTO speed sensor K031 - PTO speed sensor - (U.S.A. Export) L006 - Rear PTO control solenoid valve 40-475

Wiring diagrams

L014

freq

1

8

1

2

3

9

10

1

L010

L006

3

2

3

2

1

2

1

2

1

1

2

2

+30 USA

3

C003a

4

+15 USA

C002

7.5A

Bb016

+15 USA

2

2

C002

C002

C003a

C002

7.5A

+58

C002 D045

C003 +30

+30

GND

GND

GND

FRONT PTO SPEED SENSOR

PTO SELECTION

FRONT PTO EV

+15 HLHP

46

1

2 freq

5A

Bf003 D009

D008

3

5

6

8

9

K009

10

11

13

14 +30 ECU

8

GND

80

A D4

REAR PTO SENSOR

58

A A6

+15 TRANSMISSION

19

B A7

EV REAR PTO PROP.

6

A D2

EV PTO 1000N

4

B A6

EV PTO 540E

2

A C7

EV PTO 1400

D009

5

SIG.

3

GND

1 +30

A D7

SUPPLY

B A4

5A

Bb015

+15 USA

D008

Bb005

2 7.5A

20A

1

1

D043

+30 USA

C002

A D3

Bm003

Bf010

D008

1

D043

1

D040

D045

D042

7

L011

GND

2

freq SIG.

GND

SIG.

3

2

L009

K031 SUPPLY

SUPPLY

1

I010

K030

M001b

M003

D0068780

Fig. 3730 - P.T.O. (U.S.A.) - System l l l l l l

L009 - PTO 1,000 E engagement control solenoid valve L010 - PTO 1,000 N engagement control solenoid valve L011 - PTO 540 E engagement control solenoid valve L014 - Front PTO control solenoid valve M001b - Transmission control unit M003 - HLHP unit - USA version

Table 636 Sys- P/N tem

40-476

Description

7.5A Fuse - HLHP control unit (F1-A/5, +15) 5A Fuse - Transmission (F1-A/15, +15)

Characteristics/Notes

Position

Wiring loom

40-571 40-571

Wiring diagrams Sys- P/N tem

Description

C002

7.5A Fuse - Radar/ PTO/distributors (F1-A/16, +15) 5A Fuse - Transmission control unit (F1-B/3, +30) 7.5A Fuse - Left hand sidelights (F1B/10, +30) 20A Fuse - HLHP control unit (F2/3-6, +30) Engine ground

C003

Cab ground

Cab ground

D008

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-571 40-571 40-571 40-583 40-576

Fig. 3731

Fig. 3732

Fig. 3733

40-571

40-571

40-571 40-576

Fig. 3734

40-477

Wiring diagrams Sys- P/N tem

Description

D009

Wiring connector

D040

Wiring connector

D042

Wiring connector

D043

Wiring connector

D045

Wiring connector

I010

PTO switch

K009 04438352

PTO speed sensor Pin 1 = ground Pin 2 = square wave signal Pin 3 = 12 V power input Resistance between Pin 2 and Pin 3: approx.18 kOhm High level: 3.5-5.5 V Low level: 0.6-1.2 V

40-478

Characteristics/Notes

Position

Wiring loom

40-571 40-583

Fig. 3735

Fig. 3736

selector

Fig. 3737

40-531 40-576

40-499 40-576 40-531 40-576 40-588 40-576 40-571

40-583

Wiring diagrams Table 637 Sys- P/N tem

K030 K031

L006

Description

Characteristics/Notes

Position

Wiring loom

40-576

Front PTO speed sensor PTO speed sensor Pin 1 = ground Pin 2 = analogue signal: - (USA Export) 0 Volt with sensor covered by metal 12 Volt with sensor exposed Pin 3 = 12 V power input Rear PTO control solenoid valve

L009

PTO 1,000 E engagement control solenoid valve

L010

PTO 1,000N engagement control solenoid valve

L011

PTO 540E engagement control solenoid valve

L014

Front PTO control solenoid valve

40-499

40-531

Fig. 3738

Fig. 3739

Fig. 3740

Fig. 3741

40-531

40-531

40-531

40-588

40-479

Wiring diagrams Sys- P/N tem

Description

M003

HLHP unit - USA version

Characteristics/Notes

Position

Wiring loom

40-571

Transmission control unit

Fig. 3742

Fig. 3743

40-480

40-571

Wiring diagrams 40.3.49 - S040 - Braking (U.S.A.) E003

SMART SW

GND COM SMART SW/LED

EPB LED

HAND BRAKE LAMP

GND

+15 CLUSTER

GND

+30

+30 WOOD

4

3

2

1

12

5

3

4

2

1

B D6

A C1

B B7

A B2

A C8

EPB LEVER SIGNAL

13

GND COM EPB LEVER

14

12

11

6

5

P 1

1

2

D009

15

GND

18

GND

+30 ARMREST

17

+30 ARMREST

+5V HLHP

16

+15 CLUSTER

EPB SECONDARY LEVER

P

1

K007 0

K006

SENSOR GND HLHP

H001

C002

3A

+30

C004

C002

5A

B016

B017

B C1

D033

D033

D009

D009

D009 B C3

D032

30A

C003

20A

Bm003

+30

+15

+15

C003a

Ba002

C003a

A B5

3A

Bb004

15A

+30

Bf005

B C2

A

B

A

B C4

B4

C1

A8

A5

C6

B1

B3

A4

42

A1

B6

C8

B8

C7

+5V EPB LEVER

SMART SW

GND COM SMART SW

SPB LED

30 (MAIN BATTERY-30A)

HAND BRAKE LAMP

-31 (BACKUP BATTERY)

+30 (BACKUP BATTERY 30A)

BRAKES PRESSURE SENSOR

GND

PRESS. BRAKE SW

84

EPB LEVER SIGNAL

GND

72

GND COM EPB LEVER

GND

53

GND -31

+30

40

+15 EPB

+30

31

LIMP HOME EPB

16

LIMP HOME EPB

6

+5V HLHP

4

SENSOR GND HLHP

2

SENSOR GND HLHP

5

EPB SECONDARY LEVER

3

+30

T004 1

M003

N004

GND

+30

BATTERY AUXILIARY

D0068710

Fig. 3744 - Brakes (U.S.A.) - System (1/2) l l l l l l l l l l l l

D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D032 (M) - Wiring connector (Wiring loom 0.021.0396.4) D032 (F) - Wiring connector (Wiring loom 0.018.9992.4/10) D033 (M) - Wiring connector (Wiring loom 0.021.0396.4) D033 (F) - Wiring connector (Wiring loom 0.018.9992.4/10) E003 - Work display H001 - Armrest K006 - Brake circuit alarm pressure switch (15 Bar) K007 - E.P.B. pressure sensor M003 - HLHP unit - USA version N004 - E.P.B. device

40-481

Wiring diagrams I004

I003

K022

Jh002

V

0

1

3

0

0

1

4

B

1

p

C

A

87a

87

86 85

30

0

1

1

D013

2

GND

1

2

SIG.

3

SUPPLY

4

15A

Bb013

D008 6

10

13

14

7

9

8

+BRAKE SWITCH

GND

+50 ECU

BRAKE BODY +5V

BRAKE SENSOR

GNDCOM BRAKES BODY

M001b

M001c

Fig. 3745 - Brakes (U.S.A.) - System (1/2) l l l l l l l l l l l l l l l l

D008 (M) - Wiring connector (Wiring loom 0.020.8658.4) D008 (F) - Wiring connector (Wiring loom 0.020.8664.4) D009 (M) - Wiring connector (Wiring loom 0.020.8658.4) D009 (F) - Wiring connector (Wiring loom 0.021.0396.4) D013 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D013 (F) - Wiring connector (Wiring loom 0.020.8658.4) D034 (M) - Wiring connector (Wiring loom 0.017.8426.4) D034 (F) - Wiring connector (Wiring loom 0.021.0396.4) I003 - RH brake pedal switch I004 - LH brake pedal switch Jh002 - Brake lights relay (R3/2) K022 - Brake circuit pressure sensor M001a - Transmission control unit M001b - Transmission control unit M001c - Transmission control unit P006 - Trailer socket

40-482

D009

C002 D034

C003a

13

+15 TRANSMISSION

A B1

BRAKE SWITCH RH

A C3

BRAKE SWITCH LEFT

A C1

14

M001a

A A6

+30 5A

Bf003

5A

Bb015

+15

+15

C003a

To ISO 11783

3

3

6

1

4

P006

D0078160

Wiring diagrams Table 638 Sys- P/N tem

B016 B017

Description

C002

Fuse (30A) Fuse (30A) 3A Fuse - Work Display Fuse (F3/2, +30) 3A Fuse - Cluster (F1-A/4, +15) 15A Fuse - Brake lights (F1-A/13, +15) 5A Fuse - Transmission (F1-A/15, +15) 5A Fuse - Transmission control unit (F1-B/3, +30) 15A Fuse - Armrest (F1-B/5, +30) 20A Fuse - HLHP control unit (F2/3-6, +30) Engine ground

C003

Cab ground

Cab ground

C004

Negative terminal of the auxiliary battery

Characteristics/Notes

Position

Wiring loom

40-518 40-518 40-571 40-571 40-571 40-571 40-571 40-571 40-571 40-583

Fig. 3746

Fig. 3747

Fig. 3748

40-571

40-571

40-583

40-483

Wiring diagrams Sys- P/N tem

Description

D008

Wiring connector

D009

Wiring connector

D013

Wiring connector

D013

Wiring connector

D032

Wiring connector

D033

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-571 40-576

Fig. 3749

Fig. 3750

Fig. 3751

Fig. 3752

Fig. 3753

Fig. 3754

40-484

40-571 40-583

40-571

40-537

40-518 40-583

40-518 40-583

Wiring diagrams Sys- P/N tem

Description

Characteristics/Notes

D034

Wiring connector

E003

Work Display

H001

Armrest

I003

RH brake pedal Between Pin 1 and Pin 2: Normally closed (NC) contact switch Between Pin 3 and Pin 4: Normally open contact (NO)

Position

Wiring loom

40-509 40-583

Fig. 3755

Fig. 3756

Fig. 3757

40-571

40-571

40-571

40-485

Wiring diagrams Table 639 Sys- P/N tem

I004

K006 K007

K022

Description

Position

Wiring loom

40-571

LH brake switch

pedal Between Pin 1 and Pin 2: Normally closed (NC) contact Between Pin 3 and Pin 4: Normally open contact (NO) Brake lights relay (R3/2) Brake circuit alarm Normally open contact (NO) Switching pressure: 15 bar EPB pressure sen- Normally closed (NC) contact Resistance between pin 1 and pin sor 2: closed contact: 2200 ohms open contact: 3200 ohms Brakes circuit pres- Pin 1 = 5.0Vdc power Pin 2 = ground sure sensor Pin 3 = analogue signal Output 0.5Vdc (0 bar) Output 4.5Vdc (40 Bar) Transmission control unit Transmission control unit Transmission control unit

M003

HLHP unit - USA version

N004 P006 T004

E.P.B. device Trailer socket Positive terminal of the auxiliary battery

40-486

Characteristics/Notes

40-571 40-583 40-583

40-576

40-571 40-571 40-571

Fig. 3761

Fig. 3762

40-571

40-583 40-509 40-583

Wiring diagrams

To Direction indicators

To Work lights

M003 Monitor (HLHP2)

To Brakes

To Lights

To Lights

To work lights USA

To Accessories

To Direction indicators USA

40.3.50 - S041 - ISO 11783 (U.S.A.)

D013

77

11

12

1

10

2

3

4

5

6

13

8

9

12

36

34

74

D062

7

To fig 2/2

10

30

86

85

3

16

15

7

75

13

12

41

8

89

88

42

23

22

35

37

Trailer wl USA

24

Rear work light

6

Rear work light

4

Direction light LH

1

2

Direction light RH

10

Stop light

9

Full beam

8

Half beam

7

Supply +12V (+15)

0

6

Position light

4

Trailer WL USA

1

5

Direction light LH

0

3

CUT OFF EV

1

Supply +12V (+15) SASA PVED

2

87

GND

87

Supply +12V (+15) feedback

86

GND

85

O016

D014

30

87a

GND

O017

87a

M011 C003

3A

D0078220

+15

Bb010

I030

Fig. 3763 - ISO 11783 (U.S.A.) - System (1/2) l l l l l l l l l l l

D013 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D013 (F) - Wiring connector (Wiring loom 0.020.8658.4) D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D062 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D062 (F) - Wiring connector (Wiring loom 0.019.3659.4/10) I030 - “Performance Steering” system activation switch M003 - HLHP unit - USA version M011 - ISO 11783 control unit O016 - Diode board O017 - Diode board 40-487

Wiring diagrams

2

1

4

2

5

3

13

1

8

2

4

3

D014

4

D060

1

D086a D086

O014

10

7

9

13

11

12

To fig. 1/2

15A

R004 2

D014

Bf008

+30

+15

D044

8

3A

14

15

Bb009

1

B

D

C

H

J

H007

TBC RTN-

4

1

3

6

8

9

7

6

8

9

A4

A7

A8

D8

D1

A1

5

B

85

86 87

87a

30

85

86

87

87a

D0078210

J016

J015

Fig. 3764 - ISO 11783 (U.S.A.) - System (2/2) l l l l l l l l l l

D014 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D014 (F) - Wiring connector (Wiring loom 0.020.8658.4) D044 (M) - Wiring connector (Wiring loom 0.015.5429.4/20) D044 (F) - Wiring connector (Wiring loom 0.020.8664.4) D060 (M) - Wiring connector (Wiring loom 0.019.9827.4/10) D060 (M) - Wiring connector (Wiring loom 0.019.9828.4/10) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D060 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D064 (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D064 (F) - Wiring connector (Wiring loom 0.018.9843.4/20)

40-488

16

15

D

D067

A

30

D069a

Supply +12V (+30)

Relay 50A command

Supply +12V (+30)

4

50A

B018

30A

C002

B019

Front relay command

Supply +12V (+30)

M011

A5

C002

84

C003

TBC PWR

3

74

D069

+15

1

5

D014

+30

2

3

D064

-31 BATT

2

P024

-31 KEY

1

P025

1

Supply +12V antenna

P021 81

+30

1

250A

2

B001

-31 BATT

4

D066

3

-31 KEY

1

To Can Bus ISO 11783

+15

TBC RTN-

TBC PWR

3

P022

5

2

1

A

6

P023

1

R003

M010

Wiring diagrams l l l l l l l l l l l l l l l l l l l l l

D066 (M) - Wiring connector (Wiring loom 0.018.9843.4/20) D066 (F) - Wiring connector (Wiring loom 0.017.8887.4/10) D067 (M) - Wiring connector (Wiring loom 0.017.8887.4/10) D067 (F) - Wiring connector (Wiring loom 0.018.9843.4/20) D069 (F) - Wiring connector (Wiring loom 0.019.2617.4/70) D069a (M) - Wiring connector (Wiring loom 0.019.2617.4/70) D086 (M) - Configuration connector (Wiring loom 0.019.2617.4/70) D086a (F) - Configuration connector (Wiring loom 0.019.2617.4/70) H007 - Monitor controls J015 - ISOBUS relay (50A) J016 - ISOBUS relay (30A) M010 - Microphone O014 - Diode connector O014a - Diode board P021 - ISO 11783 socket in cab P022 - Front ISOBUS 11783 socket P023 - Front ISOBUS 11783 socket P024 - Rear ISOBUS 11783 socket P025 - Rear ISOBUS 11783 socket R003 - RS 232 connector R004 - ISO11783 diagnostic socket

Table 640 Sys- P/N tem

Description

B001

Fuse (250A)

B018

Fuse (50A)

B019

Fuse (30A) 3A Fuse - iMonitor + MMI (F1-A/9, +15) 3A Fuse - ISOBUS 11783 (F1-A/10, +15) 15A Fuse - iMonitor (F1-B/8, +30)

Characteristics/Notes

Position

Wiring loom

40-514

Fig. 3765

Fig. 3766

40-512

40-512 40-571 40-571 40-571

40-489

Wiring diagrams Sys- P/N tem

Description

C002

Engine ground

C003

Cab ground

D013

Wiring connector

D013

Wiring connector

D014

Wiring connector

D014

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-510 40-512

Fig. 3767

Fig. 3768

Fig. 3769

Fig. 3770

Fig. 3771

Fig. 3772

40-490

40-571

40-571

40-537

40-571

40-537

Wiring diagrams Sys- P/N tem

Description

D044

Wiring connector

D060

Wiring connector

D062

Wiring connector

D062

Wiring connector

D064

Wiring connector

D064

Wiring connector

Characteristics/Notes

Position

Wiring loom

40-500 40-576 40-537 40-561 40-563 40-537

Fig. 3773

Fig. 3774

Fig. 3775

Fig. 3776

40-542

40-537

40-512

40-537

Fig. 3777

40-491

Wiring diagrams Sys- P/N tem

Description

D066

Wiring connector

D067

Wiring connector

D069

Wiring connector Wiring connector Configuration connector Configuration connector

D086

Characteristics/Notes

Position

Wiring loom

40-510 40-512

Fig. 3778

Fig. 3779

40-537 40-537 40-537 40-537

Fig. 3780

40-492

40-510 40-512

Wiring diagrams Table 641 Sys- P/N tem

Description

Characteristics/Notes

H007

Monitor controls

I030

“Performance Steering” system activation switch

Position

Wiring loom

40-537

Fig. 3781

40-537

0 1

Pos

Pin

1

2

3

4

5

6

7

4

5

6

9

8

1

2

3

10

7

8

9

10

1 2 2.7659.489.0

J015

ISOBUS (50A)

J016

ISOBUS relay (30A) HLHP unit - USA version

M003

M010

Microphone

relay

Fig. 3783

Fig. 3782

40-512

Fig. 3784

40-512 40-571

Fig. 3785

40-537

Fig. 3786

40-493

Wiring diagrams Sys- P/N tem

Description

M011

ISO 11783 control unit

O014

Diode connector

Diode board

O016 O017 P021

Diode board Diode board ISO 11783 socket in cab

P022

Front ISOBUS 11783 socket Front ISOBUS 11783 socket Rear ISOBUS 11783 socket

P023 P024

Characteristics/Notes

Position

Wiring loom

40-537

Fig. 3787

Fig. 3788

Fig. 3788

Fig. 3789

40-537

40-537 40-537 40-537

40-510 40-510 40-512

Fig. 3790

40-494

40-537

Wiring diagrams Sys- P/N tem

Description

P025

Rear ISOBUS 11783 socket

R003

RS 232 connector

R004

ISO11783 diagnostic socket

Characteristics/Notes

Position

Wiring loom

40-512

Fig. 3791

Fig. 3792

40-537

40-537

Fig. 3793

40-495

Wiring diagrams 40.4 - Wiring harnesses

40.4.1 - 0.012.2018.4/20 - License plate light

D052

F026

D0067800

Fig. 3794 - License plate light (1/2) Table 642 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

DESCRIPTION

D052 F026

Wiring connector License plate light

M1

1

TABELLA COLORI / COLOURS TABLE

H1

2

D052

F026

M

Marrone/Br own

C

Arancio/Orang e

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0067810

Fig. 3795 - License plate light (2/2)

40-496

Wiring diagrams 40.4.2 - 0.014.0007.4/20 - Lights selector switch

D001

H003 H003a

D0067580

Fig. 3796 - Lights selector switch (1/2) Table 643 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D001 H003 H003a

DESCRIPTION

Wiring connector Shuttle control lever Shuttle control lever

40-497

Wiring diagrams

LOW BEAM HIGH BEAM CONTROL

DIRECTION LIGHT CONTROL

FRONT WASHER PUMP CONTROL

H003

0FF 0N 0N 0FF

1

FRONT WIPER CONTROL

2

HORN CONTROL

FL/AL LH 0

H003a 1 2 3 4

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

6

RV0.75

C0.75

NGL0.75

BV0.75

V0.75

NG0.75

MB0.75

G0.75

NR0.75

Z0.75

N0.75

B0.75

G0.75

BN1

R1

NB1

NV1

NVB1

5

22

D001

TABELLA COLORI / COLOURS TABLE M

Marrone/Br own

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0067590

Fig. 3797 - Lights selector switch (2/2)

40.4.3 - 0.014.5144.4/10 - Battery negative C001

C002

D0049921

Fig. 3798 - Battery negative Table 644 CODE STAMPED ON CONNECTOR

40-498

INTERCONNECTION CODE

C001 C002

DESCRIPTION

Battery negative terminal Engine ground

Wiring diagrams 40.4.4 - 0.015.3974.4/10 - Front axle suspension L002

1

2

DW

L003

2 1

1

7 6 5 4 3 12 11 14 10 13 9 8

2

UP

L004 LS

1

2

3

1

2

D037

K019 D0049953

Fig. 3799 - Front axle suspension (1/2) Table 645 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

DESCRIPTION

D037 K019 L002 L003 L004

DW UP LS

Wiring connector Front axle suspension position sensor Front axle ‘Down’ control solenoid Front axle “Up” control solenoid Front axle suspension Load Sensing control coil

D037 1

3

2

6

4

5

M1

7

X1

X1

1

2

L004

L003

1

2

L002

1

VB1

C1

V1

M1

2

CB1

M1 1

CN1

GL1

M1

TABELLA COLORI / COLOURS TABLE

2

K019

3

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

D0049962

Fig. 3800 - Front axle suspension (2/2)

40-499

Wiring diagrams

3 2

N1

N1

2

BN1

BN1

1

AMP

SL1

3

D042

SL1

1

40.4.5 - 0.015.4257.4/10 - PTO sensor (USA)

AMP

K031

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

D0067730

Fig. 3801 - PTO sensor (USA) Table 646 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

DESCRIPTION

D042 K031

Wiring connector PTO speed sensor - (USA Export)

40.4.6 - 0.015.5429.4/20 - Front lift control

D044

I013

6

DW

5

U

P

1

2

3

3

2

4

1

DW

3

2

1

I014 1

UP

54

A

54 L R 58 R

P015

D0067740

Fig. 3802 - Front lift control (1/2) 40-500

Wiring diagrams Table 647 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D044 I013 I014 P015

DW UP

DESCRIPTION

Wiring connector Front lift DOWN control pushbutton Front lift UP control pushbutton Front implement power outlet socket

M1 1

I013

2

3

1

I014

M1

SG0.5 S0.5

2

G1

3

A1 AN1

54A

M11.5 X1

54

2 1 3 4

D044

5 6

58L

P015

TABELLA COLORI / COLOURS TABLE

58R L R 31

M1

M

Marrone/Br own

C

Arancio/Orang e

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0067750

Fig. 3803 - Front lift control (2/2)

40.4.7 - 0.016.0642.4/20 - Rear LH lower work light on cab - Xenon version

D051

F040

D0067820

Fig. 3804 - Rear LH lower work light on cab - Xenon version (1/2) Table 648 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D051 F040

DESCRIPTION

Wiring connector RH lower rear work light

40-501

Wiring diagrams TABELLA COLORI / COLOURS TABLE 1

F040

2

M1

1

VG1

2

D051

M

Marrone/Br own

C

Arancio/Orang e

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0067830

Fig. 3805 - Rear LH lower work light on cab - Xenon version (2/2)

40.4.8 - 0.016.0642.4/20 - Rear RH lower work light on cab - Xenon version

D047

F039

D0067840

Fig. 3806 - Rear RH lower work light on cab - Xenon version (1/2) Table 649 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D047 F039

DESCRIPTION

Wiring connector LH lower rear work light

TABELLA COLORI / COLOURS TABLE

F039

1

M1

2

VG1

1 2

D047

M

Marrone/Br own

C

Arancio/Orang e

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0067850

Fig. 3807 - Rear RH lower work light on cab - Xenon version (2/2)

40.4.9 - 0.016.0650.4/10 - LH front supplementary work light on arm - Xenon version

40-502

Wiring diagrams F037

D030

D0050086

Fig. 3808 - LH front supplementary work light on arm - Xenon version (1/2) Table 650 CODE STAMPED ON CONNECTOR

F037

INTERCONNECTION CODE

D030 F037

DESCRIPTION

Wiring connector Lh front work light (on arm)

B1

1 2

1 2

M1

3

D030

4

TABELLA COLORI / COLOURS TABLE

D0050346

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

Fig. 3809 - LH front supplementary work light on arm - Xenon version (2/2)

40.4.10 - 0.016.0650.4/10 - RH front supplementary work light on arm - Xenon version

F038

D028

D0050085

Fig. 3810 - RH front supplementary work light on arm - Xenon version (1/2) Table 651 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D028 F038

DESCRIPTION

Wiring connector Rh front work light (on arm)

40-503

Wiring diagrams F038

B1

1 2

1 2

M1

3

D028

4

TABELLA COLORI / COLOURS TABLE

D0050345

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

Fig. 3811 - RH front supplementary work light on arm - Xenon version (2/2)

40.4.11 - 0.017.0496.4/10 - Supplementary RH front work light on arm

F037

1 4 2 3

2

D030

1 D0057907

Fig. 3812 - Supplementary RH front work light on arm (1/2) Table 652 CODE STAMPED ON CONNECTOR

40-504

INTERCONNECTION CODE

D030 F037 F037

DESCRIPTION

Wiring connector Lh front work light (on arm) Lh front work light (on arm)

Wiring diagrams 1

D030

2 3

VR1 M1

1 2

4

F037

TABELLA COLORI / COLOURS TABLE

D0067700

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Viole

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

Fig. 3813 - Supplementary RH front work light on arm (1/2)

40.4.12 - 0.017.0496.4/10 - Supplementary RH front work light on arm

F038

1 4 2 3

2

D028

1 D0057906

Fig. 3814 - Supplementary RH front work light on arm (1/2) Table 653 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D028 F038 F038

DESCRIPTION

Wiring connector Rh front work light (on arm) Rh front work light (on arm)

40-505

Wiring diagrams 1

D028

2 3

VR1 M1

1 2

4

F038

TABELLA COLORI / COLOURS TABLE

D0058404

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

Fig. 3815 - Supplementary RH front work light on arm (2/2)

2

40.4.13 - 0.017.0497.4/10 - Rear RH lower work light on cab

D047

2

1

1

F027

D0067780

Fig. 3816 - Rear RH lower work light on cab (1/2) Table 654 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D047 F027

DESCRIPTION

Wiring connector RH lower rear work light

TABELLA COLORI / COLOURS TABLE

D047

1

M1

2

VR1

1 2

F027

M

Marrone/Br own

C

Arancio/Orang e

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0067790

Fig. 3817 - Rear RH lower work light on cab (2/2)

40-506

Wiring diagrams

2

40.4.14 - 0.017.0497.4/10 - Rear LH lower work light on cab

D051

2

1

1

F028

D0067760

Fig. 3818 - Rear LH lower work light on cab (1/2) Table 655 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D051 F028

DESCRIPTION

Wiring connector LH lower rear work light

TABELLA COLORI / COLOURS TABLE

D051

1

M1

2

VR1

1 2

F028

M

Marrone/Br own

C

Arancio/Orang e

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0067770

Fig. 3819 - Rear LH lower work light on cab (1/2)

40-507

Wiring diagrams 40.4.15 - 0.017.8425.4/10 - Rear trailer socket

3

2

D034

4

7

1 6

P006

TRAILER EU

5

D0067630

Fig. 3820 - Rear trailer socket (1/2) Table 656 CODE STAMPED ON CONNECTOR

TRAILER EU

40-508

INTERCONNECTION CODE

D034 P006

DESCRIPTION

Wiring connector Trailer socket

Wiring diagrams

P006

2 6 7 5 4 1 3

Z-1.5 (W.L.)

2 6 7 5 4 1 3

RN-1.5 (STOP) GN-1 (+58 RH) G-1 (+58LT) A-1.5 (DIR RH) AN-1.5 (DIR LT) N1.5 (-31)

W.L. EU/USA EU EU/USA EU/USA EU/USA EU/USA

D034

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

D0078190

Fig. 3821 - Rear trailer socket (2/2)

40.4.16 - 0.017.8426.4 - Rear trailer socket (U.S.A.)

40-509

Wiring diagrams

3

D034

4

7

1 6

TRAILER USA

2

P006

5

D0067900

Fig. 3822 - Rear trailer socket (U.S.A.) (1/2) Table 657 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D034 P006

TRAILER EU

P006

7 4 6 5 3 1 2

DESCRIPTION

Wiring connector Trailer socket

L -2.5 (+15 USA) RN-1.5 (STOP) G-1 (+58LT) A-1.5 (DIR RH) AN-1.5 (DIR LT) N1.5 (-31) BN -1.5 (W.L. USA)

8 6 5 4 1 3 2

USA EU/USA EU/USA EU/USA EU/USA EU/USA USA

D034

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

D0067910

Fig. 3823 - Rear trailer socket (U.S.A.) (2/2)

40-510

Wiring diagrams 40.4.17 - 0.017.8887.4/10 - ISO 11783 - Front line C002 P022 P023

1

D067

2

D066 D0067860

Fig. 3824 - ISO 11783 - Front line (1/2) Table 658 CODE STAMPED ON CONNECTOR

Engine ground Wiring connector Wiring connector Front ISOBUS 11783 socket Front ISOBUS 11783 socket

2

C002 D066 D067 P022 P023

DESCRIPTION

1

D066

INTERCONNECTION CODE

V4

4

V8

C002

D067

8M

ECU -31(TBC RTN) FRONT

D

+15(TBC PWR) FRONT

B

CAN H ISOBUS FRONT

E

CAN L ISOBUS FRONT

F

M1 N1 A1 B1

+15

3

M4

2

-31 KEY

1

-31 BATT

3

P022

TBC RTN-

1

TBC PWR

2

CAN H B

4

CAN L B

P023

TABELLA COLORI / COLOURS TABLE M

Marrone/Br own

C

Arancio/Orang e

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0067870

Fig. 3825 - ISO 11783 - Front line (2/2)

40-511

Wiring diagrams 40.4.18 - 0.018.8803.4 - Battery positive terminal

T001

J006a

N007 J006b

D0059371

Fig. 3826 - Battery positive Table 659 CODE STAMPED ON CONNECTOR

40-512

INTERCONNECTION CODE

J006a J006b N007 T001

DESCRIPTION

Battery disconnect contactor Battery disconnect contactor Starter motor “+30” Battery positive terminal

Wiring diagrams 40.4.19 - 0.018.9843.4/20 - ISO 11783 - Rear line

D064

4

5

R2 87

R1 87

30A

R1 30

R2 30

R1 85

J016

C002

D095

R2 86

R1 86

R2 85

50A

J015 D067

P025 P024 2

50A

B018 B019

30A

1

D066

A001

D0077780

Fig. 3827 - ISO 11783 - Rear line (1/2) Table 660 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

A001 B018 B019 C002 D064 D066 D067 D095 J015 J016 P024 P025

DESCRIPTION

Alternator “B+” Fuse (50A) Fuse (30A) Engine ground Wiring connector Wiring connector Wiring connector Wiring connector ISOBUS relay (50A) ISOBUS relay (30A) Rear ISOBUS 11783 socket Rear ISOBUS 11783 socket

40-513

V8 V4

1 2 3 4 5 6 7 8 9 10 11 12 13 14

X+EP

BV1

X+EP X+EP

R2 87

D064

M4 X-31 X-31

X60

A001

1 2

MN1 M1

N1 A1 B1 M1 V1 M1 N1 A1 B1 M1 V1 C

E F

B

A D

V8 M8 M4 V4

CAN H B CAN L B

ECU GND ECU PWR TBC RTNTBC PWR

B019

B2 B3 B4 B5 B6 B7 B8 C1 C2 C3 C4 C5 C6 C7

1 2 3 4 5 6 7 8 9

14

B018

4TH SERVICE 0.75 3TH SERVICE 0.75 FUNCTION 2 0.75 FUNCTION 1 0.75 B2 SHOVEL DOWN - 0.75 B2 SHOVEL DOWN + 0.75 A2 SHOVEL UP - 0.75 A2 SHOVEL UP + 0.75 B1 DOWN - 0.75 B1 DOWN + 0.75 COMFORT DRIVE 0.75 HYDROLOCK 0.75 A1 UP - 0.75 A1 UP + 0.75

RELAY COIL 50A RELAY COIL 30A

ECU -31(TBC RTN) BACK +15(TBC PWR) BACK

10 11 12

3 1 2 4

4

2

1

3

+30 -31 BATT -31 KEY +15

CAN H B CAN L B

TBC RTNTBC PWR

Fig. 3828 - ISO 11783 - Rear line (2/2)

13

50A

CAN H ISOBUS BACK CAN L ISOBUS BACK

CAN H ISOBUS FRONT CAN L ISOBUS FRONT

R2 30

D095 J015 J016

C002 ECU -31(ECU -31) +15(ECU PWR) ECU -31(TBC RTN) FRONT +15(TBC PWR) FRONT

40-514

R2 86 R1 86

D067

D066 R2 85 R1 85

30A

R1 30 R1 87

Wiring diagrams

P024 P025

V8 V4 M1 MN1 M1 BV1

TABELLA COLORI / COLOURS TABLE M

Marrone/Br own

C

Arancio/Orange V

Verde/Green

A

Azzurro/Blue Z

Viola/Violet

B

Bianco/White N

Nero/Blac k

L

Blu/Dark Blue S

Rosa/Pink

G

Giallo/Y ello w R

Rosso/Red

H

Grigio/Gra y

D0077790

Wiring diagrams 40.4.20 - 0.018.9845.4/10 - Fuses and relays

J002 J004

30

86

87

85

30

86

87

85

B004 1

5

15A

10A

B005 B006

86

85

30

86

J003

F1 F2

RN1

15A

4

30

87

10A

8

87

85

J005

F3

3A

B008

F4

B007

F7

40A

D031

B021

B002

C8

B003

R 35

B001

250A R 50

F8

30A

F6 200A

F5

T001b

12 VIE PF

A001

D002 D0077700

Fig. 3829 - Fuses and relays (1/2) Table 661 CODE STAMPED ON CONNECTOR

F5 F6 F7 F1 F2 F3 F4 F3

INTERCONNECTION CODE

A001 B001 B002 B003 B004 B005 B006 B007 B008

DESCRIPTION

Alternator “B+” Fuse (250A) Fuse (200A) Fuse (40A) Fuse (15A) Not used Fuse (15A) Not used Fuse (3A) 40-515

Wiring diagrams Fuse (30A) Wiring connector Wiring connector Left hand work light relay (on engine cowl) Right hand work light relay (on engine cowl) Not used Not used Battery positive terminal

8 GV 2.5(W.L.RIGHT UP) 9 GV 2.5(W.L.RIGHT MED) 10 GV 2.5(W.L.RIGHT DW) +30 WEBASTO RN2.5 +30 WABASTO RN2.5

10A

F3 F4

1.5 1.5 1.5 1.5

30

86

87

85

30

86

87

85

B008

R 35

C8

B003

86

87

85

3A

30

86

87

85

F3

30A

F8

B021

R 50

B002

40A

F7

B001

200A

F6

250A

F5

30

M0.5

8 G 2.5(W.L.LEFT DW)

15A

B007

F2

J005

6 RG 1(RIGHT CORNER LIGHT RELAY)

10A

RM1

5 RN 1(+30FUSE INSTRUMENT)

B006

M0.5

4 M 1(-31)

1.5 1.5

J004

3 RG 1(LEFT CORNER LIGHT RELAY)

1 2 3 4 5 6 7 8 9 10 11 12

RM1

2 G 2.5(W.L.LEFT MED)

F1

M0.5

1 G 2.5(W.L. LEFT UP)

15A

B005

M0.5

B004

D031

J003

B021 D002 D031 J002 J003 J004 J005 T001b

RM1

F8

DESCRIPTION

J002

INTERCONNECTION CODE

RM1

CODE STAMPED ON CONNECTOR

W 2 4.5 W 2 4.5

A001 TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gray

T001b

D002

Fig. 3830 - Fuses and relays (2/2)

40-516

D0077710

Wiring diagrams

5 3

D2

3 4 3

2

D3

D7

D6

2 1

4

4

1

2 1

3 4 3

2

1

2 1

D4

D6

D1

P012

1

4

3 4 3

2

1

2 1

D5

D1

4 3

2

D2

3

P007

2 1

4

P008

1

D3

4 3

2

P009

2 1

3

D4

4

P010

1

4

3 4 3

2

1

2 1

D5

4 3

2

P011

3

7 8

1

4

12 11 10 9

2

4

D035

6

40.4.21 - 0.018.9990.4/10 - Distributors

P013 D7

D0066920

Fig. 3831 - Distributors (1/2) Table 662 CODE STAMPED ON CONNECTOR

D1 D2 D3 D4 D5 D6 D7

INTERCONNECTION CODE

D035 P007 P008 P009 P010 P011 P012 P013

DESCRIPTION

Wiring connector Utility distributor 1 Utility distributor 2 Utility distributor 3 Utility distributor 4 Utility distributor 5 Utility distributor 6 Utility distributor 7

40-517

Wiring diagrams

12 11 10 7

6

8

5

9

4 3

6

2

5 4

12 11 10

D035

7

1

9 8

3 2 1

B0.75 CAN H OUT L0.75 CAN L OUT M1 -31 V-B0.75 D7-1 +15 V-B0.75 D6-1 +15 V-B0.75 D5-1 +15 V-B0.75 D4-1 +15 V-B0.75 D3-1 +15 V-B0.75 D2-1 +15 V-B0.75 D1-1 +15 L0.75 CAN L IN B0.75 CAN H IN

1

4

2

3

3

2 1

V-B0.75 D7-1 +15 L0.75 CAN L B0.75 CAN H M1 -31

4

2

1

2

1

4 3

4

3

2 1

3

4

2

1

2

1

4 3

P013

V-B0.75 D6-1 +15 L0.75 CAN L B0.75 CAN H M1 -31

1

2 1

4

3

P012

V-B0.75 D2-1 +15 L0.75 CAN L B0.75 CAN H M1 -31

4

2

4

1

4 3

1

2

3

3

2 1

V-B0.75 D1-1 +15 L0.75 CAN L B0.75 CAN H M1 -31

4

2

4 3

P008

3

P007

SA-H7 SA-L7

SA-L6

SA-L3

SA-L2

SA-L1

SA-H3

SA-H6

SA-H2

SA-H1

SA-1

SA-L4

SA-L5 SA-H5

V-B0.75 D4-1 +15 L0.75 CAN L B0.75 CAN H M1 -31 4

2

1

1

2

4

3

4 3

2

1

4

3

V-B0.75 D3-1 +15 L0.75 CAN L B0.75 CAN H M1 -31

2 1

3

3 4 3

2 1

1

4

4

1

2

3

4 3

2

P009

3

2

1

2 1

P011

TABELLA COLORI / COLOURS TABLE 4

V-B0.75 D5-1 +15 L0.75 CAN L B0.75 CAN H M1 -31

SA-H4

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

P010

D0066910

Fig. 3832

40.4.22 - 0.018.9992.4/10 - AdBlue N009 D.M.02 1 2

4 3 2 1

.02

D.M

K034 NOx B5

2 4

3 1

I025

NOx B5

ON/OFF SW ON/OFF SW

EV .22 AT

UREA T. 16

HE

3

3

2

2

1

1

K035 UREA T.16

1 3

L013

TEMP. S.04

EV HEAT

K036

NOx A6

4 3 2 1

NOx A6

2 1

K033

TEMP. S.04

N008

SUPP. M.01

9

10

11

12

SUPP. M.01

6

7

5

8

4

1

2

3

2 3

IN MA TT BA

BACH -UP BATT.

4

O009

4

1

3

2

1

1 2 3 4

8 7 6 5

J006

B

A

D012

A

A

B

B 3A

2A

3B

2B

3C

2C

1C

2D

1D

1B

3D

5A

4A

5B

4B

5C

4C 4D

5D

6A 6B 6C 6D

7A 7B 7C 7D

MAIN BATT

1A

D032

8A 8B 8C

8D

-31

B

A

D033

2

C002 -31

+30

1 1

2

1

1 2 2

1

1

BACKFLOW

2

O007

2

O008 OUTLET

INLET

BACKFLOW

OU

TLE T

BACK-UP BATT.

O006 INLET

N007 +30

Fig. 3833 - AdBlue (1/3) 40-518

D0066790

30A

30A

B012

20A

B009

MU4

MU1

Wiring diagrams

J008

J009

Supply module

Suction line

Trottle line

J011

J012

12 11 10

18 85

6

14 87a

30

87

9 8 7

13 86

86 87a

30

87

85

R6

87a

30

87

85

R5

R4

86 87

30

87a

85 R3

3

16

85

87a

5

15 30

4

17 MTA

87

2

86

86

86

1

keng

21

K30 K31

MK6

Urea poump(M10)/ Heaters supply relay

MTA

B017

K29

K27 K28

Pressure line

FEPBBK

FEPB

J007

MK3 MF3

FSMH

10A 15A

J010 MK4

MU6

B014

FY31

87a

MK1 MU3

B011

MF1

FNOX

10A 15A

B016

B013

FY25

KENG

B010

B015

FYWG 30A

30

87

85 R2

R1

D0068470

Fig. 3834 - AdBlue (2/3) - Fusebox Table 663 CODE STAMPED ON CONNECTOR

MU1 MU2 MU3 MU4 MU5 MU6 MF1 MF2 MF3 -31

MAIN BATT BACK-UP BATT. ON/OFF SW MK1 MK2 MK3

INTERCONNECTION CODE

B009 B010 B011 B012 B013 B014 B015 B016 B017 C002 D012 D032 D033 I025 J006 J007 J008 J009

DESCRIPTION

Fuse (15A) Fuse (10A) Fuse (10A) Not used Fuse (15A) Fuse (30A) Fuse (20A) Fuse (30A) Fuse (30A) Engine ground Wiring connector Wiring connector Wiring connector Battery disconnect switch Battery disconnect contactor AD Blue pump control relay AdBlue suction line heater power supply relay AdBlue return line heater power supply relay

40-519

Wiring diagrams Table 664 INTERCONNECTION CODE

J010 J011 J012 K033 K034 K035 K036 L013 N007 N008 N009 O006 O007 O008 O009

AdBlue delivery line heater power supply relay AdBlue system power supply relay Nox sensor power supply relay Exhaust gas temperature sensor NOX sensor upline from catalytic converter AdBlue level sensor NOX sensor downline of catalytic converter AdBlue heating solenoid valve Starter motor “+30” AdBlue pump AdBlue dispenser AdBlue pick-up line with resistance AdBlue return pipeline with resistance AdBlue delivery pipeline with resistance CAN line termination connector B017

B016

B015

B013

B014

B010 B009

1 2

N007

K034 4

3

2

L013

1

3

K033 1

1

2

I025

K035

K036 4

3

2

1

3

2

1

2

3

1

4

2

3

2

3

1

3

4

1

2

2

1

CAN H CAN L GND +15 NOxa

B1 LEVEL B1 COM B1 TEMPERATURE

Z1 SW COM V1 OFF G1 ON A1 SAFETY LED

1

Temperature before SCR(B78) Temperature before SCR(B78)

1

Urea tank heating EV(Y31) Urea tank heating EV(Y31)

2

3

4

1

1

2

2

CAN H CAN L GND +15 NOXb

18

B4 EPBBK

Urea dosing EV (Y24) Urea dosing EV(Y24)

17

B4 EPBBK

30A 16

B4 EPB

B2.5 +30 B2.5 +30

20A

30A 14

15

13

B4 EPB

12

B2.5 +30

C1.5 +15 FNOX KENG

B2.5 +30 (KENG)

9

15A

8

11

B2.5 +30

10

B1.5 Supply module (K31)

B2.5 +30 (K31)

7

B1.5 FNOX KENG

10A

10A 5

15A

2

4

B1.5 FY25

1

B1.5 FY25 (KENG)

Urea tank heating EV(Y31)

SUPPLY MODULE (OUT)

30

30A

87

B1 Urea tank heating EV(Y31) IN

PINA1 PINB1

85

87a

B2.5 GND (K30)

30

86

B1 Relay coil com (K27) B1 Relay coil com (K30)

87

J010

B2.5 Pressure line (K30)

PINA1 PINB1

85

87a

B2.5 +30 (K31)

30

B2.5 +30 (KENG)

86

B2.5 +30 Urea tank heating EV(Y31) B1 Pressure line heater (K30)

85

87

UREA POUMP (M10) (K31) B1.5

PINA1 PINB1

87a

J011

B1.5 FY25 (KENG) B1.5 FNOX KENG B1 Urea pump(M10)/Heaters supply (K31)

86

B1 R4-85 GND (KENG)

30

B1 FNOX/W.gate (KENG)

PINA1 PINB1

87

B2.5 GND (K27)

85

B1 Relay coil com (K28) B1 Relay coil com (K27)

30

87a

86

SUPPLY MODULE (K27)

PINA1

87

B2.5 GND (K28)

PINB1

87a

B2.5 Suction line (K28)

85

B1 Relay coil com (K29) B1 Relay coil com (K28)

PINA1 PINB1

86

B1 Supply module heater (K27)

B1 Suction line heater (K28)

B2.5 GND (K29)

30

B2.5 Trottle line (K29)

B1 Relay coil com (K29)

B1 Trottle line heater (K29)

87

J012

1

85

87a

J007

3

86

J008

B011

N009 J009

4

MK4 MK5 MK6 TEMP.S. 04 Nox B5 UREA T. 16 NOx A6 EV HEAT.22 +30 SUPP. M. 01 D.M.02 INLET BACKFLOW OUTLET

DESCRIPTION

2

CODE STAMPED ON CONNECTOR

B1.5

SA-2

D8 D7

B1 +15

D6 D5 D4

SA-CANH1

SA-CANH2

D3

SA-CANL2

SA-CANL1

D2

B1.5 FY25 B1 FNOX/W.gate (KENG) UREA PUMP (M10) CAN L CAN H

D1 C8 C7 C6 C5

2D

3A

3B

3C

3D

4B

4C

4D

5A

5B

5C

5D

6A

6B

6C

6D

7A

7B

7C

7D

8C

8D

B8 B7 B6

8A

B5

8B

2C

4A

2A

2B

C1

1B

C002

C2

1C

1A

SA-1

C3

1D

C4

B1 Pressure line heater (K30) UREA PURGE EV(Y30) UREA PURGE EV(Y30) B1 Trottle line heater (K29) Urea dosing EV(Y24) Urea dosing EV (Y24) B1 Suction line heater (K28) B1 TEMPERATURE B1 LEVEL B1 Supply module heater (K27) Temperature before SCR(B78) B1 Urea pump(M10)/Heaters supply (K31) B1 Relay coil com (K30) B1 Urea tank heating EV(Y31) IN B1 COM UREA PRESS. AFTER PUMP (B63) UREA PRESS. AFTER PUMP (B63) Temperature before SCR(B78) UREA PUMP (M10)

D012

B4 B3 B2 B1 A8 A7 A6 A5 A4 A3 A2 A1

B2.5 GND (K29) GND B2.5 GND (K30) B1 GND (KENG) B2.5 GND (K27) B2.5 GND (K28) B1 -31 GND

B

A

B

B1 -31 G1 ON A1 SAFETY LED Z1 SW COM V1 OFF B1 +15 6

7

4

5

2

3

12

10

11

8

9

5

6

3

4

UREA PRESS. AFTER POUMP (B63) UREA PRESS. AFTER POUMP (B63) TEMPERATURE BEFORE SUPPLY MODULE (OUT) SUPPLY MODULE (K27) UREA POUMP (M10) UREA POUMP (M10) (K31) UREA POUMP (M10) UREA PURGE EV(Y30) UREA PURGE EV(Y30) 2

B2.5 Suction line (K28) B2.5 Suction line

B2.5 Trottle line (K29) B2.5 Trottle line

CAN L CAN H

B4 EPB B4 EPB

B4 EPBBK B4 EPBBK B

1

1

A

2

2

B

1

1

A

2

2

A

3

1

1

4

3

2

2

2

B2.5 Pressure line (K30) B2.5 Pressure line

SA-3

2

1

TABELLA COLORI / COLOURS TABLE

9

8

Marrone/Brown

A

Azzurro/Blue

B

Bianco/White

Nero/Black

L

Blu/Dark Blue

7

11

10

12 6

3

2

4

Arancio/Orange

Verde/Green Viola/Violet

N

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

1

2

1

2

4

1 B

5

C

V

S

2

O006

1 2 3 4

A

B

3

2

1

A

40-520

D033

O007

8 7 6 5

Fig. 3835 - AdBlue (3/3)

D032

O008

Z

1

M

O009

N008

J006

D0066800

Wiring diagrams 40.4.23 - 0.019.2378.4/40 - LH mudguard D052

LIGHT

2

1

D081 D081a

2

1

1

1

2

2

F021

PLATE

F042 A

D051

HT LIG

LIFT

2

1

PL AT

E

1

1

2

1

2

1 2

LIF T

1

D081b 1

LWL

1

F022

LWL

DIR

D023

DIR

2

F023

STOP

5 4 12 11

10 9

3 2 1

3 2 8 7 1 6

1

5 4

3 2 3

1 2 1

W O RK

STOP

2

1

PO S 3

D050

2 1

3

F024

2

2 1

1

D053

POS

WORK

3 2

DIS DO TRIB W N

3

B RI ST DI UP

1 2 1

2

3

1

PTO

2

1

1

3

2

1

DOWN

3

2

UP

2

1

3

3 1

3

2

3

2

3

2

1

1

I021 DISTRIB UP

I020 DISTRIB DOWN

3

2

1

1

I023 UP

2

PTO

3

I024

I022 DOWN

D0077880

Fig. 3836 - LH mudguard (1/2) Table 665 CODE STAMPED ON CONNECTOR

PLATE WORK LIFT LWL LIGHT DIR STOP POS DISTRIB DOWN DISTRIB UP DOWN UP PTO

INTERCONNECTION CODE

D023 D050 D051 D052 D053 D081 D081a D081b F021 F022 F023 F024 F042 F042 I020 I021 I022 I023 I024

DESCRIPTION

Wiring connector Not used Wiring connector Wiring connector Not used Configuration connector Configuration connector Not used LH rear cosmetic light Left hand rear turn indicator LH rear brake light Left hand rear sidelight Not used LH rear hazard warning light - USA version LH distributor DOWN button (on mudguard) LH distributor UP button (on mudguard) LH rear lift DOWN button (on mudguard) LH rear lift UP button (on mudguard) LH rear PTO button (on mudguard)

40-521

Wiring diagrams

2

F022

N-R 1 STOP LIGHT

5

G-N 1 POSITION LIGHT

4

A-N 1 DIRECTION

3

V-R 1.5 REAR WORK LIGHT

2

S-V 1 EXT.DISTR.SW DW

1

M 1.5 GND

2

1

2

1

-

-

M 1 GND

N-R 1 STOP LIGHT

M 1 GND

A-N 1 DIRECTION

V-B 0.75 REAR/LIFT W.L

M 0.75 GND

V-B 0.75 REAR/LIFT W.L

M 1.5 GND

V-R 1 LOW REAR WL

1

2

I023

3

V 0.75 UP

2

V-B 0.75 UP

1

I022

3 -

SA-2

V-B 0.75 DOWN

1

SA-3

I021

-

3

I020

M 0.75 GND

G-N 0.75 PLAT WIRING

V-R 1 LOW REAR WL

B 0.75 LIFT WL

M-V 0.75 SNV LIGHT

M 0.75 GND

V-B 0.75 REAR PTO

B 0.75 PTO

M 0.75 GND

1

2

1

2

3 3

2 1

2

1 1

TABELLA COLORI / COLOURS TABLE 3

2

1

2 1

1

1 1

1

2 1

2

A 1

2

D052

D081b

D081a

1

1

2

1

1

3

2

V-B 0.75 EXT.DISTR.SW DW

1

1

2

2

M 1.5 GND

S-V 1 EXT.DISTR.SW DW

3

B 1.5

1

1

1

SA-4

3

2

2

1

3

V-B 0.75 EXT.DISTR.SW UP

2

2

3

B-V 1 EXT.DISTR.SW UP -

D050

1

2

2

L 1 DW

3

3 2 1

6

1

1

5 4

V-B 1 COM LIFT/PTO SW

3

2

3 2 1 8 7 6

V 0.75 UP

7

1

2

3

5 4 12 11 10 9

8

2

1

L 1 DW

2

1

1

2

9

2

D051

3

B 0.75 PTO

1

D053

1

B-V 1 EXT.DISTR.SW UP

10

3

3

D081

1

2

11

1

2

3

D023

M-V 0.75 SNV LIGHT

M 1 GND

12

2

2

G-N 0.75 POSITION LIGHT

3

1

F021

1

B 1.5

3

M 1.5 GND

F023

1

B 0.75 LIFT WL

2

2

3

1

F024

F042

I024

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ellow

R

Rosso/Red

H

Grigio/Gray

D0077890

Fig. 3837 - LH mudguard (2/2)

40-522

Wiring diagrams

5 3

D2

3 4 3

2

D3

D7

D6

2 1

4

4

1

2 1

3 4 3

2

1

2 1

D4

D6

D1

P012

1

4

3 4 3

2

1

2 1

D5

D1

4 3

2

D2

3

P007

2 1

4

P008

1

D3

4 3

2

P009

2 1

3

D4

4

P010

1

4

3 4 3

2

1

2 1

D5

4 3

2

P011

3

7 8

1

4

12 11 10 9

2

4

D035

6

40.4.24 - 0.019.2378.4/40 - RH mudguard

P013 D7

D0066920

Fig. 3838 - RH mudguard (1/2) Table 666 CODE STAMPED ON CONNECTOR

PLATE WORK LIFT LWL LIGHT DIR STOP POS DISTRIB DOWN DISTRIB UP DOWN UP PTO

INTERCONNECTION CODE

D026 D046 D047 D048 D049 D080 D080a D080b F017 F018 F019 F020 F041 F041 I015 I016 I017 I018 I019

DESCRIPTION

Wiring connector Wiring connector Wiring connector Not used Wiring connector Configuration connector Configuration connector Not used RH rear cosmetic light Right hand rear turn indicator RH rear brake light Right hand rear sidelight Not used RH rear hazard warning light - USA version RH distributor DOWN button (on mudguard) RH distributor UP button (on mudguard) RH rear lift DOWN button (on mudguard) RH rear lift UP button (on mudguard) RH rear PTO button (on mudguard)

40-523

Wiring diagrams

12 11 10 7

6

8

5

9

4 3

6

2

5 4

12 11 10

D035

7

1

9 8

3 2 1

B0.75 CAN H OUT L0.75 CAN L OUT M1 -31 V-B0.75 D7-1 +15 V-B0.75 D6-1 +15 V-B0.75 D5-1 +15 V-B0.75 D4-1 +15 V-B0.75 D3-1 +15 V-B0.75 D2-1 +15 V-B0.75 D1-1 +15 L0.75 CAN L IN B0.75 CAN H IN

2

1

2

4

3

3

4

1

2

1

2

2 1

V-B0.75 D7-1 +15 L0.75 CAN L B0.75 CAN H M1 -31

1

4 3

4

3

3

4

P013

2 1

V-B0.75 D6-1 +15 L0.75 CAN L B0.75 CAN H M1 -31

1

1

2

P012 4 3

4

3

2 1

V-B0.75 D2-1 +15 L0.75 CAN L B0.75 CAN H M1 -31

4

2

4

1

4 3

1

2

3

3

2 1

V-B0.75 D1-1 +15 L0.75 CAN L B0.75 CAN H M1 -31

4

2

4 3

P008

3

P007

SA-H7 SA-L7

SA-L1

SA-L6

SA-L3

SA-L2

SA-H3 SA-H1

SA-H6

SA-H2

SA-1

SA-L4

SA-L5 SA-H5

4

2

V-B0.75 D4-1 +15 L0.75 CAN L B0.75 CAN H M1 -31

V-B0.75 D3-1 +15 L0.75 CAN L B0.75 CAN H M1 -31 2

1

1

2 1

4

4

4 3

2

4

3

3

3

3 4 3

1

1

2 1

4

2

3

4 3

1

2

1

2 1

40-524

2

Fig. 3839 - RH mudguard (2/2)

P009

3

P011

TABELLA COLORI / COLOURS TABLE 4

V-B0.75 D5-1 +15 L0.75 CAN L B0.75 CAN H M1 -31

SA-H4

P010

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

D0066910

Wiring diagrams 40.4.25 - 0.019.2379.4/20 - Front LH lower work lights on cab

D004

3 2

4

3

1

2

1

F005

D003 2

4 1

3

2 1

TS

IH

T.L

F006

3

W LO . W.L

2

4 1

F043 T. LIGHTS

3 4

2 1

D030 LOW W.L.

D0067540

Fig. 3840 - Front LH lower work lights on cab (1/2) Table 667 CODE STAMPED ON CONNECTOR

LOW W.L. T.LIGHTS

INTERCONNECTION CODE

D003 D004 D030 F005 F006 F043

DESCRIPTION

Wiring connector Wiring connector Wiring connector LH sidelight LH turn indicator Left hand repeater headlight

40-525

Wiring diagrams

M1 G1

4

3

1

2 1

F005

1

A1 M1

2

1

1

F006

M1.5

M1.5

2

4

3

H1.5 V1.5 M1.5 G1 2

2

1

1

M1.5

H1.5

B1.5

1

2

V1.5 G1

4

2

3

4

3

1

3

2

4

3

2

A1

SA-1

D003

3

1

B1.5 M1.5

M1

D004

3

2

4

TABELLA COLORI / COLOURS TABLE Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

3

N

Nero/Black

L

Blu/Dark Blue

4

2 1

3 4

2 1

D030

M

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

F043

D0067550

Fig. 3841 - Front LH lower work lights on cab (2/2)

40-526

Wiring diagrams 40.4.26 - 0.019.2379.4/20 - Front RH lower work lights on cab

D007

3 2

1 4 2 3

1

F003

D006 1 4 2 3

2 1

TS

IH

T.L

F004

3 1

2

W LO . W.L

4

F044 T. LIGHTS

3 4

2 1

D028 LOW W.L.

D0067560

Fig. 3842 - Front RH lower work lights on cab (1/2) Table 668 CODE STAMPED ON CONNECTOR

LOW W.L. T.LIGHTS

INTERCONNECTION CODE

D006 D007 D028 F003 F004 F044

DESCRIPTION

Wiring connector Wiring connector Wiring connector RH sidelight RH turn indicator Right hand repeater headlight

40-527

Wiring diagrams

M1 G1

4

3

1

2 1

F003

1

A1 M1

F004

2

1

1

M1.5

M1.5

2

4

3

H1.5 V1.5 M1.5 G1 2

2

1

1

M1.5

H1.5

B1.5

1

2

V1.5 G1

4

2

3

4

3

1

3

2

4

3

2

A1

SA-1

D006

3

1

B1.5 M1.5

M1

D007

3

2

4

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

3

N

Nero/Black

L

Blu/Dark Blue

4

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

2

3

1

4

F044

2 1

D028

D0067570

Fig. 3843 - Front RH lower work lights on cab (2/2)

40.4.27 - 0.019.2380.4/30 - Hazard warning lights switch (USA) I029

M012

HAZARD 02 USA

6

4

7

1 2 3 4 5 6 7 8

1

1 2 3 4 5 6 7 8

5

B

A

3

2

B

C

A

HAZARD 02 USA

C

9 8 7 6

5 4 3 2 1

C003

9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 10

D022

10 11 12

13 14 15 16 17

1 2 3 4 5

18 19 20

6 7 8 9

D068 D0077740

Fig. 3844 - Hazard warning lights switch (USA) (1/2)

40-528

Wiring diagrams Table 669 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

DESCRIPTION

C003 D022 D068 I029 M012

HAZARD 02 USA

Cab ground Wiring connector Wiring connector Hazard warning lights switch Turn indicator control unit (USA)

C8 C7 C6 C5 C4

6 5

4

7 1

B6

R 2.5 +30 HAZARD

2

M 1 -31

1 2 3 4 5 6 7 8

B7

B-L 1 DIR. LAMP LT USA

G 1.5 HAZARD ISOBUS (USA)

3

B5

1

G 1.5 HAZARD IN

B4

H-V 0.75 LEFT

B3

H-N 0.75 RIGHT

B2

R 2.5 +15

B1

B 2.5 +15

A8 A7

3

SA-3 SA-1

V-N 0.75 HAZARD LIGHT

A6

A 1 TRAILER LT

A5

V-N 1 HAZARD LT

A4

A-N 1 TRAILER RH

A3

B-N 1 HAZARD RH (USA)

A2

R 2.5 +30

A1

G 1.5 HAZARD ISOBUS (USA)

B 0.75 DIRECTIONS COM

B-N 1 HAZARD RH (USA)

B 1.5 +15

B-L 1 DIR. LAMP LT USA

15

L-R 1 DIR. LAMP RH USA

7

R 1.5 +30

B-V 1 EXTREMELY LT

6

14

B-L 1 EXTREMELY RH

5

R 1.5 +30 HAZARD (USA)

A 1 TRAILER LT

4

V-N 1 HAZARD LT

A-N 1 TRAILER RH

3

V-N 0.75 49A(EU) 20

H-V 0.75 LEFT

V-N 0.75 49A(EU) 19

2

5

H-N 0.75 RIGHT

1

17 16 15 14 13 6

V-N 0.75 49A(EU)

13

7

2

18

12 8

3

1

12 11 10 4

3

D022

TABELLA COLORI / COLOURS TABLE

9

4

17

11

20 19 18

5

16

8 6

2

M 1 -31

7

8

1

10 11 12 1

2

3

13 14 15 16 17 4

5

18 19 20 6

7

8

9

D068

9

M 2.5 -31

SA-2

C003

1 2 3 4 5 6 7 8

L-R 1 DIR. LAMP RH USA

G 1.5 HAZARD IN

4

B

V-N 0.75 49A (EU)

5

C

6

A

B8

B

C1 C

C2

M 2.5 -31

A

B-V 1 EXTREMELY LT B-L 1 EXTREMELY RH 7

2

M012

C3

I029

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ellow

R

Rosso/Red

H

Grigio/Gray

D0077750

Fig. 3845 - Hazard warning lights switch (USA) (2/2)

40-529

Wiring diagrams 40.4.28 - 0.019.2383.4/20 - Engine cowl F014 F

2

1

F015 C

2

1

RH AMP

F012

F016 2

1

F

1

F013 LT

K018 2

1

AMP

F011

-

AMP

2

2

1

C

2

1

F010 LT

F009 LT

D036

E004

K017

1

2

F008 F007

AT

RH

RH

Fig. 3846 - Engine cowl - (1/2) Table 670 CODE STAMPED ON CONNECTOR

RH RH LT LT C F LT F C RH AT -

40-530

INTERCONNECTION CODE

D036 E004 F007 F008 F009 F010 F011 F012 F013 F014 F015 F016 K017 K018

DESCRIPTION

Wiring connector Horn RH high beam headlight RH low beam headlight LH low beam headlight LH high beam headlight Rh front work light - on cowl RH centre front work light - on engine cowl Not used LH centre front work light - on engine cowl Lh front work light - on cowl Not used Air temperature sensor External air temperature sensor

D0066830

Wiring diagrams LOW BEAM LIGHTS X10

X11

S0.75 M0.75

1

S0.75 M0.75

1

2

2

2 1

2 1

2 1

1 2

1 2

1 2

1 2

LOW BEAM LIGHTS X5

X2 BEAM LIGHTS X1

GR1.5 M1.5

1

GR1.5 M1.5

1

B1.5 M1.5

B1.5 M1.5

F016 F013 K017 K018 E004 F011 F014 F015 F012

F008

2

F009

2

1 2

1 2

F007 F010

D036

V2.5 M 2.5 M0.75 GR2.5 B2.5 M 2.5 3 11 12 13 15

1 7 4 5 6 9 8

HV0.75 ZB0.75 ZV0.75 GN1 M1 M2.5 BN2.5 M2.5 GV2.5 M 2.5

S0.75

HB0.75

19 20 18 21 16

17

14 2

10

B2.5

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

D0066840

Fig. 3847 - Engine cowl - (2/2)

40-531

Wiring diagrams 40.4.29 - 0.019.2474.4/10 - Rear PTO L009 1000E

L010 1000N

D043 EV RATIO

L011 540E

D040 EV PTO

D041 EV DIFF

L006 EV PTO

L007 EV DIFF

D0066850

Fig. 3848 - Rear PTO (1/2) Table 671 CODE STAMPED ON CONNECTOR

EV PTO EV DIFF EV RATIO EV PTO EV DIFF 1000E 1000N 540E

40-532

INTERCONNECTION CODE

D040 D041 D043 L006 L007 L009 L010 L011

DESCRIPTION

Wiring connector Wiring connector Wiring connector Rear PTO control solenoid valve Differential lock control solenoid valve PTO 1,000 E engagement control solenoid valve PTO 1,000N engagement control solenoid valve PTO 540E engagement control solenoid valve

4

R-V0.75 EV750

3

V-B0.75 EV1000

2

V-Z0.75 EV1400

V-Z0.75 EV1400

2

1

M1 GND

M0.75 GND

1 1

1

5

2

D043

2 3 4 5

Wiring diagrams

SA-1

1

R-V0.75 EV750

2

M0.75 GND

1

L0.75 EV PTO

M0.75 -31

L0.75 EV PTO

1

2

R-L0.75 EV DIFF. 2

M0.75 -31

M0.75 -31 1

2

R-L0.75 EV DIFF.

1

M0.75 -31

1

2

2

1

1

2

M0.75 GND

2

V-B0.75 EV1000

L009

L010

L011

TABELLA COLORI / COLOURS TABLE 1

2

1

L007

2

D041

L006

D040

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

D0066860

Fig. 3849 - Rear PTO (2/2)

40.4.30 - 0.019.2539.4/10 - Hydraulic braking

40-533

Wiring diagrams

L012

D039

K032

D0067290

Fig. 3850 - Hydraulic braking (1/2) Table 672 CODE STAMPED ON CONNECTOR

40-534

INTERCONNECTION CODE

D039 K032 L012

DESCRIPTION

Wiring connector Trailer braking low pressure switch Trailer parking brake control solenoid valve

Wiring diagrams

L012 B12 2 1

mPm

A-N1 M1

1 2 3 4

1 3 4

2

D039 M1 H1 H-N1 A-N1

4 3 2 1

H-N1

1

K032 TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

H1

1

D0067300

Fig. 3851 - Hydraulic braking (2/2)

40.4.31 - 0.019.2571.4/10 - ISO 11786

40-535

Wiring diagrams

4

4

3

3

2

2 1

1 2 3 4 5 6 7 8

1

1 2 3 4 5 6 7 8

5

6

2

3

4 1

Wiring connector ISO 11786 control unit ISO 11786 socket ISO 11786 socket

B

C

40-536

D021 M008 P020 P020a

DESCRIPTION

M008

A

P020a

Fig. 3852 - ISO 11786 (1/2) Table 673 INTERCONNECTION CODE

B

C

P020

CODE STAMPED ON CONNECTOR

A

D021

D0067310

Wiring diagrams M1 -31 GND

C8 C7 C6 C5 C4 C3

L0.75 CAN H

C2

4 3 2

4 3 2

1

1

1 2 3 4 5 6 7 8

1

B7 B6 B5 B4 B3

M008

B

C

A

B2

1 2 3 4 5 6 7 8

2

B8

B

3

B0.75 CAN L L0.75 CAN H M1 -31 GND L1 +15

C

D021

4

A

C1

L1 +15 B1 LIFT POS L1 RADAR V1 WHEEL G1 PTO SPEED C1 LIFT OFF/ON B0.75 CAN L

SA-2

B1 SA-1

A8 A7 A6 A5 A4 A3 A2

L1 +15

6

5

4

1

2

3

2

3

4

5

6

1

1

M1 -31 GND L1 RADAR V1 WHEEL G1 PTO SPEED C1 LIFT OFF/ON B1 LIFT POS

A1

P020

TABELLA COLORI / COLOURS TABLE M

Marrone/Br own

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

P020a D0067320

Fig. 3853 - ISO 11786 (2/2)

40-537

Wiring diagrams 40.4.32 - 0.019.2617.4/70 - ISO 11783 - Cab line E

G

F

D063

M

L

H

D

K

B

A

C

J

5

2

3 6

D089

TECU TECU

51

72 50

73

94

X125 STOLL

29

5 6

1

N

2

4

1

M011

N012

3 4 7

28

R003

3 6

2

9

1

5 8

4

12

7

15

11

18

10

14

21

13

17 20

16 19

7

4

11

1

8 12

5 9

2 6

3

3B 5B

4A

6D

5C

4B

3A

5D

4C

7B

6A

8D

7C

6B

5A

7D

6C 7A

8C 8B

8A

DIODO

DIO DO

2A

4D

3C

O014

D062

2B

15

3D

18

2C

14

1A

21

5

10

17

6 7 8 9

13

1B

20

2D

16

1C

19

1D

D062a

1 2 3 4

1 2

D064

4 3

O014a

2 1

4 3 2

3

4

1

2

3

4

1

4

2

3

BY25 5

1

2 1 BY25 5

R004

9

RES CAN VEHICLE

E

G

D

GEARBOX RES.

A C B

1

1

2

3

4

4

3

2

1

2

O015 D015

F

4 5 6

3 10

I030

H

1 2

M010

7

J

8

1

2

AMP 3

4

GEA RBO RES X .

RE S HIC CA N LE 1

7

1

2

2

4

4

3

3

2

2

1

1

4 5

1

6

2

1

6

3

2

14 13

4

3

AUTOG.

120 Ω

5

4

12 11 10

9

3

3

8

VE

4

D060

O013 O013a luca

AUTOG.

ISO BU

S

luca

luca

6

4

3

3

15

17

16 5

6

7

18 8

2 1

1

2 4

1

8 9

7

5 6

4

2 3

7

4

14

1

13

4

6

3

9

5

8

8

3

D069

2

9

2

D014

1

2

12

11

10 1

ISOBUS

D086a

9

2

D013 AGI4

4

5

5

4

14

4

7

3

4

1

5

P021 D069a 6

13

1

12 11

3

2

6

AGI4

SGR1

2

3

D086

10 9

D086b

SGR1

1

6

4

3

5

1

1 2

4

5

8

1

1

2

7

2

3

6

2

6

5

3

3

3

See diagram C

4 3

4

4

AUX

2

O012 O012a

AUX

1

H007

D0077760

Fig. 3854 - ISO 11783 - Cab line (1/3) Table 674 CODE STAMPED ON CONNECTOR

ISOBUS

GEARBOX RES.

AGI4 SGR1 AUX CAN BRIDGE ISOBUS CAN BRIDGE ISOBUS

40-538

INTERCONNECTION CODE

D013 D014 D015 D060 D062 D062a D063 D064 D069 D069a D086 D086a D086b D089 H007 I030 J013 J014 J020 J021 J022 J023

DESCRIPTION

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Configuration connector Configuration connector Configuration connector Wiring connector Monitor controls “Performance Steering” system activation switch CAN-L CANBUS ISO11783 configuration relay CAN-H CANBUS ISO11783 configuration relay Stoll application relay Stoll application relay Stoll application relay Stoll application relay

Wiring diagrams Table 675 INTERCONNECTION CODE

DESCRIPTION

N

2

3

4

1

AMP 2 3

4

O014

SA-30

(+30)

M 1.5

4

2

4

3

3

2

4

4 3 2 1 4 3 2 1

R2_87

3

R2_85

9

5

4

6 3

10

16 17 18 5

6

7

14 13

8

6

5

4

2

1

3

4

8

7

1 2

5

1 2 3 4 5 6

4 5 6

1 2 3

C-N 0.75 C-N 0.75 C-N 0.75

1

4

2

5 6

9

9 3

7

8

1

2

3

3

12 11 10 4

R-N 0.75 L-B 0.75 R-N 0.75 L-B 0.75

6

5

6

1 2 3 4 5 6

M 0.75

A 0.75

B 0.75

1 M-N 1 2 B 0.75 3 Z 0.75 4 A 0.75 5 S 0.75 6 N 0.75 7 V 1 8 M 0.75 9 M 1

A M 1 B R-N 1 C L 0.75 D B 0.75 E F G H S 0.75 J Z 0.75

9

L-B 1 M 1 V 0.75 G 0.75

M 0.75

8

1 2 3 4

G-N 0.75

7

G-N 0.75

M 0.75

6

G-N 0.75

Z-H 0.75

5

10

Z-N 0.75

Z 0.75

3

2

12 13 14 15 4

21

2

8 4

R2_86

7 3

8

2

19

1

7 3

R2_30

1

20

4

6 2

R1_87

Z-B 0.75 2

B 0.5 9 10 11

1

2 1

18

3

5 1

V 1

R2_87a

R1_87a

R1_85

M 2.5 M 1 M 1

1 2 3 4 5 6 7 8 9 C 0.75 C-N 0.75 C-B 0.75 R-N 0.75 L-B 0.75

G 0.5 RS232_B C-B 0.75

A 0.75 C 0.75 M 1 A 0.75 B 0.75

B 0.5

321

16

N 0.75

S 0.75 Z 0.75

O017 V 1

O016 V 1 R1_86

L 1 M-B 1 G-N 1 R1

H 1

R6_30

J021

J022 J023 R6_87a

R6_87

R6_86

R5_87a

R5_86

R5_87

R6_85

R5_85

R5_30

R1

M 0.5

M 0.5

J020 R4_30

R4_85

R1

M 0.5

R3_85

R3_30

R1

M 0.5

R4_87

R4_86

R4_87a

J014 R3_87a

R3_87

R3_86

R2_87

M-N 1 A 0.75 R2_87a

R2_86 R2_85

M 1

Z 0.75 R1_30

R1_85

M 0.5 6

R2_30

R1_87a

R1_87

R1_86

V 0.75 G 0.75

V 0.75 G 0.75

A 0.75 C 0.75

M-N 1 M-N 1 B 0.75

J013

6

6 5

5 4

4

12 13 14 10 11

3

3

2 1

9

2

8

1

3 2

5

1 2

654

17

1

15

2

3 4

F E

14

G D

13

H A

12

J C

D086b

B

B 0.75 A 0.75

SA-10

D069

R004 M 1 M 0.75 V 1 N 0.75 S 0.75 A 0.75 Z 0.75 B 0.75 M-N 1

9 8 7 6 5 4 3 2 1

D069a 6

D086a

9 8 7 6 5 4 3 2 1

1

C-N 0.75

1 L-B 1 2 R 1.5 3 L 1 4 R 1.5 5 M 1.5 6 R-N 1.5 7 C 0.75 8 A 0.75 9 B 1 10 L 1 11 A 0.75 12 B 0.75 13 G 0.75 14 V 0.75 15 M 1.5 16 M 1.5 17 L 1 18 B 1

7

P021

B 0.75 A 0.75

4

I030

5

D014

8

D086

H007

2

1 2 3 4 5 6

5

6 7 8 9

6

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 2 3 4

R003

9

A 0.5 A-B 0.5

SA-8

9

10

CANL-10

M 1.5

3

4

S 0.75

SA-7(GND)

3

11

-

5

9

1

CANH-10-

L 0.75 B 0.75

CANL-11

8

8

2

-

B 0.75 L 0.75

2

7

3

CANH-11

-

M 1

-

1

6

4

O015

SCH-4 M 0.75

4

5

1

1

-

O013a

SA-4(GND)

-

CANL-17

2

M 1

2

L 0.75 B 0.75

ISOH-5 ISOL-5

4 3 2 1

3

B 0.75 L 0.75

4 3 2 1

O012a

O013 3

C 0.75 A 0.75

-

CANH-15

0.75 0.75 0.75 0.75 0.75 0.75

7

4

4 3 2 1

4

CANL-15 -

A 0.75 C 0.75

-

L 0.75

D060

3

-

CANH-14

CANL-16

2

8B

8C

8A

8D

7B

7D

7C

7A

6D

6C

6B

6A

5D

5C

5B

5A

4D

G 0.75 V 0.75

CANL-14 -

G 0.75 V 0.75

S Z C A V G

-

-

2

G-N 0.75

B 0.75 -

4C

K2

CANH-17

B 0.75 L 0.75

-

CANH-12

CANH-16

D089 O012

4

CANL-12 -

SCH-1

4B

8

1

6

1

4

2

2

2

8

3

6

3

4

-

A 0.75 C 0.75

-

ISOL-6

R1

4

ISOH-6 -

ISOL-1

1

2

S 0.75 Z 0.75

A 0.75 B 0.75 V 0.75 G 0.75

- B 0.5

4A

-

S 0.75 Z 0.75

C 0.75 A 0.75

D064

-

TBC-

5

H-V 1 ISOH-4

3D

30

85

3C

8687a 87

30

85

3B

8687a 87

30

85

3A

8687a 87

30

85

2D

8687a 87

30

85

5

-

2C

8687a 87

30

85

-

1

O014a

ISOH-1 -

ISOL-4

M010

TBC+

A 0.75 B 0.75 A 0.75 B 0.75

0.75 0.75 0.5 2.5 1.5

SA-6

A 0.75 M 0.75

2B

-

ISOH-3

A1

2A

A2

1C

ISOL-3 -

B 0.75 A 0.75

1B

SA-15

-CANL-13 CANH-13 -

1D

(+15)

1A

-

M 1.5

R-N 1 A-B 0.5 B 0.75 L 0.75 G 0.75 V 0.75 B 0.75 A 0.75

2

SCH-3 -

1

B 0.5

-

D062a

A 0.75 B 0.75

-

M 1

4

1

Z 0.75 S 0.75

A 0.75 C 0.75

A 0.75 C 0.75

SA-RWL -

V-G 1

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

BY255

120 Ω

7

ISOL-2 -

B 0.75 A 0.75 C-N 0.75 A 0.5

C A S M R

1

N 0.75 D8 D7 D6 D5 D4 Z 0.75 D3 S 0.75 D2 M 0.75 D1 -31 M1 C8 A1 UP + 0.5 C7 A1 UP - 0.5 C6 HYDROLOCK 0.5 C5 COMFORT DRIVE 0.5 C4 B1 DOWN + 0.5 C3 B1 DOWN - 0.5 C2 A2 SHOVEL UP + 0.5 C1 A2 SHOVEL UP - 0.5 B8 B2 SHOVEL DOWN + 0.5 B7 B2 SHOVEL DOWN - 0.5 B6 FUNCTION 1 0.5 B5 FUNCTION 2 0.5 B4 3TH SERVICE 0.5 B3 4TH SERVICE 0.5 B2 B1 N 0.75 A8 V 1 A7 M 1 A6 B-V 1 A5 M-N 1 A4 B 0.75 A3 A 0.75 A2 M 0.75 A1

ISOH-2

K1

6 5 4 3 2 1

2

-

CANL-18

8687a 87

N012

1

9

1

6

8

16 17 18 19 20 21

2

5

7

10 11 12 13 14 15

2

1

3

D062

BY255

3

CANH-18

G-N 0.5 M-B 0.5 V 0.5 M-B 1 B 0.5 A-N 0.5 M-B 0.5 R-N 0.5 H 0.5 H 1 H 1

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

3

2 1

4 4

10 9 8 7 6 5 4 3

4

3 2 1

4

D013

4

C 0.75 C-L 0.75 -

1

C-N 0.75 14 S 0.5 13 V-G 1 12 M-V 0.5 H-V 0.5 11 H-V 1

1

B 0.75 L 0.75

G-N 0.5 R-N 0.5

A 0.75

C 0.75

M-B 0.5 B 0.5 V 0.5 V 0.5

B 0.75 A 0.75

A-N 0.5 M-B 0.5 L 1

M-V 0.5 H-V 0.5

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 53 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 R-N 1 M 1 R-N 1 M 1 R-N 1 M 1 Z-N 0.75 V 1

M-N 1 Z-H 0.75

C

1

94

4

K

A

B

J

D

1

Z 0.75 A Z-B 0.75 B M 1 C D A 0.75 E C 0.75 F G H K J N L M 1 2

D015

M011

73

3

72

1

M

28

2

51

50

H

L 2

29

G

F

E

1 2

3 4

7

5 6

D063

L 0.75

RES CAN VEHICLE DIODES ISOBUS DIODES ISOBUS

H 0.5 H 1

DIODE

B-V 1

AUTOG.

Microphone ISO 11783 control unit Electronically controlled hydraulic power steering CAN line termination connector CAN line termination connector CAN line termination connector CAN line termination connector Diode connector Diode board CAN line termination connector Diode board Diode board ISO 11783 socket in cab RS 232 connector ISO11783 diagnostic socket

B 0.75

M010 M011 N012 O012 O012a O013 O013a O014 O014a O015 O016 O017 P021 R003 R004

C-L 0.75

CODE STAMPED ON CONNECTOR

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ellow

R

Rosso/Red

H

Grigio/Gray

D0077770

Fig. 3855 - ISO 11783 - Cab line (2/3) 40-539

FRONT ROFF W.L.

8

K2

4

5

F2

+15 KEY

FRONT WIPER

K1

CAN BRIDGE ISOBUS

2

1

8

CAN BRIDGE ISOBUS 3

9 6

2 1

11

8 5

20A

20A 7 4

14

20A

20A

2

3

15A

20A

6

15A 7

20A

R7

6

REAR ROFF W.L.

1

16

18

15A

R6

5

2

10

30A

40A

12

13

15

171

40A

R4

6

HALF BEAM LAMBORGHINI 1

HALF BEAM

1

REAR WINDOW DEFROST 5

4

4

7

10

13

15

17

2

6

POSITION

FULL BEAM

3

LIFT SERVICE W.L.

NORMAL/TOP HALF BEAM

BRAKE 5

4

4

3 2

5

8

NORMAL/TOP FULL BEAM

F4

6

9

12 11

30A

40A

20A

2

14

16

18

20A

R3

1

10

DIODES ISOBUS

BEACON

1

3

2

2

HYDRAULIK TRAILER BRAKE

3

6

1

5

R1-A

4

7

DIODES ISOBUS

6

5

10

15A

1

REAR LOW W.L.

AUX TRAILER W.L.

1

20A

3

1 11

5A 7.5A

F1-B

5A 15A

3A

15A 15A

7.5A

15A

15A

5A

10A

5A

F3 7.5A

F1-A

3

2

FRONT LOW W.L

3A

10A 3A

15A

7.5A

3A

15A

11

1

20A 1

2.9939.503.0/10

15A

5A

15A

7.5A

15A

5 1

5A 7.5A

5A

5A

7.5A

3A

7.5A

5A

15A

7.5A

20

3A 10A

7.5A

20

10

9

15A

5A

4

15A

7.5A

8

5A

7 2

3

7.5A

6

5A

15A 1

3A

15A

+15 KEY

2

Wiring diagrams

4

J014 J020

J013

J022 J023

J021

O016

O017

See diagram C

D0077900

Fig. 3856 - ISO 11783 - Cab line - Fuse box (3/3)

40-540

Wiring diagrams 40.4.33 - 0.019.3658.4/20 - Agrosky solenoid valve

L015 K037 O018a

1 2 3 4

3

Ω

2

3

4

1

2

0

4

12

1

2

1

O018

4 3 2 1

4 3 2 1

D063 G F E H M L 2 N 1 J K D A B C

6

5

4 1

2

3

K038

1

1 2 1

3 2

4 3

3

2

3

4

4

M013a

1

2

M013b

4

K016

D0077680

Fig. 3857 - Agrosky solenoid valve (1/2) Table 676 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D063 K016 K037 K038 L015 M013a M013b O018 O018a

DESCRIPTION

Wiring connector Wiring connector Steering wheel angle sensor Steering angle sensor (Agrosky) AGROSKY control disable solenoid valve Electronically controlled hydraulic power steering (grey connector) Electronically controlled hydraulic power steering (black connector) CAN line termination connector CAN line termination connector

40-541

Wiring diagrams D063 H 1 M

G

A J

E

N

L

M

J

K

F

H

E

C 0.75 CAN-L

D

A 0.75 CAN-H

B

C

C 0.75 CAN-L

M 1 GND -31

1

SA-2

CAN-L1 -

CAN-H1

A 0.75 CAN-H

4

M 1 GND -31

3

Z 0.75 +15 SENSOR

2

C 0.75 CAN-L

1

1 2 3 4

4 3

M 0.75 GND GND -31

2

B 0.75 + 5 VOLT + 5 VOLT

1

B 0.75 SIGNAL SIGNAL

K037

SA-1

M013b

1 2 3 4

1 2 3 4

Z 0.75 +15 SENSOR

Z-B 0.75 SIGNAL CUT OFF EV

2

A Z 0.75 +15 SENSOR

1

D

2

2

M 1 GND -31

G

C

K

A 0.75 CAN-H

3

L

4

F

N

B

M013a

CAN-H2 CAN-L2

M-N 0.75 GND GND SENSOR

4 3 2

R-V 0.75 GND + 5 VOLT

4

L-G 0.75 GND SIGNAL

M 0.75 GND GND -31

B 0.75 + 5 VOLT + 5 VOLT

5

M-N 0.75 GND GND SENSOR

R-V 0.75 GND + 5 VOLT

4

3

B 0.75 SIGNAL SIGNAL

3

2

L-G 0.75 GND SIGNAL

6

2

2

120 Ω

1

1

1

3

1

2

2

1

2

2

3

A 0.75 CAN-H

3

3

4

4

C 0.75 CAN-L

O018a 3

O018

2

M 1 GND -31

1

Z-B 0.75 SIGNAL CUT OFF EV

1

1

2

1

L015

4

TABELLA COLORI / COLOURS TABLE

3

4

2

5 6

3

4

40-542

2

Fig. 3858 - Agrosky solenoid valve (2/2)

1

1

K038

K016

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ellow

R

Rosso/Red

H

Grigio/Gray

D0077690

Wiring diagrams 40.4.34 - 0.019.3659.4/10 - On-board monitor - Armrest

8

1

19

13

7

21

14

20

3 5

25

2 3

8 11 14 17 20 9 12 15 18 21

4

5 6

1

7 10 13 16 19

26

E005a

8

1

14

20

D070

21 3

AMP 5

25 7

26

13

19

E005b D0067370

Fig. 3859 - On-board monitor - Armrest (1/2) Table 677 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D070 E005a E005b

DESCRIPTION

Wiring connector I-Monitor I-Monitor

40-543

Wiring diagrams 26

26

25

25 24

G 0.75 CAN-L AUX

23

V 0.75 CAN H AUX

22

B 0.75 CAN-L VEHICLE

21

L 0.75 CAN-H VEHICLE

C-N 0.75 + ANT

24 23 22 21

A 0.5 MIC +

20

20 19

19 SCH-2

18

B 0.5 RS232 GROUND

17

V 0.5 RS232_A RS232 TX

17

16

G 0.5 RS232_A RS232 RX

16

18

7

A-B 0.5 MIC -

E005b

9

CAN L

8 7

CAN H

6

26

S 0.75 CAN H ISOBUS

7

19

8

13

Z 0.75 CAN-L ISOBUS

5

10

9

3

11

10

1

12

11

21 AMP 25

13

12

8

14

13

14

15

14

20

15

6 5

5

2

Z 0.75 CAN-L ISOBUS

21

20

19

S 0.75 CAN H ISOBUS

C-N 0.75 + ANT

A 0.5 MIC +

B 0.5 RS232 GROUND

G 0.5 RS232_A RS232 RX

V 0.5 RS232_A RS232 TX

L-B 1 +15 MONITOR

M 1.5 GND

R-N 1 +30 MONITOR

A-B 0.5 MIC -

B 0.75 CAN-L VEHICLE

TABELLA COLORI / COLOURS TABLE

18

17

16

15

14

13

12

11

10

9

8

7

G 0.75 CAN-L AUX

V 0.75 CAN H AUX

L 0.75 CAN-H VEHICLE

6 3

9 12 15 18 21

6 5 2

8 11 14 17 20

4 1

7 10 13 16 19

1

5

21 20

E005a

Z 0.75 CAN-L ISOBUS

25

19

5 3 8

1

14

3 1

4

R-N 1 +30 MONITOR

3

1

4 SCH-1

S 0.75 CAN H ISOBUS

L-B 1 +15 MONITOR

2

2

SA-5

26

M 1 GND

7

3

13

4

M 1 GND

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

D070

D0067380

Fig. 3860 - On-board monitor - Armrest (2/2)

40.4.35 - 0.019.4559.4/10 - Rear service work light

D049

F025

D0067390

Fig. 3861 - Rear service work light (1/2) Table 678 CODE STAMPED ON CONNECTOR

40-544

INTERCONNECTION CODE

D049 F025

DESCRIPTION

Wiring connector Rear service light

Wiring diagrams

D049

V-R1

V-R1

2

M1

M1

1

2 1

F025

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

D0067400

Fig. 3862 - Rear service work light (2/2)

40.4.36 - 0.019.4688.4/10 - Front top work lights on cab

N011

F035

4

1

3

2

1 2

D059 RH

1 2

1

10

2

11

3

RH

9

F036

4 12 13 14 15 5 17 18

7 8

6

1 2

7 8

6 5 4

9

3

10

2

11

1

12

P019 F034

16

F033

1 2

1

7

1

2

8

2

3

9

3

LH

10 11

D058

4

12

4

5

13

5

6

14

6

LH

P018 7 8

6 5 4

9

3

10

2

11

1

12

D0067410

Fig. 3863 - Front top work lights on cab (1/2) Table 679 CODE STAMPED ON CONNECTOR

LH RH

INTERCONNECTION CODE

D058 D059 F033 F034 F035 F036 N011 P018 P019

DESCRIPTION

Wiring connector Wiring connector Left hand outer front work light (on cab roof) Left hand inner front work light (on cab roof) Right hand outer front work light (on cab roof) Left hand outer front work light (on cab roof) Windscreen wiper motor LH rear view mirror RH rear view mirror

40-545

Wiring diagrams

2

3

4

M 1.5 GND V-B 1.5 FRONT WORK LIGHT 1

M 1.5 GND

1

1 2

L-B 1.5 31b ZERO

2

1 2

L-N 1.5 53 FRONT WIPER

F035

4 3

L 1.5 +12 WIPER FRONT (53a)

1

N011

18

F036

2

1

1

2

S-L 0.5 COMMAND MIRROR COMMON SMALL (RH)

17

M-C 0.5 COMMAND MIRROR SX/DX SMALL (RH)

16

H-R 0.5 COMMAND MIRROR UP/DOEN SMALL (RH)

15

N-B 1.5 FRONT WORK LIGHT

L 1.5 +12 WIPER FRONT (53a)

4

L-B 1.5 31b ZERO

3

M 1.5 GND

2

L-N 1.5 53 FRONT WIPER

1

SA-1 SA-2

D059 8

5

7

6

V-B 1.5 FRONT WORK LIGHT 1

17 18

8 M 1 LED BAR -

7

M 1.5 GND

6

9 +15 MIRROR DEFROST SMALL Z 0.75

8

N-B 1.5 FRONT WORK LIGHT

16

11 Z 0.75 +15 MIRROR DEFROST BIG

M100.75 GND MIRROR DEFROST SMALL 7

6 5

8

4

9

3

10

2

11

1

12

P019

9

M 1.5 GND

5

12 M 0.75 GND MIRROR DEFROST BIG

G-N 1 LED BAR +

12 13 14 15

10

4

11

M 1.5 GND

3

12

R-N 0.75 COMAND MIRRORS DX/SX BIG (RH)

2

13

G 0.75 COMAND MIRRORS UP\DOWN BIG (RH)

1

14

C 0.75 COMAND MIRRORS COMMON BIG (RH)

9 10 11

Z 1 +15 MIRROR DEFROST

M 1.5 GND

7 1 LED BAR + G-N 6 COMAND MIRRORS UP\DOWN BIG (RH) G 0.75

R-N 50.75 COMAND MIRRORS DX/SX BIG (RH) 4 COMAND MIRRORS COMMON BIG (RH) C 0.75 3 COMMAND MIRROR UP/DOEN SMALL (RH) H-R 0.5

M-C2 0.5 COMMAND MIRROR SX/DX SMALL (RH) S-L 10.5 COMMAND MIRROR COMMON SMALL (RH)

G-N 1 LED BAR +

6

M-B 0.75 COMAND MIRROR UP/DOWN BIG (LT)

5

B-N 0.75 COMAND MIRROR DX/SX BIG (LT)

4

R 0.75 COMAND MIRROR COMMON BIG (LT)

3

B-C 0.5 COMAND MIRROR UP/DOWN SMALL (LT)

2

C-B 0.5 COMAND MIRROR DX/SX SMALL (LT)

1

G-R 0.5 COMAND MIRROR COMMON SMALL (LT)

2

M 1.5 GND

1

B 1.5 FRONT WORK LIGHT 1

2

M 1.5 GND

1

B-N 1.5 FRONT WORK LIGHT 1

14

C-B 0.5 COMAND MIRROR DX/SX SMALL (LT)

13 12

M 1.5 GND

11

B 1.5 FRONT WORK LIGHT 1

10

D058

M 1.5 GND

9

B-N 1.5 FRONT WORK LIGHT 1

8

M 1 LED BAR -

7

G-N 1 LED BAR +

6

Z 1 +15 MIRROR DEFROST

5

M 1 GND MIRROR DEFROST

4

R 0.75 COMAND MIRROR COMMON BIG (LT)

3

M-B 0.75 COMAND MIRROR UP/DOWN BIG (LT)

2

B-N 0.75 COMAND MIRROR DX/SX BIG (LT)

1

4 5 6

M 1 LED BAR -

7

G-R 0.5 COMAND MIRROR COMMON SMALL (LT)

B-C 0.5 COMAND MIRROR UP/DOWN SMALL (LT) SA-3

12 13 14

8

SA-4

10 11

Z 0.75 +15 MIRROR DEFROST SMALL

7 8 9

7

6 5

8

4

9

3

10

2

11

1

12

1 2

M 0.75 GND MIRROR DEFROST SMALL

9

1 2 3

F034

1 2

Z 0.75 +15 MIRROR DEFROST BIG

10

4 5 6

F033

M 0.75 GND MIRROR DEFROST BIG

11

1 2 3

P018

12

TABELLA COLORI / COLOURS TABLE M

Marrone/Br own

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0067420

Fig. 3864 - Front top work lights on cab (2/2)

40.4.37 - 0.019.4689.4/20 - RH rear work lights on cab roof

F029 1 2

1

1

2

2

AMP 3

3

4

4

D055

F030 1 2

D0067430

Fig. 3865 - RH rear work lights on cab roof (1/2)

40-546

Wiring diagrams Table 680 CODE STAMPED ON CONNECTOR

F030

D055 F029 F030

DESCRIPTION

Wiring connector Right hand inner rear work light (on cab roof) Right hand outer rear work light (on cab roof)

1 2

V1.5 REAR WORK LIGHT 1

2

M1.5 GND

1

V-N1.5 REAR WORK LIGHT 1

M1.5 GND

4

V1.5 REAR WORK LIGHT 1

3

M1.5 GND

2

V-N1.5 REAR WORK LIGHT 1

1

D055

4

M1.5 GND

1

AMP 2 3

1

2

1

F029

INTERCONNECTION CODE

2

TABELLA COLORI / COLOURS TABLE M

Marrone/Br own

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0067440

Fig. 3866 - RH rear work lights on cab roof (2/2)

40-547

Wiring diagrams 40.4.38 - 0.019.4689.4/20 - LH rear work lights on cab roof

F032 1 2

1

1

2

2

AMP 3

3

4

4

D056

F031 1 2

D0067431

Fig. 3867 - LH rear work lights on cab roof (1/2) Table 681 CODE STAMPED ON CONNECTOR

40-548

INTERCONNECTION CODE

D056 F031 F032

DESCRIPTION

Wiring connector Left hand inner rear work light (on cab roof) Left hand outer rear work light (on cab roof)

Wiring diagrams

F032

V1.5 REAR WORK LIGHT 1

2

M1.5 GND

1

V-N1.5 REAR WORK LIGHT 1

M1.5 GND

4

V1.5 REAR WORK LIGHT 1

3

M1.5 GND

2

V-N1.5 REAR WORK LIGHT 1

1

D056

4

M1.5 GND

1

AMP 2 3

1

2

1

F031

1 2

2

TABELLA COLORI / COLOURS TABLE M

Marrone/Br own

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0067441

Fig. 3868 - LH rear work lights on cab roof (2/2)

40.4.39 - 0.019.4711.4/10 - Semi-active cab

40-549

6 5 4

1 2 3

Wiring diagrams

N005

D038

6 5 4

1 2 3

2 1

14 13

7 6 5 4 3

12 11 10 9 8

D0067450

N006

Fig. 3869 - Semi-active cab (1/2) Table 682 CODE STAMPED ON CONNECTOR

40-550

INTERCONNECTION CODE

D038 N005 N006

DESCRIPTION

Wiring connector Left hand cab suspension Right hand cab suspension

1 2 3

Wiring diagrams

6

R-L0.75 DUMPER LEFT -

5

L-N0.75 DUMPER LEFT +

6 5 4

4

N005

3

C-L0.75 LINEAR SENSOR LEFT

2

M-N0.75 GND SENSOR

1

C0.75 GND SENSOR

D038

14 13 12 11 10 9

5 4

L0.75 LINEAR SENSOR RIGHT

3

C0.75 +5V HLHP

2

M-N1 GND SENSOR

1

SA-2 SA-1

R-B1 DUMPER RIGHT +

1 2 3

V-B0.75 DUMPER RIGHT -

5 4

6 5 4

6

3

L0.75 LINEAR SENSOR RIGHT

2

M-N0.75 GND SENSOR

1

C0.75 GND SENSOR

N006

2 1

6

C-L0.75 LINEAR SENSOR LEFT

14 13

7

L-N0.75 DUMPER LEFT +

7 6 5 4 3

8

R-B1 DUMPER RIGHT + R-L0.75 DUMPER LEFT -

12 11 10 9 8

V-B0.75 DUMPER RIGHT -

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

D0067460

Fig. 3870 - Semi-active cab (2/2)

40.4.40 - 0.019.4913.4/10 - Front top work lights on cab - LED version

1

1

2 1

1

2

4

1

3

2

1

10

2

11

3

RH

9

F036

2

F035

2

N011

4 12 13 14

D059

15

RH

5

1 2 1 2

3 2 1

1

4

2

6 5

1

7 8 9 10 11 12

2

8

7

7

1

8

2

9

3

1 2 3

LH

10 11 12

4

13

5

14

6

4 5 6

D058 LH

7 8 9

6 5 4 3

10

2

11

1

12

P018

17 18

F034

6

F033

16

P019

D0067470

Fig. 3871 - Front top work lights on cab - LED version (1/2)

40-551

Wiring diagrams Table 683 CODE STAMPED ON CONNECTOR

LH RH

INTERCONNECTION CODE

DESCRIPTION

D058 D059 F033 F034 F035 F036 N011 P018 P019

Wiring connector Wiring connector Left hand outer front work light (on cab roof) Left hand inner front work light (on cab roof) Right hand outer front work light (on cab roof) Right hand inner front work light (on cab roof) Windscreen wiper motor LH rear view mirror RH rear view mirror

3

N-B 1.5 FRONT WORK LIGHT

4

1

2

M 1.5 GND

2

M 1.5 GND

2

1

3

L-B 1.5 31b ZERO

V-B 1.5 FRONT WORK LIGHT 1

L-N 1.5 53 FRONT WIPER

M 1.5 GND

1

1

2

2

2

1

F035

4

L 1.5 +12 WIPER FRONT (53a)

1

N011

2

2

17

M-C 0.5 COMMAND MIRROR SX/DX SMALL (RH)

16 15

10

M 0.75 GND MIRROR DEFROST SMALL

L-B 1.5 31b ZERO

3

9

Z 0.75 +15 MIRROR DEFROST SMALL

M 1.5 GND

2

8

M 1 LED BAR -

L-N 1.5 53 FRONT WIPER

1

7

G-N 1 LED BAR +

6

G 0.75 COMAND MIRRORS UP\DOWN BIG (RH)

5

R-N 0.75 COMAND MIRRORS DX/SX BIG (RH)

4

C 0.75 COMAND MIRRORS COMMON BIG (RH)

3

H-R 0.5 COMMAND MIRROR UP/DOEN SMALL (RH)

2

M-C 0.5 COMMAND MIRROR SX/DX SMALL (RH)

1

S-L 0.5 COMMAND MIRROR COMMON SMALL (RH)

SA-1

SA-2

D059 8

4

7

L 1.5 +12 WIPER FRONT (53a)

17 18

Z 0.75 +15 MIRROR DEFROST BIG

6

5

11

16

V-B 1.5 FRONT WORK LIGHT 1

5

M 0.75 GND MIRROR DEFROST BIG

15

6

12

14

7

M 1.5 GND

13

8

N-B 1.5 FRONT WORK LIGHT

12

9

M 1.5 GND

4

10

G-N 1 LED BAR +

3

11

M 1.5 GND

11

12

R-N 0.75 COMAND MIRRORS DX/SX BIG (RH)

2

13

G 0.75 COMAND MIRRORS UP\DOWN BIG (RH)

10

14

C 0.75 COMAND MIRRORS COMMON BIG (RH)

1

Z 1 +15 MIRROR DEFROST

9

6

7

5

8

4

9

3

10

2

11

1

12

P019

1

F036

1

18

S-L 0.5 COMMAND MIRROR COMMON SMALL (RH) H-R 0.5 COMMAND MIRROR UP/DOEN SMALL (RH)

G-R 0.5 COMAND MIRROR COMMON SMALL (LT)

3

B-C 0.5 COMAND MIRROR UP/DOWN SMALL (LT)

2

C-B 0.5 COMAND MIRROR DX/SX SMALL (LT)

1

G-R 0.5 COMAND MIRROR COMMON SMALL (LT)

M 1.5 GND B 1.5 FRONT WORK LIGHT 1

1

4 3 2 1

1

R 0.75 COMAND MIRROR COMMON BIG (LT)

2

2

5

2

B-N 0.75 COMAND MIRROR DX/SX BIG (LT)

4

1

2

M 1.5 GND

1

B-N 1.5 FRONT WORK LIGHT 1

12 11

9

B-N 1.5 FRONT WORK LIGHT 1

8

M 1 LED BAR -

7

G-N 1 LED BAR +

6

Z 1 +15 MIRROR DEFROST

5

M 1 GND MIRROR DEFROST

4

R 0.75 COMAND MIRROR COMMON BIG (LT)

3

M-B 0.75 COMAND MIRROR UP/DOWN BIG (LT)

2

B-N 0.75 COMAND MIRROR DX/SX BIG (LT)

1

D058

2

6

8 9 12

1

5

1

7 10 11

2

M-B 0.75 COMAND MIRROR UP/DOWN BIG (LT)

M 1.5 GND

4 5 6

G-N 1 LED BAR +

6

13

10

12 13 14

7

14

M 1.5 GND B 1.5 FRONT WORK LIGHT 1

10 11

M 1 LED BAR -

B-C 0.5 COMAND MIRROR UP/DOWN SMALL (LT) SA-3

9

8

C-B 0.5 COMAND MIRROR DX/SX SMALL (LT) SA-4

8

Z 0.75 +15 MIRROR DEFROST SMALL

7

M 0.75 GND MIRROR DEFROST SMALL

9

1 2 3

F033

Z 0.75 +15 MIRROR DEFROST BIG

10

4 5 6

F034

M 0.75 GND MIRROR DEFROST BIG

11

1 2 3

P018

12

TABELLA COLORI / COLOURS TABLE M

Marrone/Br own

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0067480

Fig. 3872 - Front top work lights on cab - LED version (2/2)

40-552

Wiring diagrams

1

1 2

F031

2

40.4.41 - 0.019.4914.4/20 - LH rear work lights on cab roof - LED version

1

1 2

2 3 4

2

1

AMP

1 2 3 4

F032

D056

D0067710

Fig. 3873 - LH rear work lights on cab roof - LED version (1/2) Table 684 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D056 F031 F032

DESCRIPTION

Wiring connector Left hand inner rear work light (on cab roof) Left hand outer rear work light (on cab roof)

40-553

1 2

1

1

D056

2

2

1

2

V-N1.5 REAR WORK LIGHT 1

4

2

1

3

M1.5 GND

2

3

2

1

4

V1.5 REAR WORK LIGHT 1

4

M1.5 GND

1

AMP 2 3

F031

2

1

F032

1

Wiring diagrams

TABELLA COLORI / COLOURS TABLE M

Marrone/Br own

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0067720

Fig. 3874 - LH rear work lights on cab roof - LED version (2/2)

40.4.42 - 0.019.4914.4/20 - RH rear work lights on cab roof - LED version

40-554

1

1 2

F029

2

Wiring diagrams

1

1 2

2 3 4

2

1

AMP

1 2 3 4

F030

D055

D0067490

Fig. 3875 - RH rear work lights on cab roof - LED version (1/2) Table 685 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D055 F029 F030

DESCRIPTION

Wiring connector Right hand inner rear work light (on cab roof) Right hand outer rear work light (on cab roof)

40-555

1 2

1

1

D055

2

2

1

2

V-N1.5 REAR WORK LIGHT 1

4

2

1

3

M1.5 GND

2

3

2

1

4

V1.5 REAR WORK LIGHT 1

4

M1.5 GND

1

AMP 2 3

F029

2

1

F030

1

Wiring diagrams

TABELLA COLORI / COLOURS TABLE M

Marrone/Br own

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0067500

Fig. 3876 - RH rear work lights on cab roof - LED version (2/2)

40.4.43 - 0.019.5311.4/10 - Automatic A/C system interface

40-556

Wiring diagrams

D016 4

3 2

1 5

6

7

8

10

9

K055 2 1

3 1

4

2

K056 4 3 2 1

13

1

26 25 24 23 22 13 12 11 10

9

21 20 19 18 17 16 15 14 8

7

6

5

4

3

2

1

M015

D0066810

Fig. 3877 - Automatic A/C system interface (1/2) Table 686 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D016 K055 K056 M015

DESCRIPTION

Wiring connector Sunlight sensor Temperature sensor Air conditioning control unit (blue connector)

40-557

Wiring diagrams 4

1

3

2

2 1

G-L0.75 SENSOR SOLAR

3

M-N0.75 ATTUATORE

2

R-N0.75 ATTUATORE

1

K056

5

1

6

2

2

7

13

2 3 4 5 6 7

21 20 19 18 17 16 15 14

8 9

4

B0.75 ATTUATORE

1

13 12 11 10

C-N0.75 ATTUATORE

1

G-V0.75 SENSOR SOLAR

1

1

2

26 25 24 23 22

K055

8

M0.75 GND -31

M015

17

L0.75 +15 KEY

16

G0.75 +58 POSITION

15

R0.75 +30 KEY

14

V0.75 LINEA CAN-H AUX

10

G-L0.75 SENSOR SOLAR

9

C-N0.75 ATTUATORE

7

B0.75 ATTUATORE

6

R-N0.75 EXTERNAL SENSOR TEMPERATURE

1

B0.75 SW BINARY

9

G0.75 +58 POSITION

8

G0.75 LINEA CAN-L AUX

7

V0.75 LINEA CAN-H AUX

6

M0.75 GND -31

5

L0.75 +15 KEY

4

R0.75 +30 KEY

3

R-V0.75 EXTERNAL SENSOR TEMPERATURE

2

R-N0.75 EXTERNAL SENSOR TEMPERATURE

1

G0.75 LINEA CAN-L AUX

4

G-V0.75 SENSOR SOLAR

18

10

R-V0.75 EXTERNAL SENSOR TEMPERATURE

21

3

M-N0.75 ATTUATORE

22

9

R-N0.75 ATTUATORE

24

4

B0.75 SW BINARY

25

3

26

D016 TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

D0066820

Fig. 3878 - Automatic A/C system interface (2/2)

40.4.44 - 0.019.9825.4/10 - Agrosky antenna (Assisted Steering)

6

5

7

4

8

3

9

2

10

1

11

12

M009

D071 1

12

2

11

4

9

5

8

6

7

7

8

6

9

5

10

4

11

3

12

2

1

3

10

M009a

D0077820

Fig. 3879 - Agrosky antenna (Assisted Steering) (1/2)

40-558

Wiring diagrams Table 687 CODE STAMPED ON CONNECTOR

12

M009

11

INTERCONNECTION CODE

DESCRIPTION

D071 M009 M009a

Wiring connector “AGROSKY” Antenna “AGROSKY” Antenna

B 1 SCH V 0.5 RS232 TX RS232-B

10

G 0.5 RS232 RX RS232-B

9

B 1 SCH

6

V 0.5 RS232 TX RS232-A

1 5 6

4

8 7

SCH-4

M009a

12

B 1 SCH

7

11

V 0.5 RS232 TX

10

G 0.5 RS232 RX

9

M 0.75 GND

C-N 0.75 + ANT SCH-5

8

B 1 SCH

9

G 0.5 RS232 RX

10

V 0.5 RS232 TX

11

C-B 0.75 + ANT

12

5

G 0.5 RS232 RX RS232-A

6

-

4

C-N 0.75 + ANT

3

1

D071 2

M 0.75 GND

5

2

1

4

-

8

3

C 0.75 CAN-L AUTOGUIDANCE

SA-1

3

7

2

A 0.75 CAN-H AUTOGUIDANCE

9

1

Z 0.75 CAN-L ISO BUS

4

10

S 0.75 CAN-H ISO BUS

5

6

12

3

2

7

11

9 10 11 12

8

1

7

2 3 5

4

8 7

6

9 10 11 12

8

6

C 0.75 CAN-L AUTOGUIDANCE

5

A 0.75 CAN-H AUTOGUIDANCE

4

Z 0.75 CAN-L ISO BUS

3

S 0.75 CAN-H ISO BUS

2

C-B 0.75 + ANT

1

C-N 0.75 + ANT

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gray

D0077830

Fig. 3880 - Agrosky antenna (Assisted Steering) (2/2)

40-559

Wiring diagrams 40.4.45 - 0.019.9826.4/30 - Agrosky - I-Monitor

19

16 20

13

10

17 21

7

14 18

4

11 15

1

8 12

5 9

2 6

3

D062

N012 1 4

2 5

3 6

D013 M010

1

2 8

2

3

3 9

4 10 11

5

O013a

6

12 13 14

2

1

7

6

4

4

5

2

1

1

TO G.

AU

2

3

3

4

120 Ω

1

1 2 3 4

O013

1 2 3 4

7

1 2

2

8

4

5

4

12 11 10

9

12 13 14 15

3

4

5 6

2

3

4 1

2

4

3

2

1

3

8

4

7

Ω

O012

D014

D072

12 0

O012a

6

16 17 18

5

3

6

2

14 13

1

3

AUTOG.

9 10 11

1

D060

1

4 3 2 1

1

2 6

4

3 7

8

5 9

R003 D086

4 1

5 2

6 3

3 6 2 1

R1 SG

5

2 6

SGR1

I4 AG

3

AU

X

5

1

4

4

D086b

D086a

2 1

3 4

AGI4

H007 AUX

D0077870

Fig. 3881 - Agrosky - I-Monitor (1/2) Table 688 CODE STAMPED ON CONNECTOR

AGI4 SGR1 AUX

AUTOG.

40-560

INTERCONNECTION CODE

D013 D014 D060 D060 D062 D072 D086 D086a D086b H007 M010 N012 O012 O012a O013 O013a R003

DESCRIPTION

Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Not used Configuration connector Configuration connector Configuration connector Monitor controls Microphone Electronically controlled hydraulic power steering CAN line termination connector CAN line termination connector CAN line termination connector CAN line termination connector RS 232 connector

Wiring diagrams H007 1 2 3 4

C 0.75 CAN L AUTOG.

S 0.5 CUT OFF SUPPLY AG A 0.5 MIC +

R 2.5 +30

A-B 0.5 MIC -

CAN-L AUX

-

CAN-H AUX

CANL-13

-

M 1.5 GND

M 1 GND

M 1.5 GND

CAN H VEHICLE

R 1.5 +30 R 2.5 +30

-

SA-1

L 0.75 +15 R 1.5 +30

C 0.75 CAN L AUTOG.

SA-4

M 1 GND

-

CANL-14

-

A 0.75 CAN H AUTOG.

CANH-14

CANH-13

V 0.5 RS232 TX

-

C 0.75 CAN L AUTOG.

-

A 0.75 CAN H AUTOG.

CANL-17

A 0.75 CAN H AUTOG.

-

SCH-1

G 0.5 RS232 RX

-

CANH-17

B 0.5 RS232 GROUND

V 0.5 RS232 TX

- CANL-16

C 0.75 CAN L AUTOG. -

B 0.5 RS232 SCH

SCH-4

M 1 GND

V 0.5 RS232 TX

9 8 7 6 5 4 3 2 1

1 2 3 4

5

6 7 8 9

R003

CANH-16

G 0.5 RS232 RX C-N 0.75 + ANT

CAN-L AUX

L-B 1 +15 MONITOR+MMI

SA-3

C-N 0.75 + ANT C-N 0.75 + ANT (MON/TECO IN)

9

3

8

6

2

5

7 2

1

14 13 6

5

12 11 10 4

9

8 3

2

7 1

3

1

1

2

3

120 Ω

2

3

4

2

1

3

2

4

1

1

6 5 L-B 0.75 +15 ANTENNA 4 3 R-N 0.75 +30 ANTENNA 2 1

4

4

TABELLA COLORI / COLOURS TABLE

1 2 3 4

1 2 3 4

D086a

C 0.75 CAN L AUTOG.

-

A 0.75 CAN H AUTOG.

L-B 0.75 +15

R-N 0.75 +30 C-B 0.75 +15 ANTENNA

O012 O012a

1

1

2

3

2

120 Ω

L-B 0.75 +15

1

CAN-H AUX

SCH 1 RS232 GROUND

2

3

1

D014

-

C 0.75 CAN L AUTOG.

SCH 1 RS232 GROUND

G 0.5 RS232 RX

L-B 0.75 +15 MONITOR + MMI

L-B 1 +15 MONITOR+MMI M 1.5 GND

3

4

4

CAN-H AUX

CAN L VEHICLE

3

4

10 11 12

CAN-L AUX

CAN-H AUX

R-N 1 +30 MONITOR

2

5

16 17 18

CAN L VEHICLE C 0.75 CAN L AUTOG.

3

19 20 21

CAN H VEHICLE A 0.75 CAN H AUTOG.

4

6

13 14 15

R-N 1 +30 MONITOR

R-N 0.75 +30 A-B 0.5 MIC -

CAN-L AUX

V-G 1 +15 MONITOR + MMI M 1.5 GND

8

V 0.5 RS232 TX

7

CAN-L AUX

6

CAN-H AUX

16 17 18

M 1.5 GND

SCH-3

5

SA-2

-

G 0.5 RS232 RX

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

12 13 14 15

M 1.5 GND

4

CAN L VEHICLE CAN H VEHICLE -

3

CAN L VEHICLE CAN H VEHICLE CANH-12

D086 6 5 4 3 2 1

-

2

-

6 5 4 C-N 0.75 + ANTENNA COM 3 C-N 0.75 + ANTENNA COM 2 C-N 0.75 + ANTENNA COM 1

CANL-12 -

CAN L VEHICLE CAN H VEHICLE

M 1 GND

C-B 0.75 +15 ANTENNA

D072

1

D086b

R 1.5 +30

5 4 3 2 1

9 10 11

D060

14 13 12 11 10 9 8 7 6 5 4 3 2 1

L 0.75 +15 M 1.5 GND

SA-6

M 1 GND

M 1 GND

9 8 7 6 5 4 3 2 1

L0.5 CAN H VEHICLE B0.5 CAN L VEHICLE

-

B 0.5 RS232 GROUND

B 0.5 RS232 GROUND

D062

A-B 0.5 MIC -

M 2.5 GND

21 20 19 18 17 16 15 C-N 0.75 + ANT (MON/TECO IN) 14 A 0.5 MIC + 13 12 11 10

14 13 12 11 10 9 8 7 6 5 4 3 2 1

1 2

A 0.75 CAN H AUTOG. S 0.5 CUT OFF SUPPLY AG

V-G 1 +15 MONITOR + MMI

2

1

2 1

3

4

N012

6 5 4 3 2 1

D013

M010

4

O013 O013a

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ellow

R

Rosso/Red

H

Grigio/Gray

4

D0077870

Fig. 3882 - Agrosky - I-Monitor (2/2)

40-561

Wiring diagrams 40.4.46 - 0.019.9827.4/10 - Front work lights on cab roof - LED version with Agrosky D071 4

5

3

2

6 7

8

9

10

11

12

1

ANTENNA

N011

1 2

F035

2 1

ANTENNA

4 1 3 2

2 3

RH

1

1 2

1

9 10 11

4 3 2

4 3 2 1

F036

2 1

O013c 4 12 13 14 15 5 6 7

RH

8

16 17 18

7 8 9 10

6 5 4 3 2

11

1

12

P019

D059

1 2 3 4

1 2

3 4

5

6

9

2 1

13

2

5

2 1

12 4

2

11 14

6

1 1

8

2

9

3

10 11 4 5 6

12 13 14

D058 LH

7 8

6 5 4

9

3

10

2

11

1

12

40-562

10

1

456

CODE STAMPED ON CONNECTOR

ANTENNA

8

7

LH

D00778060

Fig. 3883 - Front work lights on cab roof - LED version with Agrosky (1/2) Table 689 LH RH

3

D060

123

P018

7

F034

2

F033

1

1 2 3 4

O013b

INTERCONNECTION CODE

D058 D059 D060 D071 F033 F034 F035 F036 N011 O013b O013b O013c P018 P019

DESCRIPTION

Wiring connector Wiring connector Wiring connector Wiring connector Left hand inner front work light (on cab roof) Left hand outer front work light (on cab roof) Right hand outer front work light (on cab roof) Right hand inner front work light (on cab roof) Windscreen wiper motor Not used Wiring connector CAN line termination connector LH rear view mirror RH rear view mirror

Wiring diagrams O013b 3 4

4

1

4

A 0.75 CAN-H AUTOG. 3

1

1 2

2

2

3

1 1

3

2

3

4

3

2

4

4

1

C 0.75 CAN-L AUTOG. 2

O013c

C 0.75 CAN-L AUTOG.

11 RS232 TX

D071

10 RS232 RX 9

B 1 SCH

8

C-N 0.75 + ANT

7

RS232 TX

-

A 0.75 CAN-H AUTOG.

12 C 0.75 + ANT.

SCH

10 11 4 5 6

12 13 14

7

N011

CAN-H1

4

1

3

2

8

6 5 4

9

3

10

2

11

1

12

4 5 6

12 13 14

1 2

2 7 8

6 5 4

9

3

10

2

11

1

12

7

6 5

8

4

9

3

10

2

11

1

12 1

8

10 11

2

7

3

1

6

16 17 18

9

2

5

2

1

12 13 14 15

8

2

4

1

1

3

7

2

D059

D058 6

14 13 12 11 10 9 8 7 6 5 4 3 2 1

5

G-R 0.5 COMAND MIRROR COMMON SMALL (LT) C-B 0.5 COMAND MIRROR DX/SX SMALL (LT) B-C 0.5 COMAND MIRROR UP/DOWN SMALL (LT) M 1 GND B 1 FRONT WORK LIGHT 1 M 1 GND B-N 1 FRONT WORK LIGHT 1 M 0.5 LED BAR G-N 0.5 LED BAR + Z 1.5 +15 MIRROR DEFROST M 1.5 GND MIRROR DEFROST R 0.5 COMAND MIRROR COMMON BIG (LT) M-B 0.5 COMAND MIRROR UP/DOWN BIG (LT) B-N 0.5 COMAND MIRROR DX/SX BIG (LT)

17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

2

M 1 GND MIRROR DEFROST BIG Z 1 +15 MIRROR DEFROST BIG M 1 GND MIRROR DEFROST SMALL SA-1 -Z 1 +15 MIRROR DEFROST SMALL M 0.5 LED BAR SA-2 G-N 0.5 LED BAR + G 0.5 COMAND MIRRORS UP\DOWN BIG (RH) R-N 0.5 COMAND MIRRORS DX/SX BIG (RH) C 0.5 COMAND MIRRORS COMMON BIG (RH) H-R 0.5 COMMAND MIRROR UP/DOEN SMALL (RH) M-C 0.5 COMMAND MIRROR SX/DX SMALL (RH) S-L 0.5 COMMAND MIRROR COMMON SMALL (RH)

18

S-L 0.5 COMMAND MIRROR COMMON SMALL (RH) M-C 0.5 COMMAND MIRROR SX/DX SMALL (RH) H-R 0.5 COMMAND MIRROR UP/DOEN SMALL (RH) Z 1.5 +15 MIRROR DEFROST C 0.5 COMAND MIRRORS COMMON BIG (RH) G 0.5 COMAND MIRRORS UP\DOWN BIG (RH) R-N 0.5 COMAND MIRRORS DX/SX BIG (RH) M 1.5 GND G-N 0.5 LED BAR + M 1 GND N-B 1 FRONT WORK LIGHT M 1 GND V-B 1 FRONT WORK LIGHT 1 L 1 +12 WIPER FRONT (53a) L-B 1 31b ZERO M 1 GND L-N 1 53 FRONT WIPER

1

12 11 10 9 8 7 6 5 4 3 2 1

4

2 1

M 1 GND N-B 1 FRONT WORK LIGHT

3

F034

2 1

2 1

2

F033

SA-4 M - 1 GND MIRROR DEFROST BIG Z 1 +15 MIRROR DEFROST BIG M 1 GND MIRROR DEFROST SMALL SA-3 Z 1 +15 MIRROR DEFROST SMALL M 0.5 LED BAR G-N 0.5 LED BAR + M-B 0.5 COMAND MIRROR UP/DOWN BIG (LT) B-N 0.5 COMAND MIRROR DX/SX BIG (LT) R 0.5 COMAND MIRROR COMMON BIG (LT) B-C 0.5 COMAND MIRROR UP/DOWN SMALL (LT) C-B 0.5 COMAND MIRROR DX/SX SMALL (LT) G-R 0.5 COMAND MIRROR COMMON SMALL (LT)

M 1 GND V-B 1 FRONT WORK LIGHT 1

1

P018

12 11 10 9 8 7 6 5 4 3 2 1

2 1

9 10 11

P019

1

F036

2

2

1

1

F035

L-N 1 53 FRONT WIPER M 1 GND L-B 1 31b ZERO L 1 +12 WIPER FRONT (53a)

1 2 3 4

S 0.75 CAN-H ISOBUS

3

Z 0.75 CAN-L ISOBUS

1

9

A 0.75 CAN-H AUTOG.

2

B 1 SCHV 0.5 RS232 TX G 0.5 RS232 RX C-N 0.75 + ANT

2

3

SCH-1 CAN-L1

8

SCH

-

1

-

7

CAN-H2

-

6

C 0.75 CAN-L AUTOG.

5

M 0.75 GND

4

4

RS232 RX

5

D060 3

6

-

2

CAN-L2

14 13 12 11 10 9 8 7 6 5 4 3 2 1

1

C 0.75 + ANT. G 0.5 RS232 RX V 0.5 RS232 TX Z 0.75 CAN-L ISOBUS S 0.75 CAN-H ISOBUS M 0.75 GND C 0.75 CAN-L AUTOG. A 0.75 CAN-H AUTOG.

SCH-2

M 1 GND B 1 FRONT WORK LIGHT 1

M 1 GND B-N 1 FRONT WORK LIGHT 1

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ellow

R

Rosso/Red

H

Grigio/Gray

D0078070

Fig. 3884 - Front work lights on cab roof - LED version with Agrosky (2/2)

40-563

Wiring diagrams 40.4.47 - 0.019.9828.4/10 - Front work lights on cab roof - Version with Agrosky D071 8

N011

9

12 11 10

1

7

2

3

4

5

6

ANTENNA

4

1

3

2

ante nna

F035

1 2

D059 RH 1 2 1

10

2

11

3

RH

9

F036

4 12 13 14 15 5 7 8

17 18

7 8 9 10

1

2

2

8 3

9

10

5 4 3 2 1

3 4

7 1

6

11 12

5

6

11 12 4

5

13

14

1

6

2

D060 D058

F034

LH

1 2

7 8 9

1 2 3

4 5 6

10 11 12 13 14

4 5 6

LH

1 2 3

7 8

6 5 4

9

3

10

2

11

1

12

P018

6

F033

16

P019

D0077990

Fig. 3885 - Front work lights on cab roof - Version with Agrosky (1/2) Table 690 CODE STAMPED ON CONNECTOR

LH RH

antenna

40-564

INTERCONNECTION CODE

D058 D059 D060 D071 F033 F034 F035 F036 N011 P018 P019

DESCRIPTION

Wiring connector Wiring connector Wiring connector Wiring connector Left hand inner front work light (on cab roof) Left hand outer front work light (on cab roof) Right hand outer front work light (on cab roof) Right hand inner front work light (on cab roof) Windscreen wiper motor LH rear view mirror RH rear view mirror

Wiring diagrams D071

12

C-B 0.75 + ANT

11

RS232 TX

10

RS232 RX

9

B 1 SCH

-

10 11 4 5 6

12 13 14

S 0.75 CAN-H ISOBUS

N011 4

1

3

2

7 8

6 5 4

9

3

10

2

11

1

12

12 13 14 15 5 6 7 8

16 17 18

1

8

2

9

3

10 11 4 5 6

12 13 14

6

7 8 9

6 5 4 3 2 1

12

7

6 5

8

4

9

3

10

2

11

1

12

2 M 1.5 GND 1 B 1.5 FRONT WORK LIGHT 1

1

4

7

5

2

3

D058 4

14 13 12 11 10 9 8 7 6 5 4 3 2 1

3

G-R 0.5 COMAND MIRROR COMMON SMALL (LT) C-B 0.5 COMAND MIRROR DX/SX SMALL (LT) B-C 0.5 COMAND MIRROR UP/DOWN SMALL (LT) M 1.5 GND B 1.5 FRONT WORK LIGHT 1 M 1.5 GND B-N 1.5 FRONT WORK LIGHT 1 M 1 LED BAR G-N 1 LED BAR + Z 1 +15 MIRROR DEFROST M 1 GND MIRROR DEFROST R 0.75 COMAND MIRROR COMMON BIG (LT) M-B 0.75 COMAND MIRROR UP/DOWN BIG (LT) B-N 0.75 COMAND MIRROR DX/SX BIG (LT)

M 0.75 GND MIRROR DEFROST BIG - SA-4 Z 0.75 +15 MIRROR DEFROST BIG SA-3 M 0.75 GND MIRROR DEFROST SMALL Z 0.75 +15 MIRROR DEFROST SMALL M 1 LED BAR G-N 1 LED BAR + M-B 0.75 COMAND MIRROR UP/DOWN BIG (LT) B-N 0.75 COMAND MIRROR DX/SX BIG (LT) R 0.75 COMAND MIRROR COMMON BIG (LT) B-C 0.5 COMAND MIRROR UP/DOWN SMALL (LT) C-B 0.5 COMAND MIRROR DX/SX SMALL (LT) G-R 0.5 COMAND MIRROR COMMON SMALL (LT)

D059 2

-

SA-1

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

1

M 0.75 GND MIRROR DEFROST BIG Z 0.75 +15 MIRROR DEFROST BIG M 0.75 GND MIRROR DEFROST SMALL Z 0.75 +15 MIRROR DEFROST SMALL SA-2 M 1 LED BAR G-N 1 LED BAR + G 0.75 COMAND MIRRORS UP\DOWN BIG (RH) R-N 0.75 COMAND MIRRORS DX/SX BIG (RH) C 0.75 COMAND MIRRORS COMMON BIG (RH) H-R 0.5 COMMAND MIRROR UP/DOEN SMALL (RH) M-C 0.5 COMMAND MIRROR SX/DX SMALL (RH) S-L 0.5 COMMAND MIRROR COMMON SMALL (RH)

2 M 1.5 GND 1 B 1.5 FRONT WORK LIGHT 1

1

F034

12 11 10 9 8 7 6 5 4 3 2 1

2

F033

2

1

P018

12 11 10 9 8 7 6 5 4 3 2 1

S-L 0.5 COMMAND MIRROR COMMON SMALL (RH) M-C 0.5 COMMAND MIRROR SX/DX SMALL (RH) H-R 0.5 COMMAND MIRROR UP/DOEN SMALL (RH) Z 1 +15 MIRROR DEFROST C 0.75 COMAND MIRRORS COMMON BIG (RH) G 0.75 COMAND MIRRORS UP\DOWN BIG (RH) R-N 0.75 COMAND MIRRORS DX/SX BIG (RH) M 1.5 GND G-N 1 LED BAR + M 1.5 GND N-B 1.5 FRONT WORK LIGHT M 1.5 GND V-B 1.5 FRONT WORK LIGHT 1 L 1.5 +12 WIPER FRONT (53a) L-B 1.5 31b ZERO M 1.5 GND L-N 1.5 53 FRONT WIPER

2 M 1.5 GND 1 N-B 1.5 FRONT WORK LIGHT

9 10 11

P019

1

10

F036

2 M 1.5 GND 1 V-B 1.5 FRONT WORK LIGHT 1

1 2

11

F035

L-N 1.5 53 FRONT WIPER M 1.5 GND L-B 1.5 31b ZERO L 1.5 +12 WIPER FRONT (53a)

1 2 3 4

B 1 SCH V 0.5 RS232 TX G 0.5 RS232 RX C-N 0.75 + ANT

3

1

-

9

Z 0.75 CAN-L ISOBUS

SCH-1

2

2

SCH

8

A 0.75 CAN-H AUTOG.

7

C 0.75 CAN-L AUTOG.

3

1

M 0.75 GND

4

6

5

D060 5

RS232 RX

4

RS232 TX

6

3

C-N 0.75 + ANT

7

2

8

14 13 12 11 10 9 8 7 6 5 4 3 2 1

1

C-B 0.75 + ANT G 0.5 RS232 RX V 0.5 RS232 TX Z 0.75 CAN-L ISOBUS S 0.75 CAN-H ISOBUS M 0.75 GND C 0.75 CAN-L AUTOG. A 0.75 CAN-H AUTOG.

SCH

SCH-2

2

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ellow

R

Rosso/Red

H

Grigio/Gray

D0078000

Fig. 3886 - Front work lights on cab roof - Version with Agrosky (2/2)

40.4.48 - 0.019.9829.4/20 - Agrosky antenna (Visual guidance)

D071 12 11 10 9 8 7

M009

1

6

7

5

8

2

9

3

3

10

4

2

11

5

1

12

6

4

D0077950

Fig. 3887 - Agrosky antenna (Visual guidance) (1/2) Table 691 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D071 M009

DESCRIPTION

Wiring connector “AGROSKY” Antenna 40-565

Wiring diagrams 12

G 0.5 RS232 RX

5

V 0.5 RS232 TX

4

C 0.75 CAN-L AUTOG.

3

A 0.75 CAN-H AUTOG.

2

C-N 0.75 + ANT

1

M 0.75 GND

6

-

SA-1

M 0.75 GND

5

C 0.75 CAN-L AUTOG.

4

A 0.75 CAN-H AUTOG.

3

6

7

6

5

M009

4

8

7

3

C-N 0.75 + ANT

8

D071 2

9

7

10

1

SCH-1

8

SCH-2

9

11

B 1 SCH

-

9

SCH

-

10

10

V 0.5 RS232 TX G 0.5 RS232 RX

12

M 0.75 GND

11

11

12

2 1

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gray

D0077960

Fig. 3888 - Agrosky antenna (Visual guidance) (2/2)

40.4.49 - 0.020.1009.4 - Front LH lower work lights on cab (USA)

F037

1 4 2 3

2

D030

1 D0057907

Fig. 3889 - Front LH lower work lights on cab (USA) (1/2) Table 692 CODE STAMPED ON CONNECTOR

LOW W.L. T.LIGHTS

40-566

INTERCONNECTION CODE

D003 D004 D030 F005 F005a F043

DESCRIPTION

Wiring connector Wiring connector Wiring connector LH sidelight LH sidelight Left hand repeater headlight

Wiring diagrams 1

D030

2 3

VR1 M1

1 2

4

F037

TABELLA COLORI / COLOURS TABLE

D0067700

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Viole

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

Fig. 3890 - Front LH lower work lights on cab (USA) (2/2)

40.4.50 - 0.020.1009.4 - Front RH lower work lights on cab (USA)

F038

1 4 2 3

2

D028

1 D0057906

Fig. 3891 - Front RH lower work lights on cab (USA) (1/2) Table 693 CODE STAMPED ON CONNECTOR

LOW W.L. T.LIGHTS

INTERCONNECTION CODE

D006 D007 D028 F003 F003a F044

DESCRIPTION

Wiring connector Wiring connector Wiring connector RH sidelight RH sidelight Right hand repeater headlight

40-567

Wiring diagrams 1

D028

2 3

VR1 M1

1 2

4

F038

TABELLA COLORI / COLOURS TABLE

D0058404

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

Fig. 3892 - Front RH lower work lights on cab (USA) (2/2)

40.4.51 - 0.020.1026.4/10 - LH front supplementary work light on arm (U.S.A.)

F037

2 1 1

2

D029a 1

2

D029 2 1

2

4

3

1

2

1

D030

2 1

2 1

F006 D0078041

Fig. 3893 - LH front supplementary work light on arm (U.S.A.) (1/2) Table 694 CODE STAMPED ON CONNECTOR

40-568

INTERCONNECTION CODE

D029 D029a D030 F006 F037

DESCRIPTION

Wiring connector Wiring connector Wiring connector LH turn indicator Lh front work light (on arm)

Wiring diagrams 2

M 1.5 GND

1

D029

2

2

B 1.5 FRONT LOW W.L.

1

4

3

1

2

4

A 1 HAZARD RH (USA)

3

M 1.5 GND SA-1

2

1

1

D030

B 1.5 FRONT LOW W.L.

2

M 1 GND

1

F006

2

2

A 1 HAZARD RH (USA)

1

1

B 1.5 FRONT LOW W.L.

1

M 1 GND

B 1.5 FRONT LOW W.L.

2

M 1 GND

1

1

2 1

1

2

2

F037

2

D029a

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ellow

R

Rosso/Red

H

Grigio/Gray

D0078051

Fig. 3894 - LH front supplementary work light on arm (U.S.A.) (2/2)

40.4.52 - 0.020.1026.4/10 - RH front supplementary work light on arm (U.S.A.)

F038

2 1 1

2

D027a 1

2

D027 2 1

2

4

3

1

2

1

D028

2 1

2 1

F004 D0078040

Fig. 3895 - RH front supplementary work light on arm (U.S.A.) (1/2) Table 695 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D027 D027a D028 F004 F038

DESCRIPTION

Wiring connector Wiring connector Wiring connector RH turn indicator Rh front work light (on arm) 40-569

Wiring diagrams 2

M 1.5 GND

1

D027

2

2

B 1.5 FRONT LOW W.L.

1

4

3

1

2

4

A 1 HAZARD RH (USA)

3

M 1.5 GND SA-1

2

1

1

D028

B 1.5 FRONT LOW W.L.

2

M 1 GND

1

F004

2

2

A 1 HAZARD RH (USA)

1

1

B 1.5 FRONT LOW W.L.

1

M 1 GND

B 1.5 FRONT LOW W.L.

2

M 1 GND

1

1

2 1

1

2

2

F038

2

D027a

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ellow

R

Rosso/Red

H

Grigio/Gray

D0078050

Fig. 3896 - RH front supplementary work light on arm (U.S.A.) (2/2)

40.4.53 - 0.020.5056.4 - Brake hydraulic system pressure sensor - 60 km/h

1 2

4 3

D090

4 1

2 3

K039

D0077930

Fig. 3897 - Brake hydraulic system pressure sensor - 60 km/h (1/2) Table 696 CODE STAMPED ON CONNECTOR

40-570

INTERCONNECTION CODE

D090 K039

DESCRIPTION

Wiring connector Brake hydraulic system pressure sensor - 60 Km/h

Wiring diagrams 4

M 0.75 GND

3

B 0.75 TW6 CAN-H

2

L 0.75 TW6 CAN-L

1

V-B 0.75 +12

1 2

4 3

D090

M 0.75 GND

2

V-B 0.75 +12

1

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ellow

R

Rosso/Red

H

Grigio/Gray

2

TABELLA COLORI / COLOURS TABLE

K039 1

3

3

4

4

CAN-L CAN-H

D0077940

Fig. 3898 - Brake hydraulic system pressure sensor - 60 km/h (2/2)

40.4.54 - 0.020.8658.4 - Side instrument panel

I003

I001

RIGHT 1

I004

3

1

7

4

2

2

6

3

1 4

G006

2 1

5A

3B

2B 3A

1C

1B

1D 3D

6A 5D

8A

6 5 4 3 2 1

7D 8D

8C

8B

6D 7C

6C 7B

6B 7A

4D 5C

4C 5B

4B 5A

2D 3C

2C 3B

2B 3A

1C

1B

TOP LH

C003

RH

ICE RV 4

1

STOOL

1

4 5 6 1 2 3

AMBIENT SX

LO W LT

6 5 3 4 2 1

FR

1

4

2

3

2

4

3

O003a

1

1

K002

1

3

2

2

2

FR LOWLT

Ω

1

2

2

2

D003

120

AMBIENT SX

1

3

P001

C003a

STOOL

1

D010

O003

1

2

SE

1A

2A

4A

6A

8A

B

2

94 72 50

28

1A

2A

1

7A

2C

1

6B

3C

2

6C 7B

2D

4A

2

7C

4B

3

14 16 13 15 10 12 9 11 8 7

6D

5B

A

8B

4C

B

8C

5C

1A 1B 1C 1D 2A 2B 3A 2C 2D 3C 3B 1A 3D 4A 1B 4B 4C 5B 5A 2A 4D 5C 2B 3A 5D 2C 6A 2D 3C 3B 6B 7A 6C 3D 4A 6D 7C 7B 4B 7D 4C 5B 5A 8A 4D 5C 8B 8C 5D 6A 8D 6B 7A 6C 6D 7C 7B 7D 8A 8B

1C

7D 8D

4D

A

1D 3D 5D

8C

D007

3

4

2

1D

D009

RH

8D

FR LOW

G007

6

3 1

1 2

2

K001

73 51

29

7 4 3

1

TOP LH RH

SERVICE 5

FR LOWRH

3

1 14 1

15 2

16

3

17 4

13

18 5

19 6

20 7

21 8

22 9

23 10

24

11

25 12

26

1

13

31

21

32

11

22

1

33

12

23

2

34

13

24

3

35

14

25

4

10

36

15

26

5

37

16

27

6

38

17

28

7

39

18

29

8

40

19

30

9

DX

18 20 22 17 19 21

20

T

10

EN BI

P002

M003

D008 A

AM

D001

E003

D006

4

1

AMBIENT DX

4

2

E002

B

6

6 5 4 3 12 11 10 9

1

1

LEFT

T

FT

7

2

RI GH

LE

2

E001 8

3

5

4

P TO LH LT

D004

PET

LH

K003

O002

To sheet 2

2

CAR

1

4 3 2

4

1 4

22 1

3

2

1

1

8D 8C

7D 6D

91 57

74

2D

40

23

5A 4A

3B 2B

1C

7A 6A

5B 4B

3C 2C

1D

8A

7B 6B

5C 4C

8B

7C 6C

5D 4D 3D

3A 2A

1B

6

24 41 4

3

1

2

7

5

M002a

58

75

1A

1 41 7 013 16 2 5 81 1 14 17 3 61 9 2 1518

21

42

63

84

D012

O002a

105

CARPET LH

43

2

4

F001

85 64

1

Ω

3

2

2

I002

1

3

TOP LH LT

120

M002 INE ENG

3

2

2

1

1

16 13 10 14 17 11 1518 9 12 8

6

ENGINE

4

3

2

3

3

1

120 Ω

7

2

1

2

5

3

4

O001

4

1

4

M001

O001a

1 4 2 5 7 10 3 6 8 11 13 9 12 14 15

9

8

7

6

5

4

3

2

1

15

14

13

21

20

19

12

11

10

18

17

16

27

26

25

33

32

31

24

23

22

30

29

28

42

41

40

39

38

37

36

35

D011

1 4 7 1013 16 2 5 8 1114 17 3 6 9 12 1518

M001b

34

M001a

4

M001c

D0077590

Fig. 3899 - Side instrument panel (1/3)

40-571

Wiring diagrams Table 697 CODE STAMPED ON CONNECTOR

F3-1 F3-2 F3-3 F3-4 F3-5 F3-6 F3-7 F3-8 F3-9 F3-10 F1-A-1 F1-A-2 2 F1-A-3 F1-A-4 F1-A-5 F1-A-6 F1-A-7 F1-A-8 F1-A-9 F1-A-10 F1-A-11 F1-A-12 F1-A-13 F1-A-14 F1-A-15 F1-A-16 F1-A-17 F1-A-18 F1-A-19 F1-A-20 F4-1-4 F4-2-5

INTERCONNECTION CODE

DESCRIPTION

Ba001 Ba002 Ba003 Ba004 Ba005 Ba006 Ba007 Ba008 Ba009 Ba010 Bb001 Bb002 Bb003 Bb004 Bb005 Bb006 Bb007 Bb008 Bb009 Bb010 Bb011 Bb012 Bb013 Bb014 Bb015 Bb016 Bb017 Bb018 Bb019 Bb020 Bc001 Bc002

15A Fuse - Lights fuse and power outlet socket (F3/1, +30) 3A Fuse - Work Display Fuse (F3/2, +30) 7.5A Fuse - Air conditioning compressor fuse (F3/3) 5A fuse - Tierra fuse (F3/4, +30) 15A Fuse - Rear work light fuse (F3/5) 15A Fuse - Rear work light fuse (F3/6) 5A fuse - Tierra fuse (F3/7, +15) 5A fuse - Fuse (F3/8, +15) 7.5A Fuse - Air conditioning fuse (F3/9, +15) 15A Fuse - U.S.A. trailer lights fuse (F3/10, +15) 10A Fuse - ISO 11786 (F1-A/1, +15) 5A Fuse - EPB (F1-A/2, +15) 15A Fuse - Windscreen wiper (F1-A/3, +15) 3A Fuse - Cluster (F1-A/4, +15) 7.5A Fuse - HLHP control unit (F1-A/5, +15) 7.5A Fuse - Pneumatic seat (F1-A/6, +15) 7.5A Fuse - Engine (F1-A/7, +15) 15A Fuse - EU/USA emergency lights (F1-A/8, +15) 3A Fuse - iMonitor + MMI (F1-A/9, +15) 3A Fuse - ISOBUS 11783 (F1-A/10, +15) 7.5A Fuse - Rear view mirrors (F1-A/11, +15) 10A Fuse - Rear windscreen wiper (F1-A/12, +15) 15A Fuse - Brake lights (F1-A/13, +15) 3A Fuse - Work light display (F1-A/14, +15) 5A Fuse - Transmission (F1-A/15, +15) 7.5A Fuse - Radar/PTO/distributors (F1-A/16, +15) 5A Fuse - SGR Transmission (F1-A/17, +15) 5A Fuse - Radio (F1-A/18, +15) 7.5A Fuse - External electric power outlet sockets (F1-A/19, +15) 3A Fuse - Ignition key (F1-A/20, +15) 20A fuse - Webasto (heater) (F4/1-4, +30) 20A Fuse - Low rear work light relay protection (F4/2-5, +30)

INTERCONNECTION CODE

DESCRIPTION

Table 698 CODE STAMPED ON CONNECTOR

F4-3-6 F4-8-11 F4-13-14 F4-17-18 R6-1-5 R6-2-6 R6-4-8 F1-B-1 F1-B-2 F1-B-3 F1-B-4 F1-B-5 F1-B-6 F1-B-7 F1-B-8 F1-B-9 F1-B-10 F1-B-11 F1-B-12 F1-B-13 F1-B-14 F1-B-15 F1-B-16 F1-B-17 40-572

Bc003 Bc008 Bc013 Bc017 Be001 Be002 Be004 Bf001 Bf002 Bf003 Bf004 Bf005 Bf006 Bf007 Bf008 Bf009 Bf010 Bf011 Bf012 Bf013 Bf014 Bf015 Bf016 Bf017

20A Fuse - Seat/brakes (F4/3-6, +15) 20A Fuse - Rear defrost (F4/8-11) 30A fuse - Heating unit (F4/13-14, +30) 40A Fuse - Heating system (F4/17-18, +30) 15A Fuse - Front work lights (R6/1-5) 15A fuse - ABS trailer socket (R6/2-6, +15) 15A Fuse - Front work lights (R6/4-8) 7.5A Fuse - SGR Transmission (F1-A/1, +30) 7.5A Fuse - Air conditioning system fuse (F1/2, +30) 5A Fuse - Transmission control unit (F1-B/3, +30) 15A Fuse - Turn indicator relay protection (F1-B/4, +30) 15A Fuse - Armrest (F1-B/5, +30) 5A Fuse - Radio (F1-B/6, +30) 15A Fuse - Lights relay protection (F1-B/7, +30) 15A Fuse - iMonitor (F1-B/8, +30) 15A Fuse - Lights relay protection (F1-B/9, +30) 7.5A Fuse - Left hand sidelights (F1-B/10, +30) 5A Fuse - Road lights/Top lights relay protection (F1-B/11, +30) 5A Fuse - Lights (F1-B/12, +15) 7.5A Fuse - Right hand sidelights (F1-B/13, +30) 15A Fuse - Sidelights relay protection (F1-B/14, +30) 3A Fuse - Cab lights (F1-B/15, +30) 15A Fuse - Ignition key (F1-A/16, +30) 10A Fuse - Hitch relay protection (F1-B/17, +30)

Wiring diagrams CODE STAMPED ON CONNECTOR

F1-B-18 F1-B-19 F1-B-20 F2-1-4 F2-2-5 F2-3-6 F2-7-10

INTERCONNECTION CODE

DESCRIPTION

Bf018 Bf019 Bf020 Bm001 Bm002 Bm003 Bm007

15A Fuse - Work light display (F1-A/18, +30) 5A fuse - Webasto (thermo call) (F1-B/19, +30) 15A Fuse - Trailer lights relay protection (F1-B/20, +30) 20A Fuse - Tractor electric power outlet sockets (F2/1-4, +30) 20A Fuse - Cab electric power outlet sockets (F2/2-5, +30) 20A Fuse - HLHP control unit (F2/3-6, +30) 20A Fuse - EU/USA emergency lights (F2/7-10, +30)

INTERCONNECTION CODE

DESCRIPTION

Table 699 CODE STAMPED ON CONNECTOR

F2-8-11 F2-9-12 F2-13-14 F2-15-16 F2-17-18

FR LOW LT TOP LH LT FR LOW RH TOP LH RH STOOL ISO BUS MON MMI ISO 11783

Bm008 Bm009 Bm013 Bm015 Bm017 C002 C003 C003a C003b D001 D002 D003 D004 D006 D007 D008 D009 D010 D011 D012 D013 D014 D014a D015

20A Fuse - Front work lights relay protection (F2/8-11) 20A Fuse - Steering (F2/9-12, +30) 30A Fuse - Engine (F2/13-14, +30) 40A Fuse - Ignition key relay protection (F2/15-16) 40A Fuse - Ignition key relay protection (F2/17-18) Engine ground Cab ground Cab ground Cab ground Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector

INTERCONNECTION CODE

DESCRIPTION

Table 700 CODE STAMPED ON CONNECTOR

A/C ISO 11786 EU CONF.

USA CONF. WEBASTO

TIERRA EXTER.LIGHT

CARPET LH

D015a D016 D021 D022 D023 D024 D025 D026 D046 D068 D073 D074 D075 D076 D077 D077a D078 D079 E001 E002 E003 F001 G001

Configuration connector Wiring connector Wiring connector Configuration connector Wiring connector Wiring connector (yellow) Wiring connector (brown) Wiring connector Wiring connector Configuration connector Wiring connector Wiring connector Wiring connector Wiring connector Configuration connector Configuration connector Wiring connector Wiring connector Instrument panel Instrument panel Work Display LH carpet light Cab courtesy light 40-573

Wiring diagrams CODE STAMPED ON CONNECTOR

AMBIENT RH AMBIENT LH

INTERCONNECTION CODE

DESCRIPTION

G001a G006 G007 H001 H001a H002

Cab courtesy light Right hand ambient light Left hand ambient light Armrest Armrest Work light switch

INTERCONNECTION CODE

DESCRIPTION

Table 701 CODE STAMPED ON CONNECTOR

I001 I002 RIGHT I003 LEFT I004 I006 SWITCH COM I007 LIGHT SW I008 TOP SW I009 PTO SEL I010 LIFT SW I011 SUSP. CAB I012 +15 KEY Ja001 LIFT SERVICE W.L. Jd001 REAR WINDOW DE- Jd003 FROST HALF BEAM LAMBO- Jd006 RGHINI REAR ROFF W.L. Je001 FRONT ROFF W.L. Je002 FRONT LOW W.L. Jg001 AUX TRAILER W.L. Jg002 REAR LOW W.L. Jg003 HYDRAULIC TRAILER Jg004 BRAKE BEACON Jg006 NORMAL/TOP FULL Jh001 BEAM BRAKE Jh002 NORMAL/TOP HALF Jh003 BEAM FULL BEAM Jh004 POSITION Jh005 HALF BEAM Jh006 +15 KEY Jn001 FRONT WIPER Jn002

Hazard warning lights switch Switch for courtesy lights on the steps RH brake pedal switch LH brake pedal switch Starter switch Safety switch Road lights switch Top lights switch PTO selector switch Rear hitch control switch Semi-active cab control switch Ignition key relay (F3/1) Hitch service light relay (R4/1) Rear defrost relay (R4/3) Same bonnet relay (R4/6) Relay for front work lights on cab roof (R6/1) Relay for rear work lights on cab roof (R6/2) Relay for low front work lights (R1-A/1) Relay for trailer electrical power outlet sockets (R1-A/2) Relay for low rear work lights (R1-A/3) Trailer braking relay (R1-A/4) Lights relay (R1-A/6) Road lights/Top lights relay (R3/1) Brake lights relay (R3/2) Road lights/Top lights relay (R3/3) High beam relay (R3/4) Sidelights relay (R3/5) Low beam relay (R3/6) Ignition key relay (R7/1) Front windscreen wiper relay (R7/2)

Table 702 CODE STAMPED ON CONNECTOR

40-574

INTERCONNECTION CODE

K001 K002 K003 K004 M001 M001a M001b M001c M002 M002a M003 M003

DESCRIPTION

Clutch pedal pressed proximity sensor Clutch pedal position sensor Accelerator pedal position sensor Operator present sensor Transmission control unit Transmission control unit Transmission control unit Transmission control unit Engine control unit Engine control unit HLHP unit HLHP unit - USA version

Wiring diagrams CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

DESCRIPTION

M004 N013 O001 O001a O002 O002a O003 O003a O004 O004a O005 P001 P002 P003 P004 R001 R002

Engine

CAN AUX

Hazard lights flasher unit Pneumatic seat compressor CAN line termination connector CAN line termination connector CAN line termination connector CAN line termination connector CAN line termination connector CAN line termination connector CAN line termination connector CAN line termination connector Diode and resistance board LH front loudspeaker RH front loudspeaker Auxiliary cab power outlet socket (25A) Power outlet socket in cab Diagnostic socket CANBUS diagnostic connector D023 5

4

11

D076

10 9

12 11

3

8

10

2

7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

12

6

9

1

H001a

8 7 6

D075

4 3 2 1

H001

1

2

3

4

5

6

7

8

9

G001

10 11 12 13 14 15 16 17 18 19 20 21

2

2

1

N013

1

G001a

3 2

K004

1 3 2 1

P003

9

8

7

6

1 2

D046

2

11

9 4

HT IG

4

3

10 9

8

7

2

1

6

5

8

1

2

SUSP. CAB

7 4 5 8

6 1

9

5

4

6

3

10

2

1

7 7

5

6

4 1

2

3

9

8

WEBASTO

10

8

I010

SUSP. CAB

LIFT SW

I011 I012

3

9 10 11 12 13 14

9

2 3 10

PTO SEL

D073

ISO 11786

1 2 3 5 6 7

L

LIFT SW

CLIMA

D021

P004

SE

4

4

PT O

EXTER. LIGHT

CLIMA

13 7 10 1 4 8 1114 2 5 9 12 15 3 6

2 1

MA B L N PC KUV RD J T S E HG F

4

3

12 5

11

R.L

10

TE

D079

D016 R002 R001

EX

12

8

3

7

6

10

1

D026

4 3 2 1

D074 I007

3

2

2

2

1

1

1

O004a

4

3

3

4

4

4

CAN AUX

SWITCH COM

20

1

2

3

3

SWITCH COM

17

7

NF. CO

18

8

19

9

EU

10

1

2

11

3

12

4

5

13

14

15

16

6

CAN AUX

4

D022

O004 2

6

1

78

See diagram B

120Ω

11

TO BAS WE

IS O

See diagram A

To sheet 1

EU CONF.

US 1 2

3

NF A CO

D068

2

3 2

1

30 P X 7 4

5

9

6

7 8

2

3

10

1

8

9 12

6

8

5

2

4

1

3

7

11 10

15 14 13

18 17 16

21 20 19

6

3

5

2

4

1

9 12 8 7

11 10

15 14 13

18 17 16

21 20 19

S 12 11 9 10 5

4

8 3

7 2

6 1

10 1 2

4

9

8

20

19

7

18

6

17

16

9

15

8

14

7

5 4

50 15

1

21 9

19 7

13 1

15 3

14 2

16 4

17 5

18 6

23 11

24 12

22 10

20 8

4 8 6

5

7

6

3

2

1

5

4 3

2

1

8 7 6 18 17 16 14 13 6

5

4

10 12 11

9

I009 TOP SW

LIGHT SW

8 3

2

7 1

15 14 13 12

11 10 4

3

2

9 1

5

MON MMI

D024 D025 I008

4

3

D014

H002

2

6

TIERRA

5

2

3

TOP SW

LIGHT SW

I006

3

5

ISO BUS

1178

TIERRA

D078

MON MMI

ISO

ISO 11783

4

3

2

1 1

AMP 2 3

2

4

4

D013 ISO BUS

3

1

D077a

O005

6

5

13

6

3

12

4

11

1

1

D015 D015a

5

4

M004 D002

6

5

4

3

.

USA CONF.

C003b

C002

1

1

AMP 2 3

2

4

4

2

1

D014a 4

3

3

D077

D0077600

Fig. 3900 - Side instrument panel (2/3)

40-575

Je001

Jd001

Je002 15A 3

15A

Ja001

Bc003

Bc001

Jd003

Jd006

Be001 Be002

Fig. 3901 - Side instrument panel - Fuse box (3/3) See diagram B 2

Jg001

Jn001 +15 KEY

Jg002

Jg004

20A 20A

20A 20A

2

20A 20A

FRONT WIPER

Bc008 Bc002 Jh001 Jh002 Jh003

Jh004 Jh005 Jh006

2

1

K1

HALF BEAM CAN BRIDGE ISOBUS

4

DIODES ISOBUS

NORMAL/TOP HALF BEAM

CAN BRIDGE ISOBUS

POSITION

1

R1-A

11

20

10

1

1

5

4

3

2

1

8

7

6

5

7.5A

15A

5A

5A

7.5A

3A 15A

15A 15A

15A

15A

5A

10A

5A

15A

5A 15A

7.5A

15A

F1-B

F3

15A

11

20

10

9

8

7

6

K2

7.5A

5A

5A

15A

7.5A

15A

5A

7.5A

3A

15A

DIODES ISOBUS

REAR LOW W.L.

5

6 2

BRAKE

R3

7.5A

10A

15A

3A

5A

7.5A

5A

5A

7.5A

3A

3

3

6

5

F2

3

3

2

2

F1-A

3A

BEACON

6

R7

1

9 6

10

HYDRAULIK TRAILER BRAKE 5

1

HALF BEAM LAMBORGHINI 8 5

FULL BEAM

7 4

12

NORMAL/TOP FULL BEAM

11

13

4

30A

3

1

10

14

15

F4

2

3A

15A

7.5A

7.5A

7.5A

3A

15A

5A

10A

AUX TRAILER W.L.

Bf010 Bf011

7

2

Bf008 Bf013 Bf009 Bf012

6

FRONT LOW W.L

Bf006 Bf015 Bf007 Bf014

1

4

Bm013

15A

40A

171

1

20A

Bf003 Bf018

5

1

Bf004 Bf017 Bf005 Bf016

REAR WINDOW DEFROST

40A

3

16

18

6

R4

20A

Bm015

8

Bf001 Bf020 Bf002 Bf019

FRONT ROFF W.L. 6

9

12

20A

Bm017

2 5

8

11

1

+15 KEY

R6

5 4

7

10

30A

40A

20A

Bb010 Bb011

2

Bb009 Bb012

LIFT SERVICE W.L.

Bb008 Bb013

Bb007 Bb014

REAR ROFF W.L.

Bb006 Bb015

1

Bb005 Bb016 Ba005 Ba010

4

Bb004 Bb017 Ba004 Ba009

1

Bc013

Bb003 Bb018 Ba003 Ba008

Bb002 Bb019 Ba002 Ba007

Bb001 Bb020 Ba001 Ba006

13

Bc017

14

15

17

40-576 16

18

2.9939.503.0/10

1

4

3

2

Wiring diagrams

4

See diagram A

Jg003

Jg006

Bm009 Bm003

Bm008 Bm002

Bm007 Bm001

Jn002

Be004

D0077670

Wiring diagrams 40.4.55 - 0.020.8664.4 - RH transmission

A001a D+

K029

K030

FZW SPEED 3

1 2 3

D043

K024 WEBASTO

L017

4

3

2

D044 6

5

4

3

2

6

5

4

3 2 1

5

2

1

2

1

4

3

2

1

1

CO.PA.

2

DR HY

SW

3

2

TEM. SENS.

1

TEM.SENS.

K027 OIL F.P.

OIL F.P. 2

2

SA

U

1

1

PTO RATIO

3

K025

1

K028

CO.PA.

1

C002

2

USA

5

EV FZW

1

D042

PTO RATIO

HYDR SW

EV FZW

P014

2

1

1

2

A

3

D045

1

7

6

10 11 12

T

3

3

9 4

1

5

8

2

8 5

2

4

1

12 11 10 9

7 6

PO S FRON

FZWEED SP

WEBASTO

2

D093

3

D093a

D+

2

1

POS FRONT

T AF DR GHT RI

R

3

B

R 2

2

BR BO AK. DY

2

1

2

3

2

3

1

1

2

3

4

1

K020

R SG

1

A C

B 1

2

3

4

LIMP

RADAR

2

1

HYDRY

M006 STEER

BRAK. BODY

3

1

3A 3B 3C 3D

4A 4B 4C 4D

7A 7B 7C 7D

2A 2B 2C 2D

6A 6B 6C 6D

5A 5B 5C 5D

8A 8B 8C 8D

1A 1B 1C 1D

3A 3B 3C 3D

4A 4B 4C 4D

7A 7B 7C 7D

K022

D039

AIR

6A 6B 6C 6D

A

K026

F

DIF

2A 2B 2C 2D

EV DOWN

EV

5A 5B 5C 5D

P

D008

RADAR

L008

1A 1B 1C 1D

8A 8B 8C 8D

LIM

HYDRY

AIR

EV DO WN

A

3

2

1

3

2

1

DRAFT RIGHT

1

D038

D040

L005

CABIN

1 9

2 3 4

10

5

11

6

12

7

13

8

14

15

16

1 2

IA

3

2

1

2

3

2

1

K023

4 5 6 7 3

EV PTO

SS

PO RE S. AR

RU

K021 STEER

13 14

EV DIFF

8 9 10 11 12

CABIN

D041

M005 SGR

RUSSIA

EV PTO

POS. REAR

D0077630

Fig. 3902 - RH transmission (1/2) Table 703 CODE STAMPED ON CONNECTOR

R CABIN HYDRY EV PTO EV DIFF USA PTO RATIO CO.PA. EV FZW WEBASTO LIMP STEER BRAK.BODY POS. REAR HYDR SW DRAFT RIGHT

INTERCONNECTION CODE

A001a C002 D008 D038 D039 D040 D041 D042 D043 D044 D045 D093 D093a K020 K021 K022 K023 K024 K025

DESCRIPTION

Alternator “D+” Engine ground Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Not used Not used Steering system pressure switch Brakes circuit pressure sensor Rear lifter position sensor Not used Lift draft sensor (RH) 40-577

Wiring diagrams INTERCONNECTION CODE

2

M 1 GND

1

H-N 1 EV. EPB

K027

1

2

3

R 1

4

5

R 1

1

L 1

6L

7

9

8

8

9

7

10

6

L 1 X174/B_D4 +15 WEBASTO RELAYS

11

5

L 1 DENSO ECU

12 4

A-V 1 DENSO FANS RELAY COILS

11

3

L 1 X174/B_C1 +15 CLIMA DENSO WEBASTO

M 2.5 GND 10

2

R 1 +30 CLIMA DENSO/ WEBASTO

1

A-G0.75 OIL TEMP.SENSOR M-N0.75 GND COM

2

1

1

M-N0.75 GND COM V-G1 FRONT HITCH POSITION C0.75 5V HLHP XLF

M0.75 GND FRONT PTO V0.75 FRONT PTO EV

1

M-B 1.5 +15 ISO

2

1

H-R1.5 +30 DIN 2 H-R1.5 +30 DIN 2

3

1

M2.5 GND EXTERNAL SOCKET

12

B_C1

R 1 +30 CLIMA DENSO/ WEBASTO B-R1 EV PTO 1000 Z-R1 EV PTO 1400 A-G0.75 OIL TEMP.SENSOR M-N0.75 FRONT PTO SPEED SENSOR Z0.75 BUZZER A-R0.75 HYDRAULIK PRESS.SW

B_A8

B_C6 B_C5

D008

B_C4 B_C3 B_C2 B_B8 B_B7 B_B6 B_B5 B_B4 B_B3 B_B2 B_B1 B_A7 B_A6 B_A5 B_A4 B_A3 B_A2 B_A1 A_D8 A_D7

3A 3B 3C 3D

A_D6 A_D5 A_D4 A_D3 A_D2

4A 4B 4C 4D

A-G1 OIL FILTER PRESSURE C0.75 STEERING CIRCUIT PRESSURE L1 D+ R-L0.75 EV DF M-B0.75 GNDCOM BRAKES BODY

R-L0.75 EV DF M0.75 EV REAR PTO PROP.

B_C7

7A 7B 7C 7D

SA-1

C-B0.75 EV DOWN Z-N0.75 EV DOWN+

B_C8

6A 6B 6C 6D

SA-4

B_D1

2A 2B 2C 2D

SA-5

B_D2

5A 5B 5C 5D

R 1.5 +30 WEBASTO (HEATER) R 1.5 +30 WEBASTO (HEATER) V0.75 FRONT PTO EV C-L0.75 EV REAR PTO PROP. B-G0.75 TRANSM.PEDAL SW DIG. CLUTCH C-B0.75 EV DOWN B-V1 +15 RADAR/PTO SENSOR/DISTR. B0.75 EV PTO 750 H-R1.5 +30 DIN 2 Z-B0.75 RADAR SIGNAL

B_D3

1A 1B 1C 1D

1

L 1 X174/B_C1 +15 CLIMA DENSO WEBASTO L 1 DENSO ECU M-L 1 THERMO CALL 85 V-R1 SPEED PTO SIGNAL USA R-G0.75 ISO SGR A0.75 DIRECTION LEFT G-N0.75 +58 S0.75 CONFORT PK DW S-G0.75 CONFORT PK UP

B_D4

2A 2B 2C 2D

1

4

B_D5

1A 1B 1C 1D

M-B 0.75 RUSSIA KIT

B_D6

8A 8B 8C 8D

2

6

3

B_D7

3A 3B 3C 3D

1

7

5

2

B_D8

A-V 1 DENSO FANS RELAY COILS H-N 1 EV TRAILER EPB L 1 X174/B_D4 +15 WEBASTO RELAYS H-N0.75 AIR A-N0.75 DIRECTION RIGHT V-L1.5 +12 VOLT TRAILER BRAKE A-N0.75 TRAILER LIGHT (HYDR.) V-B0.75 DUMPER RIGHT R-B1 DUMPER RIGHT + R-L0.75 DUMPER LEFT L-N0.75 DUMPER LEFT + C-L0.75 LINEAR SENSOR LEFT L0.75 LINEAR SENSOR RIGHT

SA-6

2

8

1

SA-2

4A 4B 4C 4D

2

1

7A 7B 7C 7D

1

2

6A 6B 6C 6D

2

12 11 10 9

1

2

5A 5B 5C 5D

1

D093a

1

B

1

2

A

1 2 3

1 2 3

2

3

1

V-R1 SPEED PTO SIGNAL USA M0.75 GND PTO SENSOR B-V1 +15 PTO SENSOR

3

10 11 12

4

M-L 1 THERMO CALL 85

A-R0.75 HYDRAULIK PRESS.SW

9

5

S-L 1 THERMO CALL 86/30

1

8

6

R 1.5 +30 WEBASTO (HEATER)

Z-G1 +5v HLHP STRAINGHT H-N0.75 RIGHT DRAFT SIGNAL M-N0.75 GND COM

1

7

R 1.5 +30 WEBASTO (HEATER)

1

2

D093

1

2

1 2

2

3

2

8A 8B 8C 8D

A_D1 A_C8 A_C7 A_C6 A_C5 A_C4 A_C3 A_C2

G0.75 BRAKES BODY +5V H-N0.75 RIGHT DRAFT SIGNAL

A_C1 A_B8

1

2

3

2

1

A_B7 3 2

3

1

L005 L008 D041

1

2

2

1

K023 D040

H-N0.75 AIR

3

2

L017

1

3

3

2

1

K026 K025 K024 D042

2 1

1

1

1

2

M1 GND

2

3

A-G1 OIL FILTER PRESSURE

3

2

K030 A001a

1

VISTA A

2

A

1 3

M0.75 GND FRONT PTO 1 M-N0.75 FRONT PTO SPEED SENSOR 2 B-V1 +15 FRONT PTO 3

P014

L1 D+

K029

SGR RADAR RADAR

Compressed air pressure sensor Oil tank filter clogging sensor Oil temperature sensor Front hitch position sensor Front PTO speed sensor Not used Rear lift DOWN control solenoid valve “EPB” solenoid valve Internal transmission control unit Radar Radar Auxiliary power outlet socket (30A)

K028

K026 K027 K028 K029 K030 L005 L008 L017 M005 M006 M006 P014

2

AIR OIL F.P. TEM.SENS. POS FRONT FZW SPEED RUSSIA EV DOWN

DESCRIPTION

D045

CODE STAMPED ON CONNECTOR

1

R-V0.75 REAR HITCH POSITION C0.75 5V HLHP XLF M-N0.75 GND COM

SA-3

C-L0.75 EV REAR PTO PROP. M0.75 GND EV PTO

G-N0.75 +15 TRANSMISSION SGR R-N0.75 +30 SGR R-V0.75 REAR HITCH POSITION Z0.75 CAN H SGR C0.75 CAN L SGR L0.75 BRAKE SENSOR

A_B6

M-B 1.5 +15ISO/RUSSIA KIT C0.75 5V HLHP XLF M-N0.75 GND COM Z-G1 +5v HLHP STRAINGHT V-G1 FRONT HITCH POSITION

A_A8

S-L 1 THERMO CALL 86/30 Z-N0.75 EV DOWN+ H-R1.5 +30 DIN 2

A_A3

M1 GND

A_B5 A_B4 A_B3 A_B2 A_B1 A_A7 A_A6 A_A5 A_A4 A_A2 A_A1

X181

GND [32]

M-L1 REVERSE R-V0.75 WM LIMP HOME M-G1 FRONT 1

1

M0.75 GND RADAR Z-B0.75 RADAR SIGNAL B-V1 +15 RADAR 2

3

C0.75 STEERING CIRCUIT PRESSURE 1

1

C

B

M-B0.75 GNDCOM BRAKES BODY G0.75 BRAKES BODY +5V L0.75 BRAKE SENSOR

4

7

8

6

4

5

2

3

1

M-N1 GND COM C0.75 5V HLHP XLF L0.75 LINEAR SENSOR RIGHT C-L0.75 LINEAR SENSOR LEFT L-N0.75 DUMPER LEFT + R-L0.75 DUMPER LEFT R-B1 DUMPER RIGHT + V-B0.75 DUMPER RIGHT -

H-N 1 EV TRAILER EPB A-N0.75 TRAILER LIGHT (HYDR.) V-L1.5 +12 VOLT TRAILER BRAKE M0.75 GND TRAILER BRAKE 4

1

1

2

2

2 2

3

3 3

3

1

5

4

M1.5 GND EV/ BUZZER Z-R1 EV PTO 1400 B-R1 EV PTO 1000 B0.75 EV PTO 750 Z0.75 BUZZER

A

5

4

5

4

6 6

5

S-G0.75 CONFORT PK UP S0.75 CONFORT PK DW G-N0.75 +58 A0.75 DIRECTION LEFT A-N0.75 DIRECTION RIGHT M0.75 GND CONFORT

1

4

3

2

1

2

3

2 2

3

3

1

2

1

3

2

3

C002

Z0.75 CAN H SGR 2 C0.75 CAN L SGR 3 M0.75 GND SGR GROUP 6 B-G0.75 TRANSM.PEDAL SW DIG. CLUTCH 7 B-G0.75 TRANSM.PEDAL SW DIG. CLUTCH 8 M-L1 REVERSE 10 R-V0.75 WM LIMP HOME 12 R-N0.75 +30 SGR 13 G-N0.75 +15 TRANSMISSION SGR 14 M-G1 FRONT 15 R-G0.75 ISO SGR

M 2.5 GND

1

>P.B.T.P.< 3

2

1

6

5

4

3

2

1

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gray

Fig. 3903 - RH transmission (2/2)

K020

1 9

10 2

11 3

M005

12 4

1

Viola/Violet

13 5

2

Azzurr o/Blue

Z

14 6

3

Arancio/Orange

A

15 7

4

4

C

Verde/Green

16 8

3

Marrone/Brown

V

M006

2

M

K022 K021

1

1 2

D038

D044

5 13 14 8 9 10 11 12 3 4 5 6 7

D039

TABELLA COLORI / COLOURS TABLE

40-578

1

A B C A

D043

D0077640

Wiring diagrams 40.4.56 - 0.020.8854.4 - Windscreen washer pumps

N018 2

FP

1

2 1

FP

1 2 3 4

1 2 3 4

D075

RP 2 1 2 1

N019 RP

D0077720

Fig. 3904 - Windscreen washer pumps (1/2) Table 704 CODE STAMPED ON CONNECTOR

FP RP

INTERCONNECTION CODE

D075 N018 N019

DESCRIPTION

Wiring connector Windscreen washer pump Rear windscreen washer pump

40-579

Wiring diagrams N019

N018

2

2

2

2

1

1

M 1 GND

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ellow

R

Rosso/Red

H

Grigio/Gray

D075

Fig. 3905 - Windscreen washer pumps (2/2)

40-580

M 1 GND 4

Bianco/White

N

3

Azzurr o/Blue

B

3

2

A

Viola/Violet

-

1

Verde/Green

Z

2

4

V

1

3

Arancio/Orange

2

C

1

Marrone/Brown

G 1 FRONT WIPER PUMP

TABELLA COLORI / COLOURS TABLE

Z 1 FRONT WIPER PUMP

SA-1

M

2

M 1 GND

Z 1 FRONT WIPER PUMP

1

G 1 FRONT WIPER PUMP

2

1

1

1

D0077730

Wiring diagrams 40.4.57 - 0.020.8862.4 - Roof P028 ANTENNA

NN TE AN A

G004

D057

P017

2

I028

1

D056 4

3

2

1

6 5 4

6 5 4 3 2 1 14 13 12 11 10 9 8 7

LH

D058 LH

2

1

2

1

3 2 1

G003

8

6

3

2

9

5

7

2

1

I026 DEFROST

1

21 43 7 65 98 110 121

8 7 6 5

4 3 2 1

G005

TH

4

5

7

6

8

9

1

2

3

10

4

5

7

9

8

6

1

2

3

10

MO ER LL CA

4

3

2

1

LIGHT BAR

1

1

2

2

2

A

4

I031 LIGHT BAR

8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9

RH

1

3

O011

RH

THERMO CALL

DEFROST

4

H006

N010

D059

M017

D094

D055

1

2

CAN RADIO

9

3

8 7

6

2

5

1

4

10 11 12

16 17 18

19 20 21

13 14 15

9

3

8 7

6

2

5

1

4

10 11 12

16 17 18

19 20 21

13 14 15

4

6

5 2

3

8

1

9

D024

9 13 10 14

1

5

9

D025

2

1

2

1

G002

1115 12 16

4 7

3

H005

1 5 2 6 3 7 4 8

2

10

C005

8

I027

P016

6

7

CA RA N DIO

P026 2

1

D054 D0077650

Fig. 3906 - Roof (1/2) Table 705 CODE STAMPED ON CONNECTOR

LH LH RH RH CAN RADIO

INTERCONNECTION CODE

C005 D024 D025 D054 D055 D055 D056 D056 D057 D058 D058 D059 D059 D094 G002 G003 G004 G005 H005

DESCRIPTION

Cab ground (roof) Wiring connector (yellow) Wiring connector (brown) Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Right hand courtesy light on cab roof Left hand courtesy light on cab roof Cab courtesy light Side instrument panel courtesy light Right hand electric rear view mirror control lever 40-581

40-582

Fig. 3907 - Roof (2/2)

8

3

9

6

D024

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gray

2

5

8

1

7

3

9

6

10 11 12

19 20 21

16 17 18

D025

I031

1

10

4

5

I027

9

6

8

7

M0.75 GND

G1 +58

G1 +58 G1 +58

R-N1 SIGNAL DEFROST G0.75 +58

M1 GND

L 1 REAR RH+

3

L-N 1 REAR RH-

10

R-V1 +12

M6 GND

2

M1 GND

3

M0.5 GND M1 GND M6 GND M1 GND

4

-

5

SA-7

1

SA-10 G-N1 MIRROR LED LIGHT

1 2 3 4 5 6 7 8 9

1

1

1

1

M1 GND N-R1 +15 MIRROR UP SMALL B-C0.5 COMAND MIRROR UP/DOWN SMALL (LT) M-B0.75 COMAND MIRROR UP/DOWN BIG (LT) C-B0.5 COMAND MIRROR DX/SX SMALL (LT) B-N0.75 COMAND MIRROR DX/SX BIG (LT) G-R0.5 COMAND MIRROR COMMON SMALL (LT) R0.75 COMAND MIRROR COMMON BIG (LT) G0.5 +58

M1 GND

Z-B1 CAB LIGHT SW

Z1 CAB LIGHT WOLP

B-N0.75 COMAND MIRROR DX/SX BIG (LT) M-B0.75 COMAND MIRROR UP/DOWN BIG (LT) R0.75 COMAND MIRROR COMMON BIG (LT) M1 GND

14

13

12

11

10

9

8

7

6

5

4

3

2

1

M1 GND

Z1 OUT DEFROST SW G-N1 MIRROR LED LIGHT M1 GND B-N1.5 FRONT WORK LIGHT 1 M1.5 GND B1.5 FRONT WORK LIGHT 1 M1.5 GND B-C0.5 COMAND MIRROR UP/DOWN SMALL (LT) C-B0.5 COMAND MIRROR DX/SX SMALL (LT) G-R0.5 COMAND MIRROR COMMON SMALL (LT)

1

B1 FRONT WORK LIGHT 1

M1.5 1 G-V1.5 FLASHER COMAND 2

6 5 4

2

9

8

7

6

5

M1.5 GND 1 G-V1.5 FLASHER COMAND 2

D057

D054

G004

7

3

4

N-R1 +15 MIRROR DOWN BIG H-R0.5 COMMAND MIRROR UP/DOWN SMALL (RH) G0.75 COMAND MIRRORS UP\DOWN BIG (RH) M-C0.5 COMMAND MIRROR SX/DX SMALL (RH) R-N0.75 COMAND MIRRORS DX/SX BIG (RH) S-L0.5 COMMAND MIRROR COMMON SMALL (RH) C0.75 COMAND MIRRORS COMMON BIG (RH) G1 +58 G1 +58

M1 GND

G0.75 REAR POUMP M1 GND G1 +58

V1 31b ZERO N1 (53/1Sp) SPEED R-V1.5 +12

SA-1

2

1

8

7

6

5

3

2

1

M6 GND

4 3 2 1

7

8

9

6

10

M0.5 GND G0.75 +58 M0.5 GND H-L0.75 LED ATTIVAZIONE

SA-9

9

8

7

6

-

3

9

6

8

10

5

4

3

H-G0.75 LIGHT BAR COMANDO H-R1 +15 RADIO

654321 1211109 8 7

8

2

7

5

2

3

4

6

7

1

C005

2

M 0.75 GND

21

20

19

18

17

H-G0.75 LIGHT BAR COMANDO H-L0.75 LED ATTIVAZIONE

M6 GND

8

15

16

M 1 GND

SA-5

1

13

14

V1.5 87 REAR WPRK LIGHT C-B1.5 87 REAR WPRK LIGHT

G-R 1 +30 RADIO

V-N 1 FRONT LT-

C1.5 REAR WORK LIGHT 1 V-N1.5 REAR WORK LIGHT 1

H-V 1 X107/6 FRONT RH-

M-V 1 FRONT LT+

10

12

9

11

7

H-V 1 FRONT RH+

8

6

5

4

3

2

1

21

20

19

L1.5 +12 WIPER FRONT (53a) L-N1.5 53 FRONT WIPER L-B1.5 31b ZERO G-V1.5 FLASHER COMAND

Z2.5 REAR DEFROST R-N1 SIGNAL DEFROST N-R1 +15 MIRROR R 0.75 +30 WEBASTO (THERMO CALL) S-L 0.5 THERMO CALL 86/30 18 M-L 0.5 THERMO CALL 85

17

16

15

14

13

M 0.75 GND

13 14 15

H-R 1 +15 RADIO

12

11

10

9

7

G-N1 MIRROR LED LIGHT Z-B1 CAB LIGHT SW Z1 CAB LIGHT WOLP B1 FRONT WORK LIGHT 1

V-B1.5 FRONT WORK LIGHT 1 G1 +58 G0.75 REAR POUMP

8

1

1

S-L 0.5 THERMO CALL 86/30

4

19 20 21

16 17 18

13 14 15

10 11 12

2

5

G1 +58

7

M1 GND

1

4

1

1

B-N1.5 FRONT WORK LIGHT 1

2

N-B1.5 FRONT WORK LIGHT 1 R-V2.5 +12 B1.5 FRONT WORK LIGHT 1

2

2

R-V1.5 +12 V1 31b ZERO M1.5 GND N1 (53/1Sp) SPEED

6

1

1 2

3

4

G1 +58

4

4

2

1

1

3

1

1

2

M1 GND

5

1

P016 2

2

2

3

2

2

D055 1

G002 2

O011 R0.75 +30 WEBASTO(THERMOCALL)

D058

5

B 1 REAR LT-

3

4

M1.5 GND V1.5 87 REAR WPRK LIGHT 2 M1.5 GND 1 V-N1.5 REAR WORK LIGHT 1 M1.5 M1 GND

X101 12

M1.5 GND 8

11

SA-2

N-B1.5 FRONT WORK LIGHT 1 7

10 -

SA-8 SA-4

7

M0.5 GND V 0.75 TW1 CAN-L 2

R 0.75 ANTENNA ELETTRICA

M2.5 GND Z2.5 REAR DEFROST

4

M1.5 GND 3 C-B1.5 87 REAR WPRK LIGHT 2 M1.5 GND 1 C1.5 REAR WORK LIGHT 1 G-R 1 +30 RADIO

2 1

N010 M-L 0.5 THERMO CALL 85

7

1

4

5

2

1

9

3

2

4

4

I028 6

1

5

9

G0.75 COMAND MIRRORS UP\DOWN BIG (RH) 12

C0.75 COMAND MIRRORS COMMON BIG (RH) 13

R-N0.75 COMAND MIRRORS DX/SX BIG (RH) 11

Z1 OUT DEFROST SW 14

M1.5 GND 10

G-N1 MIRROR LED LIGHT 9

R-V 1 REAR LT+ 16

M-V 1 FRONT LT+ 15

H-V 1 FRONT RH+ 14

L 1 REAR RH+ 13

B 1 REAR LT12

R 0.75 ANTENNA ELETTRICA V 0.75 TW1 CAN-L G 0.75 TW1 CAN-H V-N 1 FRONT LT11

H-V 1 X107/6 FRONT RH10

L-N 1 REAR RH9

H-R 1 +15 RADIO

7

M 1 GND 8

4

6

5

3

8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9

M017 H006

4 3 2 1

9 1

2

D056 2

3

P017 1

3

6

2

8

8

ANTENNA

9 13 10 14

LIGHT BAR THERMO CALL

H006 I026 I027 I028 I031 M017 N010 O011 P016 P017 P026 P028

1115 12 16

DEFROST INTERCONNECTION CODE

1 5 2 6 3 7 4 8

CODE STAMPED ON CONNECTOR

8 7 6 5

G003

4 3 2 1

Wiring diagrams

DESCRIPTION

Left hand electric rear view mirror control lever Rear view mirror demister switch Rear screen wiper switch Door open warning signal switch Light Bar switch Webasto ECU Rear screen wiper motor Rear defrost heater element RH rear loudspeaker LH rear loudspeaker Radio Electric aerial

6 5 4 3 2 1 14 13 12 11 10 9 8 7

3 2 1

R-V 1 REAR LT+

H-R0.5 COMMAND MIRROR UP/DOWN SMALL (RH) 15

S-L0.5 COMMAND MIRROR COMMON SMALL (RH) 17 M-C0.5 COMMAND MIRROR SX/DX SMALL (RH) 16

18

D059

V-B1.5 FRONT WORK LIGHT 1 5 L1.5 +12 WIPER FRONT (53a) 4 L-B1.5 31b ZERO 3

M1.5 GND 6

L-N1.5 53 FRONT WIPER 1

M1.5 GND 2

G 0.75 TW1 CAN-H 1

X105

D094

X103 1

P028 P026

2

1

R-V1 +12 R-V1.5 +12

SA-3

I026

G005

H005

TABELLA COLORI / COLOURS TABLE

D0077660

Wiring diagrams 40.4.58 - 0.021.0396.4 - LH transmission

N002

N003

FP 2

2

N004

RP

1

1

2

FP

2

1

EPB

D037

1

1 2 3 4 5 6 7 8 A

A B C 1 2 3 4 5 6 7 8

RP

B C

4

2

BRAKR 60Km/H 4

SUSP.

10 11 12 3

1 2

9

4 5 6 7

5

13 14

8

6

8 9 10 11 12

7

3

R:PTO SPEED

D090

SUSP.

K009 D035 1

3

1 2

EPB

1 2 3

1 2

7

1

6

3

5

4

2

A

B

B

Schlemmer

D034

8

O PT D R. EE SP

BRAKE 60 Km/H

3

B A

ABS SOK

BUSTER

A

DRAFT LEFT

EV

1 2 3 1 2

1

3

21 18 15 12 9 6

2

5

4 1

3

1

2 3

1

BRAKE PRESS S URE 2

1

2

1

BU ST ER

2 1

2

1

AXLE SP. 2

1

COOLANT L

1 3

4 2

1

A

K015 AC SW

2

B

2 1 8A 8B 8C 8D

K013

K014 AXLE SP.

7A 7B 7C 7D

COOLANT L

6A 6B 6C 6D 5A 5B 5C 5D 4A 4B 4C 4D 3A 3B 3C 3D

8A 8B 8C 8D 7A 7B 7C 7D 6A 6B 6C 6D 5A 5B 5C 5D 4A 4B 4C 4D 3A 3B 3C 3D 2A 2B 2C 2D

2A 2B 2C 2D

1A 1B 1C 1D

1A 1B 1C 1D

B A

2 1

3

L

A

FILTER

3

K012

12 10 11 6 9 8 5 4 7 2 3 1

D031

1

BUSTER

C002

SW

2

AC

K006

MA BATTERY

1

BONNET

MA BATTERY

D032

2

2

D036

BRAKES PRESSURE

3 4

C004

A

ASM

ASM

FILTER

B

1

K016

Y BK ER TT BA

T001a

2

T004

A

K007

1

BONNET

FUEL

FUEL

B

2

K010

3 4

FUEL

BK BATTERY

3

1

DRAFT LEFT

K005 D033

2

K008

EV UP

K

2

L001

K

BUSTER

1

ABS SOK

1

1

D092

2

P005

K011

20 17 14 11 8

K SO

19 16 13 10 7

S AB

FUEL

ABS SOK

UP

D091

B

D009 L

D0077610

Fig. 3908 - LH transmission (1/2) Table 706 CODE STAMPED ON CONNECTOR

L MA BATTERY BK BATTERY BONNET SUSP. BRAKE 60 KM/H ABS SOK ABS SOK FUEL BUSTER BRAKE PRESSURE DRAFT LEFT R.PTO SPEED FUEL

INTERCONNECTION CODE

C002 C004 D009 D031 D032 D033 D034 D035 D036 D037 D090 D091 D092 K005 K006 K007 K008 K009 K010

DESCRIPTION

Engine ground Negative terminal of the auxiliary battery Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Wiring connector Water in fuel sensor Brake circuit alarm pressure switch (15 Bar) EPB pressure sensor Lift draft sensor (LH) PTO speed sensor Fuel level sensor 40-583

7A 7B 7C 7D

6A 6B 6C 6D

D009

D092

B

2A 2B 2C 2D

1A 1B 1C 1D

3A 3B 3C 3D

4A 4B 4C 4D

5A 5B 5C 5D

6A 6B 6C 6D

7A 7B 7C 7D

8A 8B 8C 8D

2A 2B 2C 2D

3A 3B 3C 3D

4A 4B 4C 4D

5A 5B 5C 5D

1A 1B 1C 1D

Fig. 3909 - LH transmission (2/2)

A

1

1

1

A 0.75 DIRECTION LEFT

A-N 0.75 DIRECTION RIGHT N-R 1 X132/A_A6 54S STOP

G-N 0.75 AMBIENT TEMP.

G 0.75 X132/A_A3 58R POS

H-L 1.5 BAR LIGHT G-N 0.75 X132/A_A2 58L POS

B 1 X132/A_B1 A/C COMPRESSOR M-N 0.75 GND COM SMART SW

R-V 0.75 X132/A_B8 GND SENSOR HLHP

H 1.5 LOW BEAM LIGHT

H-G 0.75 SPEED PTO SIGNAL (HLHP-19)

V-N 0.75 HIGH BEAM LIGHT

H 1.5 LOW BEAM LIGHT

B 1 + FRONT AXEL + front axle speed sensor CAN L

B_A2

Z-G 1 +8 VOLT HLHP

S-M 1 BOOSTER PRESS SW

H-G 1.5 W.L.LEFT DW

D036

H-L 1.5 BAR LIGHT M 2.5 GND

V-B 1 HORN

N-R 1 AUTO CLIMA TEMP

K013

K012

G-N 0.75 AMBIENT TEMP.

20

C 0.75 AMBIENT TEMP.

21

R-V 0.75 AUTO CLIMA TEMP

17

18

19

B 1.5 W.L.LEFT MED

V-N 1.5 HIGH BEAM LIGHT

H 1.5 LOW BEAM LIGHT

M 2.5 GND

16

15

13

14

M 2.5 GND

V 1.5 W.L.RIGHT UP

M 2.5 GND

M 2.5 GND

G-V 1.5 W.L.RIGHT MED

G 1.5 W.L. LEFT UP

10

11

12

8

9

6

7

4

5

M 2.5 GND

G-N 1.5 W.L.RIGHT DW

3

M 1 GND

1

2

M 1.5 GND

B 1 GND -31 GND B 1 AIR FILTER AIR FILTER

C-B 0.75 COLLANT LEVEL(1S) M-N 1 B-R 0.75 COLLANT LEVEL(2+)

1 2

1 2 3

G-V 1.5 +15 ABS TRAILER SOCKET

1

V-N 0.75 WORNING LAMP.

B 1 X132/B_D8 PRESSUR SWITCH COMPRESSOR

B_D8

2

B 1 X132-B_D7 PRESSUR SWITCH COMPRESSOR

3

G-L 0.75 EPB LEVER SIGNAL

B_D6

B 1 ASM SEGNAL 1 ASM SEGNAL

B_D7

R-N 0.75 LEFT CORNER LIGHT RELAY

M-N 1

B_D4

B_D5

B_D3

G 1.5 TRAILER WORK LIGHTS

M-V 0.75 +12 VOLT TRAINER (+15USA)

B_D1

V-N 0.75 WORNING LAMP.

B_D2

R-V 0.75 AUTO CLIMA TEMP

B_C7

N-R 1 AUTO CLIMA TEMP

B_C8

V-Z 0.75 X132/B_C5 +50 KEY

B-G 0.75 X132/B_C4 LIMP HOME EPB

M-A 0.75 GND COM EPB LEVER

H-R 1 +15 EPB

V-B 0.75 X132/B_B7 SMART SW

B_C5

B_C6

B_C4

B_C2

B_C3

B 1 FRONT SPEED FRONT AXLE SPEED

M-B 0.75 EV UP+

B 0.75 EV UP-

C-B 0.75 COLLANT LEVEL(1S)

M-V 0.75 X132/B_B2 TRAILER RELAY COIL EPB

L-G 0.75

Z 0.75 FRONT WIPPER POUMP

B_B8

B_C1

B_B6

B_B7

B_B5

B_B3

B_B4

B_B1

M-V 0.75 +12 VOLT TRAINER (+15USA)

B_B2

G 0.75 REAR WATER POUMP

H 0.75 LEFT DRAFT SIGNAL

CAN H

B_A7

B_A8

B_A6

B_A4

B_A5

B_A3

V-N 0.75 HIGH BEAM LIGHT

C 0.75 AMBIENT TEMP.

B 1 ASM SEGNAL 2 ASM SEGNAL

R-N 0.75 X140/5 FUSE PDU3(INSTRUMENT+30)

R-G 0.75 RIGHT CORNER LIGHT RELAY

A_D7

A_D8

B_A1

A_D5

A_D3

A_D4

A_D6

A_D1

A_D2

V 0.75 X132/A_C8 CA1 EPB LED

V-B 0.75 X132/A_C7 +12 RADAR/PTO SENSOR/DISTR/STEER

A_C8

G-L 0.75 X132/A_C6 EV LS F.A.

A_C6

C-N 1 EV UP F.A.

A_C7

C-B 0.75 X132/A_C4 EV DOWN F.A.

V-B 0.75 X132/A_C3 FRONT AXLE POS.SENS

A_C4

A_C5

B-R 0.75 COLLANT LEVEL(2+)

M-H 1 +5V EPB LEVER

V-B 1 HORN

B 1 AIR FILTER AIR FILTER

B 1 FUEL (2) WATER IN FUEL

B-N 0.75 HAND BRAKE LAMP

B 1 FUEL (1) WATER IN FUEL

A_C2

A_C3

A_C1

A_B7

A_B8

A_B5

A_B6

A_B3

A_B4

A_B2

G-V 1.5 +15 ABS TRAILER SOCKET

A_A8

A_B1

G 1.5 W.L. LEFT UP

A_A6

M 0.75 GND

A_A7

R-G 0.75 RIGHT CORNER LIGHT RELAY

A_A3

B 1.5 W.L.LEFT MED

1

A_A4

2

A_A5

3

A_A1

R-N 0.75 X140/5 FUSE PDU3(INSTRUMENT+30)

4

A_A2

5

M 0.75 GND

H-G 1.5 W.L.LEFT DW

6

L 0.75 BRAKES PRESSURE SENSOR

7

K007

V 1.5 W.L.RIGHT UP

B 1 FUEL (1) WATER IN FUEL

G-V 1.5 W.L.RIGHT MED

8

B 1 FUEL (2) WATER IN FUEL

12 11 9 10 8 7 6 5 4 3 2 1 9

1

10

2

R 4 30 (main battery-30A)

2

3

4 1

M 0.75 GND 4

CAN H1 3

CAN L1 2

V-B 0.75 +15 1

S-M 1 BP2

1 2

11 CAN-H1

4 3

12 B 1 + FRONT AXEL + front axle speed sensor 1

A 2 2

R-N 4 +30 MAIN (BATTERY 30A) 3 3

R-N 4 +30 MAIN (BATTERY 30A) B 1 GND -31 GND

B 1 FRONT SPEED FRONT AXLE SPEED 1

CAN-L1

1

1

2

2

3

3

1

2

B B 1 X132/A_B1 A/C COMPRESSOR

3

T001a B 1 X132-B_D7 PRESSUR SWITCH COMPRESSOR 2

B 1 X132/B_D8 PRESSUR SWITCH COMPRESSOR 1

1

R-N 4 +30 (BACKUP BATTERY 30A) 1

1

R-N 4 +30 (BACKUP BATTERY 30A)

A B 1 ASM SEGNAL 1 ASM SEGNAL

2

C004 2

2

B

1

A 0.75 DIRECTION LEFT

2

G 1.5 TRAILER WORK LIGHTS

1 3

B 1 ASM SEGNAL 2 ASM SEGNAL

1

K005

2 B 1 GND SENSOR GND SENSOR HLHP

1

A

A-N 0.75 DIRECTION RIGHT M 1.5 GND

SA-2 2

T004 G-N 0.75 X132/A_A2 58L POS

2

B 3

1

2

3

10 11 12 4

5

6

7 9 8

7

14

13

12

11

10

9

8

4 5 6

2

R-V 0.75 GND SENSOR HLHP G-L 0.75 X132/A_C6 EV LS F.A.

3

1

C-N 1 EV UP F.A.

Z-G 1 +8 VOLT HLHP V-B 0.75 X132/A_C3 FRONT AXLE POS.SENS

M 1 GND

1

C-B 0.75 X132/A_C4 EV DOWN F.A.

2

1 L-G 0.75

S-M 1 BP1

M 0.75 GND

A B

M 4 GND

R-N 4 +30

C8

M 4 -31 (BACKUP BATTERY)

B6

B3 B4

C6 C7

L 0.75 CAN002 CAN L1 G-L 0.75 EPB LEVER SIGNAL L 0.75 BRAKES PRESSURE SENSOR

B8

A8

H-R 1 +15 EPB B 0.75 CAN002 CAN H1

B1

C1 C2 C3

B-N 0.75 HAND BRAKE LAMP R-N 4 +30 (BACKUP BATTERY 30A)

B2

A5 A6

A2

V-B 0.75 X132/B_B7 SMART SW B-G 0.75 X132/B_C4 LIMP HOME EPB

A4

M 4 X135/- GND -31 M-H 1 +5V EPB LEVER V-Z 0.75 X132/B_C5 +50 KEY

M-N 0.75 GND COM SMART SW M-A 0.75 GND COM EPB LEVER V 0.75 X132/A_C8 CA1 EPB LED

A1

2

R 4 30 (main battery-30A)

1

M 0.75 GND

M-V 0.75 X132/B_B2 TRAILER RELAY COIL EPB

1 2

M 0.75 GND

G 0.75 REAR WATER POUMP

3

Z 0.75 FRONT WIPPER POUMP

1 2

2

Z-G 1 +8 VOLT HLHP

1

B 0.75 EV UP-

H 0.75 LEFT DRAFT SIGNAL

M-B 0.75 EV UP+

R-V 0.75 GND SENSOR HLHP

1

3

A 4

2

N002 N003

L001 K008

D091

K011

K010

8 9

3

B

8 1

7 2

3

6

G 0.75 X132/A_A3 58R POS

4

5

N-R 1 X132/A_A6 54S STOP

5

2

6

1 1

A 1

7

1

M-V 1.5 +12 VOLT TRAILER R-N 2.5 +30

6 3

8 1 2

4

B A

R-N 2.5 +30

V-B 0.75 +12 RADAR/PTO SENSOR/DISTR/STEER

4

M 0.75 GND

CAN H1

5

V-B 0.75 +D2 1

B

20 17 14 11 8

H-G 0.75 SPEED PTO SIGNAL (HLHP-19)

1 CAN L1

1

A

21 18 15 12 9

2 V-B 0.75 +D1

2

2

3

3

2

V-B 0.75 +D3

4 V-B 0.75 +D6

1

5 V-B 0.75 +D5

V-B 0.75 +D4

1

V-B 0.75 +D7

2

CAN L

2

6

2

8A 8B 8C 8D

40-584 7 13 14

B

4

D031 8

1 1

A

19 16 13 10 7

2 2 A

1

D032 M 0.75 -31

9 2 1 B

C

1

2

A

3

2 B

C

2

3 1

3

D034 10 2

N004

1

K009 CAN H

11

K011 K012 K013 K014 K015 K016 K016 L001 N002 N003 N004 P005 T001a T004

1

3 1 2 3 4 5 6 7 8

D035 12

INTERCONNECTION CODE

2

BUSTER FILTER COOLANT L AXLE SP. AC SW ASM ASM EV UP FP RP EPB K

2

CODE STAMPED ON CONNECTOR

2

1 2 3 4 5 6 7 8

D033

B A

Wiring diagrams

DESCRIPTION

Not used Air cleaner clogged sensor Engine coolant level sensor Front axle speed sensor Air conditioning pressure switch Steering angle sensor Wiring connector Rear lift ‘UP’ control solenoid valve Windscreen washer pump Rear screen washer pump E.P.B. device Air conditioning compressor Battery positive terminal Positive terminal of the auxiliary battery

D037 3 4 5 6 7 10 11 12

1 2

SA-3 SA-1

SA-6 SA-9

P005 K016

K015

M 4 -31 (BACKUP BATTERY)

R-N 4 +30 (BACKUP BATTERY 30A)

K014

C002

SA-8 1

D090

R-N 2.5 +30

R-N 2.5 +30 G-N 1.5 W.L.RIGHT DW

X135

R-N 0.75 LEFT CORNER LIGHT RELAY

K006

SA-4

SA-5

1

TABELLA COLORI / COLOURS TABLE

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gray

D0077620

Wiring diagrams 40.4.59 - 0.021.0489.4 - Auxiliary heating - Webasto

1 2

1

P029b GROUP WEBASTO

7

5

6

8

1

2

3

4

12 11 10 9

B

M016 WEBASTO RELAIS 4

2

1

2

1

B

C

A

WEBASTO

C

WEBASTO RELAIS 4

A

WEBASTO

2

D093

GROUP WEBASTO

1 2 3 4 5 6 7 8

FUEL POUMP

FUEL POUMP

1 2 3 4 5 6 7 8

N020

1 2

1 2

O019

G WE ROU BA P ST O

DIAGN OSTIC

O019a

2

1

R005 DIAGNOSTIC

12

10 11

8 9

6 7

4 5

2 3

1

P029a GROUP WEBASTO

D0078010

Fig. 3910 - Auxiliary heating - Webasto (1/2) Table 707 CODE STAMPED ON CONNECTOR

WEBASTO WEBASTO RELAIS 4 FUEL PUMP GROUP WEBASTO GROUP WEBASTO DIAGNOSTIC

INTERCONNECTION CODE

D093 M016 N020 O019 O019a P029a P029b R005

DESCRIPTION

Wiring connector Relay unit Webasto circuit pump LED carrier connector Diode Webasto unit Webasto unit Webasto diagnostic connector

40-585

Wiring diagrams 6 5

8

1

2

3

4

12 11 10 9

M 2.5 GND

SA-1

L 1 +15 WEBASTO RELAY L 1 DENSO ECU A-V 1 DENSO FANS RELAY COILS L 1 +15 CLIMA DENSO/WEBASTO R 1 +30 CLIMA DENSO/WEBASTO

M-G 1

R 1.5 +30 WEBASTO

B-C 1

R 1.5 +30 WEBASTO

S-L 1 THERMO CALL 86/30

S-L 1 THERMO CALL 86/30

A-V 1 DENSO FANS RELAY COILS

M-L 1 THERMO CALL 85

R 1 +30 CLIMA DENSO/WEBASTO

1

1

M-L 1 THERMO CALL 85 M 0.75 GND

2

2

L 1 +15 WEBASTO RELAY

B-L 1 Z-G 1 DIODO

M-G 1

1

2

2

B-L 1

SA-3

1

2

G-R 1 DIAGNOSTIC

2

R005

1

O019a

L 1 +15 CLIMA DENSO/WEBASTO R 1 +30 CLIMA DENSO/WEBASTO

B

B-L 1

SA-2

2 1

C

O019

A

L 1 +15 CLIMA DENSO/WEBASTO

B

M-G 1 M 0.75 GND L 1 DENSO ECU

C

M 0.75 GND SA-4

M016 A

S-L 1 THERMO CALL 86/30

SA-5

C8 C7 C5 C3 C1 B6 B5 B4 B3 B2 B1 A8 A7 A6 A5 A4 A3 A2 A1

1 2 3 4 5 6 7 8

10 9 8 7 6 5 4 3 2 1

1 2 3 4 5 6 7 8

7

D093

2 4 6 12 10 8

1 5 7 11 9

P029a

3

SA-7

12 9 6 3 2

R 2.5 +30 WEBASTO M 2.5 GND G-R 1 DIAGNOSTIC B-C 1 Z-G 1 DIODO

SA-6

-

P029b V-C 1.5 FUEL POUMP A 1.5 FUEL POUMP

V-C 1.5 FUEL POUMP A 1.5 FUEL POUMP

2 1

TABELLA COLORI / COLOURS TABLE 1

2

2 1

2

1

N020

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ellow

R

Rosso/Red

H

Grigio/Gray

D0078020

Fig. 3911 - Auxiliary heating - Webasto (2/2)

40.4.60 - 0.021.0490.4 - Trailer socket with ABS brakes

40-586

Wiring diagrams D091 TO BODY

B A

P027

DY BO TO

A SO BS CK ET 1 2 3 1 2 3

D092 ABS SOCKET

D0077970

Fig. 3912 - Trailer socket with ABS brakes (1/2) Table 708 CODE STAMPED ON CONNECTOR

TO BODY ABS SOCKET

INTERCONNECTION CODE

D091 D092 P027

DESCRIPTION

Wiring connector Wiring connector Trailer socket

40-587

Wiring diagrams D091 B A

B A

7

M 4 -31 R-N 4 +30

6 5

P027

V-N 0.75 WARNING ABS LAMP

4

M 4 -31

3

M 1.5 -31

2

G-V 1.5 +15 ABS TRAILER SOCKET

1

D092

R-N 4 +30 V-N 0.75 WARNING ABS LAMP

3 2

2

2

1

1

M 1.5 -31

3

3

G-V 1.5 +15 ABS TRAILER SOCKET

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gray

1

D0077980

Fig. 3913 - Trailer socket with ABS brakes (2/2)

2

L014

1

1

D045

2

40.4.61 - 0.900.0816.0 - Front PTO

D0055361

Fig. 3914 - Front PTO (1/2) Table 709 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D045 L014

DESCRIPTION

Wiring connector Front PTO control solenoid valve

TABELLA COLORI / COLOURS TABLE

D045

1

1

2

2

L014

M

Marrone/Br own

C

Arancio/Orang e

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0055371

Fig. 3915 - Front PTO (2/2) 40-588

Wiring diagrams 40.4.62 - 04217216 - Preheating relay power supply

B020 A001

J032b

D0060901

Fig. 3916 - Preheating relay power supply (1/2) Table 710 CODE STAMPED ON CONNECTOR

K2b

INTERCONNECTION CODE

A001 B020 J032b

DESCRIPTION

Alternator “B+” Pre-heating relay supply fuse (150A) Preheating relay

B020

J032b

150A

A001

D0060811

Fig. 3917 - Preheating relay power supply (2/2)

40.4.63 - 04217217 - Preheating

A010

J032a

D0060910

Fig. 3918 - Preheating (1/2) Table 711 CODE STAMPED ON CONNECTOR

R4 K2a

INTERCONNECTION CODE

A010 J032a

DESCRIPTION

Preheating device Preheating relay

40-589

Wiring diagrams

A010

J032a

D0060800

Fig. 3919 - Preheating (2/2)

40.4.64 - 04218107 - Engine K051 B70

J032a K2a

M014 Y25

K048

J032 K2

D088

B48

X32.2

D087 X32.1

K044 B49

D011 X17.1

N007

K047 B43

K050 B51

K046

X17.1 X32.1 X32.2 K2 K2a B49 B40.2 B40.1 B43 B48 B6 B51

40-590

D011 D087 D088 J032 J032a K044 K045 K046 K047 K048 K049 K050

B44

B6

L016 Y19

D0060922

Fig. 3920 - Engine - (1/2) Table 712 INTERCONNECTION CODE

B40.2

K049

B40.1

CODE STAMPED ON CONNECTOR

K045 K052

DESCRIPTION

Wiring connector Wiring connector Wiring connector Preheating relay Preheating relay RAIL pressure sensor Crankshaft speed sensor Camshaft speed sensor Engine coolant temperature sensor Turbine air temperature/pressure sensor Oil pressure sensor Fuel low pressure sensor

Wiring diagrams CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

39 40 42 41

33 12

5 5 2 7

1 2

1 2

30 20 19

Not used Engine oil temperature sensor Proportional solenoid valve Turbocharger Starter motor

31 25 32

1 15 21

1 2 3

1

24

9 14 13

28 29 22 23

26

27

17

6 7

8

2

3

5 4 18 10 11 16

1

2

1

1

2 3 4

1

2 3 4

1

2 3 4

1

2

2 3

4

M014

2

J032 J032a N007

1

K050

1 2

K049

3

K048

2

K047

L016

2

K046

D088

1

K045

5

D087

2 5 7

K044

D011

34 35 36 37

K052

K051 K052 L016 M014 N007

K051

B70 B44 Y19 Y25

DESCRIPTION

TABELLA COLORI / COLOURS TABLE M

Marrone/Br own

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0071991

Fig. 3921 - Engine - (2/2)

40.4.65 - 04436707 - Left hand rotating beacon

E007

D057

D0050223

Fig. 3922 - Left hand rotating beacon (1/2) Table 713 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D057 E007

DESCRIPTION

Wiring connector Left hand rotating beacon

40-591

Wiring diagrams

TABELLA COLORI / COLOURS TABLE M1

E007

1

Z1

2

D057

M

Marrone/Br own

C

Arancio/Orang e

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0050234

Fig. 3923 - Left hand rotating beacon (2/2)

40.4.66 - 04436707 - RH rotating beacon

E006

D054

D0050222

Fig. 3924 - Right hand rotating beacon (1/2) Table 714 CODE STAMPED ON CONNECTOR

INTERCONNECTION CODE

D054 E006

DESCRIPTION

Wiring connector Right hand rotating beacon

TABELLA COLORI / COLOURS TABLE M1

E006

Z1

1 2

D054

M

Marrone/Br own

C

Arancio/Orang e

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0050233

Fig. 3925 - Right hand rotating beacon (2/2)

40-592

Wiring diagrams 40.4.67 - 04502029 - Fuel injectors A009 A008 A007 Y15.6

A006 Y15.3

A005 A004

Y15.4

Y15.2

Y15.5

Y15.1

D064 D088 X32.2

D063 D087 X32.1

D0073021

Fig. 3926 - Fuel injectors - (1/2) Table 715 CODE STAMPED ON CONNECTOR

Y15.1 Y15.5 Y15.3 Y15.6 Y15.2 Y15.4 X32.1 X32.2

INTERCONNECTION CODE

A004 A005 A006 A007 A008 A009 D087 D088

DESCRIPTION

Cylinder 1 injector Cylinder 2 injector Cylinder 3 injector Cylinder 4 injector Cylinder 5 injector Cylinder 6 injector Wiring connector Wiring connector

40-593

Wiring diagrams

1

2

7

5

5

5

2

7

2

1

2

1

2

1

A009

2

A008

1

A007

2

A006

1

A005

A004

D088

5

D087

2

TABELLA COLORI / COLOURS TABLE M

Marrone/Br own

C

Arancio/Orange

V

Verde/Green

A

Azzurr o/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Blac k

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ello w

R

Rosso/Red

H

Grigio/Gra y

D0073031

Fig. 3927 - Fuel injectors - (2/2)

40-594

INDEX

0 0.012.2018.4/20 - License plate light 0.014.0007.4/20 - Lights selector switch 0.014.5144.4/10 - Battery negative 0.015.3974.4/10 - Front axle suspension 0.015.4257.4/10 - PTO sensor (USA) 0.015.5429.4/20 - Front lift control 0.016.0642.4/20 - Rear LH lower work light on cab - Xenon version 0.016.0642.4/20 - Rear RH lower work light on cab - Xenon version 0.016.0650.4/10 - LH front supplementary work light on arm - Xenon version 0.016.0650.4/10 - RH front supplementary work light on arm - Xenon version 0.017.0496.4/10 - Supplementary RH front work light on arm 0.017.0497.4/10 - Rear LH lower work light on cab 0.017.0497.4/10 - Rear RH lower work light on cab 0.017.8425.4/10 - Rear trailer socket 0.017.8426.4 - Rear trailer socket (U.S.A.) 0.017.8887.4/10 - ISO 11783 - Front line 0.018.8803.4 - Battery positive terminal 0.018.9843.4/20 - ISO 11783 - Rear line 0.018.9845.4/10 - Fuses and relays 0.018.9990.4/10 - Distributors 0.018.9992.4/10 - AdBlue 0.019.2378.4/40 - LH mudguard 0.019.2378.4/40 - RH mudguard 0.019.2379.4/20 - Front LH lower work lights on cab 0.019.2379.4/20 - Front RH lower work lights on cab 0.019.2380.4/30 - Hazard warning lights switch (USA) 0.019.2383.4/20 - Engine cowl 0.019.2474.4/10 - Rear PTO 0.019.2539.4/10 - Hydraulic braking 0.019.2571.4/10 - ISO 11786 0.019.2617.4/70 - ISO 11783 - Cab line 0.019.3658.4/20 - Agrosky solenoid valve 0.019.3659.4/10 - On-board monitor - Armrest 0.019.4559.4/10 - Rear service work light 0.019.4688.4/10 - Front top work lights on cab 0.019.4689.4/20 - LH rear work lights on cab roof 0.019.4689.4/20 - RH rear work lights on cab roof 0.019.4711.4/10 - Semi-active cab 0.019.4913.4/10 - Front top work lights on cab - LED version 0.019.4914.4/20 - LH rear work lights on cab roof - LED version 0.019.4914.4/20 - RH rear work lights on cab roof - LED version 0.019.5311.4/10 - Automatic A/C system interface 0.019.9825.4/10 - Agrosky antenna (Assisted Steering) 0.019.9826.4/30 - Agrosky - I-Monitor 0.019.9827.4/10 - Front work lights on cab roof - LED version with Agrosky 0.019.9828.4/10 - Front work lights on cab roof - Version with Agrosky 0.019.9829.4/20 - Agrosky antenna (Visual guidance) 0.020.1009.4 - Front LH lower work lights on cab (USA) 0.020.1009.4 - Front RH lower work lights on cab (USA) 0.020.1026.4/10 - LH front supplementary work light on arm (U.S.A.) 0.020.1026.4/10 - RH front supplementary work light on arm (U.S.A.) 0.020.5056.4 - Brake hydraulic system pressure sensor - 60 km/h 0.020.8658.4 - Side instrument panel 0.020.8664.4 - RH transmission 0.020.8854.4 - Windscreen washer pumps 0.020.8862.4 - Roof 0.021.0396.4 - LH transmission 0.021.0489.4 - Auxiliary heating - Webasto 0.021.0490.4 - Trailer socket with ABS brakes 0.900.0816.0 - Front PTO 04217216 - Preheating relay power supply 04217217 - Preheating 04218107 - Engine 04436707 - Left hand rotating beacon 04436707 - RH rotating beacon 04502029 - Fuel injectors

40-496 40-496 40-498 40-499 40-499 40-500 40-501 40-502 40-502 40-503 40-504, 40-505 40-506 40-506 40-507 40-509 40-510 40-511 40-512 40-514 40-516 40-518 40-520 40-522 40-524 40-526 40-528 40-529 40-531 40-533 40-535 40-537 40-540 40-542 40-544 40-545 40-547 40-546 40-549 40-551 40-552 40-554 40-556 40-558 40-559 40-561 40-563 40-565 40-566 40-567 40-568 40-569 40-570 40-571 40-576 40-579 40-580 40-583 40-585 40-586 40-588 40-589 40-589 40-590 40-591 40-592 40-592

2 2.8519.133.0/20 - Transmission control unit

40-28

I

INDEX 2.8519.134.0/50 - HLHP control unit

40-26

4 45 cc variable displacement pump

10-181

6 63 cc variable displacement pump

10-183

9 939267 - Tyre fitting (23/11/2010) 939272 - Pulling force sensor (23/11/2010)

30-696 30-695

A A - Starting and charging A/C drive belt alignment and tension adjustment AC system alarms Air conditioning system Air trailer braking system - CH Export version Air trailer braking system - DE Export version Air trailer braking system - Italy version All Round Tester (ART® SAME) Alternator tightening torques Ancillary utility distributor - 10-way version Armrest alarms ART connection Assembly and disassembly of the camshaft (L3) Assembly and disassembly of the connecting rod drum (L3) Assembly and disassembly of the control elements (L3) Assembly and disassembly of the crankshaft (L3) Assembly and disassembly of the distribution valve (L3) Assembly and disassembly of the oil intake pipe (L3) Assembly and disassembly of the piston cooling nozzles (L3) Attaching rear axle to gearbox (7210 TTV Agrotron ->WSXW830400LD50010) Axle pivot bearings assembly Axle shaft assembly Axle Stub - Assembly (7210 TTV Agrotron ->WSXW830400LD50010) Axle Stub - Disassembly (7210 TTV Agrotron ->WSXW830400LD50010)

40-42 30-179 20-484 10-164 10-216 10-213 10-211 20-7 0-13 10-208 20-459 20-6 30-158 30-132 30-166 30-119 30-161 30-168, 30-169 30-107, 30-108 30-564 30-622 30-598 30-558 30-514

B B - Fuses B0 - Engine Basic electronics for mechanics (1/2) Basic electronics for mechanics (2/2) Battery terminal tightening torques Bevel pinion assembly Bodywork - Cab - Platform Brake assembly Brake Assembly (7210 TTV Agrotron ->WSXW830400LD50010) Brake Disassembly (7210 TTV Agrotron ->WSXW830400LD50010) Braking system

40-42 30-8 40-4 40-7 0-12 30-628 10-164 30-649 30-555 30-517 10-206

C C - Grounds C0 - Engine accessories Care and maintenance - Adjustments and settings Care and maintenance - SCR Care and maintenance work - Belt transmissions Care and maintenance work - Cooling system II

40-52 30-185 10-88 10-76 10-84 10-77

INDEX Care and maintenance work - Electrical system Care and maintenance work - Engine cleaning Care and maintenance work - Fuel distribution system Care and maintenance work - Intake system Care and maintenance work - Lubricant oil system Cartridge valve tightening torques Changing the crankshaft ring gasket (flywheel side) Check and adjust valve clearances Check the camshaft (L3) Check the crankshaft bearings (L3) Check the endfloat of the crankshaft (L3) Checking the bevel gear pair Commissioning and calibrating the tractor Components Compression test Compressor Connecting rod drum check (L3) Conversion factors Crankshaft check (L3)

10-90 10-80 10-68 10-80 10-60 30-7 30-18 30-40 30-160 30-131 30-125 30-612 20-108 40-26 30-35 10-218 30-140 0-10, 0-23 30-122

D D - Intermediate connections D0 - Transmission Description of function (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV ->WSXAD30400LD50010) Diagnostic sockets and connections Diagnostic tools Diagnostics Differential - Disassembly (7210 TTV Agrotron ->WSXW830400LD50010) Differential assembly - carrier Differential disassembly Disassembly and assembly of the gear box (L3) Disassembly and completion of the pilot unit (L3) Disassembly of clutch (all-wheel-drive) (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of control (TCU) (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of Control (TCU) (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV ->WSXAD30400LD50010) Disassembly of control unit (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of drive shaft (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of Drive Shaft (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV ->WSXAD30400LD50010) Disassembly of filter head (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of hydrostatic unit (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of Hydrostatic Unit (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV ->WSXAD30400LD50010) Disassembly of inductive sensors (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of Inductive Sensors (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV ->WSXAD30400LD50010) Disassembly of intermediate housing (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of Intermediate Housing (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV ->WSXAD30400LD50010) Disassembly of K1 clutch Disassembly of K2 clutch (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of K2 Clutch (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV ->WSXAD30400LD50010) Disassembly of K3/K4 clutch Disassembly of K3/K4 clutch and P3/P4 planetary drive Disassembly of KR clutch Disassembly of KV clutch Disassembly of output shaft (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of Output Shaft (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV ->WSXAD30400LD50010) Disassembly of P1 ring gear carrier Disassembly of P1/P2 Planetary drive Disassembly of P3/P4 planetary drive Disassembly of P5/P6 Planetary drive Disassembly of park lock (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of pinion (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of plug-in module (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of Plug-In Module (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV ->WSXAD30400LD50010)

Agrotron

40-55 30-235 10-155

20-5 20-7 20-2 30-519 30-604 30-612 30-151, 30-154, 30-157 30-171, 30-175 30-298 30-262 30-262 Agrotron

Agrotron

30-269 30-310 30-312

Agrotron

30-268 30-258 30-260

Agrotron

30-289 30-289

Agrotron

30-308 30-309

Agrotron

30-250 30-254 30-256

Agrotron

30-252 30-251 30-254 30-249 30-306 30-307

Agrotron

30-242 30-245 30-253 30-247 30-304 30-302 30-290 30-291

III

INDEX Disassembly of pressure relief valves (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of pump (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of Pump (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Disassembly of shifting drum (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of Shifting Drum (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Disassembly of spur gear (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of suction filter (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of Suction filter (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Disassembly of Valve Block (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Disassembly of valve block (all-wheel-drive / park lock) (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of valve block (filter head, pressure relief valves, thermocouple) (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of valve block (hydraulic control) (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of Valve Block (P.R.V. - Pressure Relief Valve) (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Disassembly of valve block (pressure reducing valve) (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of valves, pressure sensor, inductive sensors (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of W.H. and E.C.U. (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Disassembly of wiring harness, valve block and plate (7210 TTV Agrotron ->WSXW830400LD50010) Disassembly of wiring harnesses and control unit Disassembly of wiring harnesses and control unit (7210 TTV Agrotron ->WSXW830400LD50010)

30-268 30-263 30-265 30-241 30-241 30-302 30-267 30-267 30-276, 30-279 30-278 30-274 30-281 30-282 30-283 30-269 30-287 30-271 30-285 30-283

E E - On-board instruments and visual and audible indicators E0 - Rear axle ECU alarms ECU interrogation ECUs interrogated by the All Round Tester (ART®) and SDF Analyser Electrical and electronic components (1/2) Electrical and electronic components (2/2) Electrohydraulic control valve alarms Electronic battery master switch alarms Engine Engine accessories Engine alarms Engine control unit Engine description - Coolant diagram Engine description - Electrical/electronic system Engine description - Exhaust gas after-treatment Engine description - Exhaust gas recovery Engine description - Fuel circuit diagram Engine description - Images of engine Engine description - Lubricant oil diagram EPB Alarms

40-78 30-446 20-160 20-2 20-2 40-13 40-21 20-462 20-497 10-2 10-112 20-160 40-30 10-21 10-26 10-23 10-22 10-20 10-8 10-18 20-488

F F - External lights F0 - Front axle Faults - Engine management Fitting and removing counterweight drive system, checking (L3) Fitting and removing crankshaft bearings (L3) Fitting and removing the temperature sender (exhaust gas) (L3) Fitting BDS cables Fitting blanking elements (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Fitting brakes (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Fitting lifter, oil feed and blanking elements (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Fitting of rear axle to the transmission (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Fitting the axle housing (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) IV

40-79 30-590 10-94 30-112 30-128 10-128 30-686 30-473 30-504 30-468 30-444 30-507

INDEX Fitting the differential (7210 TTV Agrotron ->WSXW830400LD50010) Fitting the differential (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Fitting the lifter (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Fitting the oil feed (7230 TTVAgrotron ->WSXAD00400LD50010, 7250 TTVAgrotron ->WSXAD30400LD50010) Fitting the PTO (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Fitting the PTO transmission (7210 TTV Agrotron ->WSXW830400LD50010) Flange assembly Fluids - SCR reduction agent Front axle Front axle - Version with disc brakes

30-550 30-500 30-468 30-471 30-473 30-536 30-600 10-56 10-162 10-162

G G - Interior lights G0 - Bodywork - Cab - Platform General safety rules

40-82 30-657 0-2, 0-15

H H - Electrical and manual controls H0 - Hydraulic system Handbrake adjustment HLHP alarms How diagnostics works How to select the ECU interrogated Hydraulic front axle suspension Hydraulic pump Hydraulic system Hydraulic trailer braking system - Export version Hydraulic trailer braking system - Italy version

40-82 30-684 30-657 20-462 20-2 20-2 10-197 10-185 10-178, 10-178 10-201 10-199

I I - Circuit breakers Index Repair instructions (7210 TTV Agrotron ->WSXW830400LD50010) Index Repair instructions (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Installation Installation and removal of the crankshaft sleeve Installation and removal of the high pressure pump, Assembly position B Installation and removal of the rotation device Installation and removal of the rotation device (torsional vibration damper) Installation of solenoid valves and cartridge valves Installing and removing the temperature transmitter (Exhaust gas) Installing and removing the thermostat Introduction

40-83 30-2 30-4 30-6 30-20 30-54 30-229 30-231 30-6 30-220 30-207 0-2, 0-15, 40-2, 40-2

J J - Relays

40-88

K K - Sensors and transmitters

40-90

L L - Electromagnets and solenoid valves L0 - Electrical system Lifting instructions Lifting Unit - Assembly (7210 TTV Agrotron ->WSXW830400LD50010) Lifting Unit - Disassembly (7210 TTV Agrotron ->WSXW830400LD50010)

40-95 30-686 0-4, 0-17 30-530 30-529

V

INDEX Load sensing valve, pressure cut-off valve

10-188

M M - Electrical/electronic devices, flasher units and timers Main power relay switch (TGC/RME-SA1) Maintenance - Maintenance schedule Malfunctions - Malfunction table Master cylinder Menus available for each ECU Motor description - construction type

40-96 40-35 10-58 10-92 10-206 20-3 10-2

N N - Electric motors and actuators NOx sensor (L3)

40-99 10-123, 10-123

O O - Resistors, rheostats, diodes and diode boards Oil Supply - Assembly (7210 TTV Agrotron ->WSXW830400LD50010) Oil Supply - Disassembly (7210 TTV Agrotron ->WSXW830400LD50010) Operating materials - Coolant Operating materials - Fuel Operating materials - lubricant oil

40-100 30-533 30-528 10-54 10-53 10-51

P P - Various services Pipes and closing components (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Planetary reduction gear assembly Pneumatic trailer braking valve with unbraked front axle (2-way) Positioning of the diagnostic sockets Power steering Preassembly of housing lid (7210 TTV Agrotron ->WSXW830400LD50010) Preassembly of Housing Lid (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Preassembly of transmission housing (7210 TTV Agrotron ->WSXW830400LD50010) Pressure cut-off valve Pressure limiting valve Pressure sensor (L3) Pressure transducer (L3) Priority valve Procedure for checking EPB travel (7210 TTV Agrotron ->WSXW830400LD50010) Procedure to check EPB stroke (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) PTO Transmission - Disassembly (7210 TTV Agrotron ->WSXW830400LD50010) Putting in service - Agrosky Putting in service - Air conditioner Putting in service - ASM Putting in service - Basic procedure for startup Putting in service - Delete alarms Putting in service - Distributors Putting in service - End of line settings Putting in service - Engine Putting in service - Introduction (Software HLHP versione SC134AE) Putting in service - Lift Putting in service - MR-D Cabin Putting in service - Park brake Putting in service - PTO Putting in service - Suspension Putting in service - System Putting in service - Transmission

VI

40-102 30-445 30-635 10-222 20-5 10-196 30-376 30-333 30-349 10-219 10-221 10-113 10-112 10-195 30-565 30-578 30-522 20-155 20-150 20-123 20-108 20-158 20-138 20-112 20-147 20-108 20-125 20-155 20-154 20-122 20-129 20-131 20-113

INDEX

Q Quick pressure release valve

10-220

R R - Diagnostics R0 - Rear lift Rear Axle Housing - Preassembly (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of clutch (all-wheel-drIve) (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of control (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of Control (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Reassembly of control unit (hydrostatic unit) (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of drive shaft (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of Drive Shaft (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Reassembly of filter head (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of hydrostatic unit (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of Hydrostatic Unit (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Reassembly of Inductive Sensors (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Reassembly of inductive sensors, pressure sensors, valves (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of intermediate housing (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of Intermediate Housing (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Reassembly of K1 Clutch Reassembly of K2 Clutch Reassembly of K3/K4 clutch (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of K3/K4 Clutch (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Reassembly of KR clutch Reassembly of KV Clutch Reassembly of output shaft (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of Output Shaft (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Reassembly of P1 Ring gear carrier Reassembly of P1/P2 planetary drive Reassembly of P3/P4 planetary drive Reassembly of P5/P6 planetary drive Reassembly of park lock (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of pinion (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of plate (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of Plug-In Module (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Reassembly of pressure relief valves (PRV) (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of pump (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of Pump (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Reassembly of spur gear (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of suction filter (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of Suction filter (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Reassembly of Transmission Housing (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Reassembly of valve block (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of Valve Block (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Reassembly of valve block (all wheel-drive / park lock) (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of valve block (filter head, pressure relief valves, thermocouple) (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of valve block (hydraulic control) (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of Valve Block (P.R.V. - Pressure Relief Valve) (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Reassembly of valve block (pressure reducing valve) (7210 TTV Agrotron ->WSXW830400LD50010)

40-104 30-695 30-530 30-363 30-399 30-345 30-386 30-350 30-314 30-387 30-400 30-346 30-334 30-383 30-353 30-317 30-419 30-403 30-409 30-414 30-406 30-419 30-374 30-331 30-431 30-426 30-408 30-422 30-359 30-355 30-377 30-319 30-386 30-397 30-343 30-372 30-403 30-349 30-313 30-380 30-337, 30-339 30-393 30-394 30-391 30-336 30-390

VII

INDEX Reassembly of W.H. and E.C.U. (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Reassembly of wiring harnesses (7210 TTV Agrotron ->WSXW830400LD50010) Reassembly of wiring harnesses and control unit (7210 TTV Agrotron ->WSXW830400LD50010) Reinstallation of cartridge (7210 TTV Agrotron ->WSXW830400LD50010) Reinstallation of Cartridge (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Reinstallation of plug-in module (7210 TTV Agrotron ->WSXW830400LD50010) Remote control valve - 12-way version Remote control valve - 14-way version Remote control valve - 8-way version Removal and assembly of the fan support Removal and installation of the air conditioning compressor Removal and installation of the exhaust pipe (auxiliaries) Removal and installation of the fuel filter console Removal and installation of the fuel lift pump Removal and installation of the thermostat housing Removal and refitting of fuel lines (fuel lift pump - pilot block) Removal and refitting of fuel lines (pilot block - fuel lift pump) Removal and refitting of fuel lines (pilot block - high pressure pump) Removal and refitting of fuel lines (rail, cylinder head, pilot block - fuel filter) Removal and refitting of oil cooler (auxiliary services) Removal and refitting of the lubricating oil pipe (exhaust gas turbocharger) Removal and refitting of the lubricating oil return pipe (exhaust gas turbocharger) Removal and refitting of the air intake pipe Removal and refitting of the alternator (ribbed V-belt, level 1) Removal and refitting of the alternator (ribbed V-belt, level 2) Removal and refitting of the camshaft speed sensor Removal and refitting of the charge air duct Removal and refitting of the charge air manifold Removal and refitting of the common rail Removal and refitting of the crankcase breather Removal and refitting of the crankshaft speed sensor Removal and refitting of the cylinder head cover Removal and refitting of the exhaust gas turbocharger Removal and refitting of the fan support Removal and refitting of the flywheel (fixing elements) Removal and refitting of the front cover (fixing elements) Removal and refitting of the heater Removal and refitting of the heater (details) Removal and refitting of the high-pressure pump, Installation position A Removal and refitting of the injector Removal and refitting of the lube oil cooler housing Removal and refitting of the oil filler pipe Removal and refitting of the oil sump pan Removal and refitting of the pilot block Removal and refitting of the starter motor Removal and refitting of the torsional vibration damper Removal and refitting of the V-belt pulley Removal and refitting of the water pump Removal of cartridge (7210 TTV Agrotron ->WSXW830400LD50010) Removal of Cartridge (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Removing and fitting fuel lines (fuel delivery pump - fuel control block) (L3) Removing and fitting NOx sensor (L3) Removing and installing the belt tensioner (Level 1). Removing and installing the belt tensioner (Level 2) Removing and installing the console (Level 1) Removing and installing the support console (Level 1) Removing and installing the support console (Level 2) Removing and installing the support plate (Level 1) Removing and installing the vee-groove pulley (#1) Removing and installing the vee-groove pulley (#2) Removing and refitting the valve timing system (L3) Removing brakes (7230 TTVAgrotron ->WSXAD00400LD50010, 7250 TTVAgrotron ->WSXAD30400LD50010) Removing the axle housing (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Removing the differential (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Removing the lifter (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Removing the oil feed (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010)

VIII

30-334 30-381 30-388 30-437 30-440 30-373 10-209 10-210 10-208 30-215 30-232 30-87 30-185 30-187 30-211 30-189 30-195 30-193 30-198 30-43 30-92 30-94 30-77 30-224 30-223 30-227 30-74 30-75 30-66 30-8, 30-11 30-226 30-37 30-89 30-214 30-33 30-23 30-202 30-204 30-50 30-58 30-45 30-28 30-25 30-47 30-221 30-31 30-30 30-79 30-236 30-238 10-124 10-130 30-81 30-97 30-104 30-85 30-103, 30-105 30-82 30-98 30-101 30-164 30-449 30-446 30-451 30-467 30-466

INDEX Removing the PTO (7230 TTV Agrotron ->WSXAD30400LD50010) Renewal of the crankshaft oil seal Repair level III Replace the crankshaft O-ring (flywheel end) (L3) Replacing the starter ring gear on the flywheel (L3)

->WSXAD00400LD50010,

7250

TTV

Agrotron

30-454 30-14 30-2, 30-4 30-147 30-109, 30-110

S S0 - Wheels S001 - Electrical engine governor S002 - Starter S003 - Preheating S004 - AdBlue S005 - Transmission S005A - Transmission - Version with performance steering S006 - Front axle suspension S007 - Instrument panel S008 - Lights – Version without front hitch S009 - Lights – Version with front hitch S010 - Turn indicators S011 - Work lights S012 - Semi-active cab suspension S013 - Manual air conditioner S014 - Automatic air conditioning S015 - +15 Positives S016 - +30 Positives S017 - CAN BUS Line - Standard version S017A - Standard CAN BUS line - Version with automatic A/C system S017B - Visual guidance Can Bus line - Version without ISO11783 S018 - CAN BUS Line - Version with ISO 11783 S018A - ISO11783 Can Bus line - Version with visual guidance S018B - ISO11783 Can Bus line - Version with assisted steering S018C - ISO11783 Can Bus line - Version with performance steering S019 - CAN BUS line - Version without I-Monitor S020 - PTO S021 - Front and rear hitches S022 - Brakes S023 - Hydraulic trailer braking S024 - Hydraulic distributors S025 - Windscreen wipers S026 - Radio S027 - Accessories S028 - Diagnostics S029 - Monitor S030 - Agrosky - Version with visual guidance, without ISO11783 S031 - ISO 11783 S031A - ISO11783 Can Bus line - Version with visual guidance S031B - ISO11783 Can Bus line - Version with assisted steering S031C - ISO11783 Can Bus line - Version with performance steering S032 - Webasto S033 - Lights - Version without front hitch (U.S.A.) S034 - Lights - Version with front hitch (U.S.A.) S035 - Turn indicators (U.S.A.) S036 - Work lights (U.S.A.) S037 - +15 Positives (U.S.A.) S038 - +30 Positives (U.S.A.) S039 - PTO (USA) S040 - Braking (U.S.A.) S041 - ISO 11783 (U.S.A.) Safety notes Safety precautions for removal and refitting operations SDF Analyser SDF Analyser/CVT Diag connection SDF Analyser/PC Tester connection Separating rear axle from transmission (7210 TTV Agrotron ->WSXW830400LD50010) Separation of Rear Axle from Transmission (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Serdia 2010 Serdia 2010 connection Servo-brake valve for front axle Solenoid valve tightening torques Speed indicator (L3) Standard tightening torques

30-696 40-106 40-112 40-116 40-120 40-125 40-133 40-141 40-144 40-147 40-156 40-168 40-178 40-194 40-196 40-200 40-207 40-210 40-216 40-231 40-245 40-250 40-268 40-277 40-286 40-297 40-309 40-315 40-321 40-331 40-336 40-341 40-346 40-349 40-366 40-371 40-373 40-379 40-388 40-397 40-407 40-418 40-422 40-431 40-442 40-450 40-465 40-469 40-474 40-480 40-487 0-2, 0-15 0-3, 0-16 20-11 20-6 20-6 30-513 30-235 20-14 20-6 10-198 30-6 10-121 0-12

IX

INDEX Starter motor tightening torques Steering cylinders assembly Steering gear pump - Version with compressor Steering gear pump - Version without compressor Steering position sensor assembly Supplementary heater - Webasto - Disassembly and reassembly Supplementary heater - Webasto - Troubleshooting Supplementary heater - Webasto - Wiring diagrams Supplementary heating - Webasto - Description of operation Supplementary heating - Webasto - Faults Supplementary heating - Webasto - Functional tests Supplementary heating - Webasto - General description Supplementary heating - Webasto - Maintenance Supplementary heating - Webasto - Technical specifications System diagram (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Systems

0-13 30-592 10-204 10-203 30-686 30-674 30-659 10-174 10-170 10-172 30-663 10-165 30-664 10-173 10-151 40-106

T T - Power supply points (+15 o +30) Technical data - Engine data and adjustment data Technical data - Tools Temperature sender (exhaust gas) (L3) Temperature sender (L3)

40-104 10-102 10-104 10-133 10-114, 10-115, 10-118, 10-119, 10-129 30-210 0-8, 0-21 30-684 0-5, 0-18 0-12 30-590 10-224 10-224 10-221 10-225 10-134 10-139 TTV Agrotron

Thermostat check (with thermostat disassembled) Threadlockers, adhesives, sealants and lubricants Tightening the hydraulic power steering unit fastener screws Tightening torques Tightening torques for nuts and bolts of electrical connections Toe-in/steering angle/assembly tests Trailer air brake boost solenoid valve Trailer air braking valve (1-way) Trailer air braking valve (2-way) Trailer parking brake control solenoid valve Transmission Transmission (50 Km/h) (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 ->WSXAD30400LD50010) Transmission (60 Km/h) (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Transmission (7210 TTV Agrotron ->WSXW830400LD50010) Transmission alarms Transmission control (7230 TTV Agrotron ->WSXAD00400LD50010, 7250 TTV Agrotron ->WSXAD30400LD50010) Transport and storage - Transport Transport and storage - Transport and storage

10-145 10-134 20-229 10-159 10-97 10-99

U Usage - Active regeneration Usage - Controlling engine operation Usage - Passive regeneration Usage - Starting procedure Use - Environmental conditions Use - exhaust gas after-treatment systems Use - First start-up Use - Stop procedure

10-45 10-37 10-47 10-35 10-28 10-43 10-30 10-49

W Wheel hub assembly Wheel rim to hub screws and nuts tightening torques Wiring harnesses

X

30-638 0-14 40-496

*307.W.0980.en.6.05* 02/2015 SAME DEUTZ-FAHR ITALIA S.p.A. Viale F. Cassani, 15 - 24047 Treviglio (BG) Italy T + 39.0363.4211 F + 39.0363.421638 www.samedeutz-fahr.com

Deutz-Fahr is a www.deutz-fahr.com

trademark