TTV-7210-7230-7250.pdf
May 7, 2017 | Author: Taras Marian | Category: N/A
Short Description
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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
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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
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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
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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
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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
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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.
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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.
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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
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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
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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 (--).
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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
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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
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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
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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
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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.
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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.
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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
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
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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.
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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
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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
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Calibrations and electronic diagnosis
Fig. 275
Fig. 276
Fig. 277
Fig. 278
Fig. 279
Fig. 280
Fig. 281
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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.
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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.
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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.
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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.
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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
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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.
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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.
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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.
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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.
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Calibrations and electronic diagnosis
Fig. 293 - Summary page graphic display
Fig. 294 - Running graphic display Possible interactions
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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
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Calibrations and electronic diagnosis Interrupt measurement (pause).
Fig. 300
Fig. 301
Fig. 302
Fig. 303
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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:
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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.
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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!
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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!
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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:
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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.
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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).
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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.
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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
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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”:
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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.
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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.
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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.
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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.
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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
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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
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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
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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.
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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.
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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.
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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:
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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!
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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:
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Calibrations and electronic diagnosis
Fig. 351 - Editing the favorites list Important The favorites list can consist of only 10 favorites!
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Calibrations and electronic diagnosis Favorites can be removed or added to the list by using following arrows:
Fig. 352
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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
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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
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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.).
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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
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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.
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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!
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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.
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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.
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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
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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:
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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
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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.
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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
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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
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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.
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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 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
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
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